Fig.

0-1 937H loader with bucket outline dimensional diagram

-1-
 Emergency
braking

Tire

Fig. 0-2 937H loader driven system diagram

-2-
 I. Application and characteristic
1. Application
937H-type loader is one kind of multi-purpose and high efficient construction machinery, which is a new
generation product based on our experiences in designing and manufacturing loader for many years. The working
devices of the machinery include timber gripper, bucket, bulldozing plate, plate fork and hook, etc., and these
units can be easily replaced when necessary.The machinery applies to the loading and unloading of tree stem and
log by forestry sectors in hill field and lumber yard. In infrastructure projects and road contruction and
maintenance, the loader applies to the loading and unloading of sand, rock, clay etc., and also applies to short
distance transportation, bulldozing, land flattening, as well as digging, hoisting, traction and so on. The machinery
is also applicable to similar operations in various mines, factories, railway stations, docks, freight yards,
warehouse and other places.

2. Characteristic
937H-type loader is front four-wheel drive, articulated frame, hydraulic steering wheel loader, which mainly has
the following characteristics:

1. Adopt hydromechanical transmission, that is, install hydraulic torque converter between the engine and
transmission, which can make the best use of the engine power, increase output torque, and can adapt to the
outside load change in certain range, automatically adjusting to reach continuously variable transmission, and
be able to prevent engine from flameout and prevent components from being disabled by overloading.

2. Adopt hydraulic gear shift transmission, flexible axle operation which is easy, convenient and safe.

3. Adopt front/rear axle four-wheel drive, hub reduction and low pressure width section tire, enable the loader
has great driving force, strong clambing ability, and is able to run and work on rough road.

4. Adopt articulated frame, with small turning radius, which is flexible.

5. Adopt full hydraulic steering gear, which is easy to operate, highly structured and convinient for
maintenance.

6. Adopt double channel air-on-oil caliper disc brake system, which is of big braking force, convinient
dismounting, safe and reliable.

7. Working devices adopt hydraulic operation system, which is easy, convinient and flexible for operation,
stable and reliable.

8. Adopt fully closed driving cab, which is spacious and bright and with a wide view. The seat is good
cushioning and confortable.

9. Air conditioner system is installable, with confortable operation enviroment.

10. Adopt new Z-shape linkage, monopivot, high pivot working unit, with larger breakout force and higher
working efficiency.

11. Installed pneumatic controling emergency brake system, which ensures safety and reliability when braking
and stopping on hill.

-3-
 II. Main technical performance and parameter
1. Technical performance
Bucket capacity (heaped) 1.4-3.2m3

Rated capacity 3000kg

Maximun dumping clearance:

Bucket(bottom surface tilt 45o) 2934mm

Dumping reach of Maximum dumping clearance:

Bucket(bottom surface tilt 45o) 1043mm

Upper arm lifting time 5.1s

Upper arm lowering time 3.0s

Bucket topple over time 1.1s

Vehicle speed Drive Reverse

I 0 -6.6km/h 0-8.2km/h

Ⅱ 0-13.8km/h 0-17.0km/h

III 0-30.1km/h 0-29.0km/h

Minimum turning radius (front wheel center) 4885mm

Steering angle left and right 38°

Maximum clambing power 270

Maximum traction 96000N

Maximum digging power 96000N

2. Main dimension and weight

Vehicle length: bucket lies flat on ground 7000mm

Vehicle width (wheel outside) 2305mm

Vhicle height (driving cab roof) 3136mm

Bucket width 2430mm

Wheel base 2750mm

Wheel track 1855mm

Minimum ground clearance 360mm

Vehicle weight: with bucket 10200(1±5%)kg

-4-
 3. Engine system
Modle Dongfeng Cummins 6BT5.9-C130
Vertical water-cooling four-stroke direct
Type
injection
Number of cylinder – cylinder
6-102×120
diameter × stroke
Rated power 97KW

Rated Speed 2200r/min

Maximum torque 560N.m

Feul comsumption rate ≤220g/KW.h

Over runing mode Motor

Weight 500Kg

4. Driven system
4.1 Hydraulic torque converter mode Single stage single phase three wire working wheel mode

Torque efficiency 3.1

Cooling mode Oil cooling pressure cycling

Outlet oil pressure 0.245-0.34MPa (2.5-3.5kgf/cm2)

4.2 Transmission mode Cylinder spur gear parallel shaft hydromatic shift

Gear and speed ratio Drive Reverse

GearⅠ 4.575 3.574

GearⅡ 2.128 1.663

GearⅢ 0.803 0.627

Fuel pump CBGj1032(SAE)

Clutch Multi-disc wet-type frication clutch

Clutch working oil pressure 1.47-1.86MPa (15-19kgf/cm2)

4.3 Front and rear axle main turning

Type Spiral bevel gear stage 1 deceleration

Deceleration ratio 3.889

4.4 Hub reduction

Type Cylinder spur gear planetary drive

Deceleration ratio 4.941

4.5 wheel and tire (four-wheel alike)

Tyre specification 17.5-25-12PR

Tyre pressure 0.275-0.294MPa (2.8-3kgf/cm2)

-5-
 Tire rim type 14.00

5. Brake system
Driving foot braking

Type Dual pipeline air-over-hydraulic gripper disc four-wheel brake

Emergency brake system Pneumatic control

6. Steering system
Type Full hydraulic articulated frame steering

Steering fuel pump CBGj2050

Steering fuel cylinder number – cylinder diameter× stroke 2-φ70×357mm

Hydraulic steering control unit type BZZ1-400

Hydraulic steering control units displacement 400ml/r

System working pressure 14Mpa

7. Working device hydraulic system

Working fuel pump CBGj210（SAE）

Geometric displacement 100ml/r

Lifting fuel cylinder number – cylinder diameter × stroke 2-φ125 × 697mm

Roll-over fuel cylinder number – cylinder diameter × stroke 1-φ 50 ×470mm

Rated working pressure 16Mpa

Distribution valve double or tripple integral multiple directional control valve

8. Electrical system
System voltage 24V

Battery 2×115E41R

Engine 28V/55A

Starting motor 24V/6kW

Single wire system Negative pole grounding

9. Refueling capacity
Engine oil 13.5L

Feul tank 130L

-6-
Hydraulic torque converter and transmission system 35L

Hydraulic fuel tank 120L

Front axle main drive 1×9L

Rear axle main drive 1×8L

Hub reduction gear 4×3.5L

Brake system 2× 0.5L

10. Air conditioning and heating system (selection parts)

This system adopts refrigerant system and heating apparatus

AC modle BKG116-1
Refrigerating capacity 4200W

Compressor modle GY5H14

Heating capacity 5000W

Voltage 24V·DC

Electrical power consumption ≤410W

-7-
 III. Operating Devices and Meters
Before driving, it is necessary to know the location and function of each operating device, meter and indicating
light. The arrangement of devices and meters in cab is shown in Fig. 3 - 1. The operator falls into the habit of
watching the instrument board always in operation and discovers any abnormal condition on time.

Fig. 3 – 1 Operationequipments and instruments in cab

1.Hand Brake 2.Chair 3.Steering Column 4.Brake Pedal

5.Combination 6.Accelerator Pedal 7.Work Handling
Instrument

-8-
 1、Instrument Panel：

Engine fault indication

Turn signals
1.
Engine water
temperature
Torque converter Oil
temperature2.

oil level gage

Engine
oilPressure

Fault alarm indication Fault alarm indication

area 1 area 2

Function and application scope of each instrument are listed as following:

(1)Engine water temperature meter:：

Indicate the water temperature in the cylinder cover of engine. When the engine works normally, the suitable

temperature is between 60℃and 95℃; The highest temperature should not exceed 95℃. Insulation measures shall

be taken when temperature is too low in winter.

(2) Hour meter：

Indicate accumulated working times of engine

(3)Engine oil pressure meter：

Indicate engine oil pressure of engine. When the engine works normally the needle should be within the green

zone. When needle exceeds the green zone, you should stop the machine, check the cause, adjust and

troubleshoot.

(4)Torque converter oil temperature meter：

Indicate oil temperature of torque converter. When the torque converter works normally, the suitable temperature

is from 80℃ to 110℃.The maximum operating temperature in short time should not be over 120℃. When

temperature exceeds normal scope and approximates to maximum value, change transmission handle to lower

level, reduce rotation speed of engine or stop operation until oil temperature is reduced to normal scope.

(5) Gearbox pressure meter：

By connecting the pressure oil from the torque converter inlet valve to the clutch, the gearbox makes the shifting.

-9-
Its normal working pressure is from 1.47 to 1.86MPa(15-19 kg/cm²).The pressure would go down a little when

the torque converter oil gets high temperature after a long work. But the minimum pressure should not be less than

1.28MPa(13kg/cm²), otherwise the clutch could not work reliably.

(6) Brake air pressure meter：

Indicate the air pressure in the air reservoir. Its normal scope is from 0.6MPa to 0.73MPa (6 to 7.5 kg/cm²); When

the air pressure is lower than 0.6MPa, the brake could not work reliably. So you shouldstart work until the

pressure going up. If the air pressure does not rise high, you must stop the machine and check at once.

(7) Fuel level meter：

Indicate fuel oil level. When the needle points to 0, it means the oil is run out; when it points to 1, it means the oil

tank is full.
2. Indicating lamp and switch
(1) Charging indicating lamp: It indicates that the battery is being charged when this indicating lamp lights up.

(2) Low transmission oil pressure indicating lamp: This indicating lamp lights up when the transmission oil
pressure is below 1.2Mpa.

(3) Left/right turn indicating lamp (green):

The left turn indicating lamp and the front and rear turn lamps on the left side continue to flash when the turn
indicating lamp switch lever is pushed forward and the right turn indicating lamp and the front and rear turn lamps
on the right side continue to flash when this switch lever is pulled backward.

(4) Parking brake indicating lamp: This indicating lamp lights up when the handbrake is applied.

(5) Service brake indicating lamp: This indicating lamp lights up when the brake pedal is stepped down.

(6) High beam indicating lamp: This indicating lamp lights up when the high beam is turned on.

(7) Low engine oil pressure alarm indicating lamp: This indicating lamp lights up when the engine oil pressure
reaches the red alarm zone.

(8) Gear change-over indicating lamp: Reserved.

(9) Emergency brake indicating lamp: Reserved.

(10) Low braking pressure indicating lamp: Reserved.

(11) Ignition key start switch:

As shown in Figure 3-2, insert the key into the ignition switch, rotate clockwise the key to On position, and then
rotate clockwise to Start position to turn on the starter motor and start the diesel engine. Under cold weathers,
rotate the starter switch counter-clockwise to Preheat position and then start the engine after preheating the air
intake.

- 10 -
 Figure 3-2 Key preheating starter switch

3. Control levers and pedals:

(1) Gearshift lever: (See Figure 3-3)

Push forward the drive/reversing lever: The machine travels

forward

Pull backward the drive/reversing lever: The machine travels

backward

Shift the drive/reversing lever to neutral position: The machine

stops.

It’s the 1st gear when the speed lever is pushed forward
Figure 3-3 Gearshift control lever
It’s the 2nd gear when the speed lever is shifted to neutral position

It’s the 3rd gear when the speed lever is pulled backward

(2) Accelerator pedal:

Control the fuel supply amount to the engine. When the accelerator pedal is released, the engine runs at idle speed.
When the accelerator pedal is stepped down, the engine speed increases along with the increasing of the fuel
supply amount.

(3) Brake pedal:

The machine applies the braking when the brake pedal is stepped down. Meanwhile, the cut-off valve disengages
the transmission clutch to cut off the power from drive system. In such case, the tail brake indicating lamp lights
up.

(4) Parking brake control lever:

Used to apply the parking brake. Pull upward to apply the brake and push downward to release the brake. Before
starting up the machine, make sure to release the handbrake control lever.

(5) Working device control lever:

The location and the functions of the 937H working device control lever are shown in Figure 3-4. The swing arm
control lever has four positions: Lift, neutral, lower, and float. The rotating bucket control lever has three positions:
Dump, neutral, and retract. The clamping jaw control lever (if any) has three positions as well. If the rotating
bucket control lever or the clamping jaw control lever is not at the neutral position, the reset spring will function
to automatically drive the control lever to neutral position.

- 11 -
 Figure 3-4 937H Working device control lever

4. Heating and air conditioning system (optional)

The driver cab of 937H loader is equipped with the fan and the optional heating and air conditioning system can
be equipped. When the cool air is needed, pull out the fan switch to run the fan. When the strong cool air is needed,
turn the air conditioner switch to refrigeration position. The refrigeration level can be adjusted as required. Under
cold winter weathers, turn the air conditioner switch to heating position to increase the temperature within the
driver cab and greatly improve the working environment.

- 12 -
 IV Loader operation
(I) Safe operation procedure
The driver has great responsibility to safely drive the loader, before driving and operating, the driver should know
something about the performance, structure, operation and technical maintenance about the loader. Meanwhile,
refer to the safe operation instruction for detailing information; follow close to the line of operation procedure to
ensure safe operation, make use of the loader and extend the working life of it.

1. Driver should know well and obey trafic regulations, unqualified drivers is not allowed to drive the loader.
When learning to drive, there must be a qualified driver to guide.

2. Before starting, check the vehicle and get fully prepared as required. If found any part that is fault, should
eliminate and repair it before driving the loader.

3. Before starting or operating, look around to see if there are people and obstacles, and ring the horn.

4. When engine is running, it is strictly prohibited to that any person stand between front wheel and rear wheel,
between swing arm and front frame, in the bucket, and in the gripper.

5. When engine is running, don't check and repair the loader, if checking is required when engine is running, it
must be supervised by trained driver.

6. When loader is running, any person is prohibited to get on or off the loader.

7. When loader is running, any place is not allowed to carry passengers except for the driving cab.

8. When loader is running, avoid inappropriate overspeed and quick turn, especially when driving on rough
road or on narrow road, steep hill, and winding road, it is only allowed to use gear Ⅰand gear Ⅱ; and when
drving on flat road, it is allowed to use gear Ⅲ.

9. When driving down hill, strictly prohibit engine flameout and coasting in neutral, otherwise it will cause
hydraulic malfunction, and cause serious traffic accident.

10. When loader is performing loading and unloading operation, it is only allowed to use gear I, and braking is
required when changing direction. It is definitely not allowed to drive toward stock pile in high speed.

11. When operating, it is strictly prohibit that any person stand or walk in lifting arm and gripper or bucket.

12. When gripping or shovaling, avoid laterality on one side and lifting to highest position to carry materials. If
there is obstacle, and required lifting pass, should be carefull, after past the obstacle, immediately lower
down the swing arm to the normal position of about 400 mm from the ground.

13. When examing and repairing engine, ig. Electrical system, should cutoff power supply, this can be done by
pull open grounding switch or dismantle battery grouding wire.

14. Before leaving the driver cab when finished job, lie flat the bucket and gripper on the ground and stall the
engine, turn off the battery switch.

15. When opening hot engine water tank lid and hydraulic fuel tank lid, wear gloves or cover with cloth, slowly
unsrew it, to prevent hot water and hot oil from spraying out from the tank by pressure, and scalding people.

16. When vehicle is fault, and needed to be dragged back by other vehicles, dismantle the front/rear driving
shaft.

17. Oil being used must be clean, and coincident with the specified type and quality standard.

18. Caution of fire when refueling and maintenance the loader. Smoking is prohibited.

19. Accidents caused by test operating, operating, maintenance that are not abiding by this instruction are not
included in the "three warranties”.

- 13 -
20. When loder is running or operating, turn off driving cab door.

21. Other safety rule, please refer to Security Manual.

(II) New vehicle test run and run-in

When received a new loader, the user must test run the loader for 50 hours, the test run process is very important
to the entire work life of the loader. Duraring test run period, the loader is not able to run at maximun load at once,
after 50 hours, it can be gradually increased to the maximun load. To run-in every part of the accessories, the
driver must be carefull when test run the loader, frequently check and change fuel, otherwise accessories will be
wore down, or even disabled.

1. Preparation for test run

(1) Check if every part of the machine is installed firmly, if accessories are complete, and if there it is disabled.

(2) Check if every control handle is loose, if bar system is disabled and other conditions.

(3) Check fuel, cooling, brake, torque converter and transmission, and all tubes and connectors in hydraulic and
air pressure system.

(4) Check the tensioning in engine fan belt.

(5) Check if tire charging is in accordance with authorised pressure.

(6) Check battery electrolyte and wire connection.

(7) Fill up lubrication and fuel of the authorised brand and capacity.

2. Empty load running (initial 5 hours)

(1) Place every control lever in middle position, pull up emergency brake handle, make engine idle run for 1
hour, in the earlier half hour, run it at 800～1000r/min, then gradually increased to normal speed for the other
half hour, and check gauge reading and voice.

(2) when air pressure reaches 0.6 Mpa, press emergency brake handle, drive sequencely at gear Ⅰ, Ⅱ, and Ⅲ,
the backward run-in for 1～1.5 hours. Frequently steer and operate working units stablly, check if work units
are normal; check if there is leakage of water and oil in the system; check if brake is liable, steering is
flexible, and every gauge reading is normal; and check if light and steering signal is normal.

(3) After run-in for 5 hours, maintenance the vehicle according to regular techinical maintenance regulations,
and completely inspect the fixation of every bolt and nut, especially engine cylinder cover bolt, air tube bolt,
front/rear axle fixation bolt, rim nut, driving axle joint bolt and rocker bolt etc.. Clean engine oil filter and
fuel filter.

3. 50% rated load test-run (5 to 30 hours)

(1) Load capacity is 50% of the rated capacity; engine can run at rated speed.

(2) Snatching and shoveling motion not to be fast and rough.

(3) Check and maintenance the loader according to regular technical maintenance regulations after test-run.

4. 70~80% rated load test-run (30 to 50 hours)

(1) After test-run for 20 hours, if loader checking normal, it can be increased to 70~80% load for operation.

(2) Strictly execute regular technical maintenance in test-run, check the load overall after 50 hours test-run.

(3) Change engine oil, and use diesel to clean engine lubrication system and filter element. Change oil in torque
converter, transmission and tube system; change oil in working hydraulic system; clean the filter; clean and
change oil for front/rear axle case and hub reducation gear.

- 14 -
(4) After 50 hours of test-run, if all parts are checked normal, it is allowed to enter into normal working stage
according to specified loading capacity.

(5) Make record in test-run, if any abnormal condition is found, or any problems that cannot be solved, please
contact with manufacturer for support.

(III) Driving of loader

1. Check before driving

Check the following before starting:

(1) Engine oil level should be under maximun mark <refer to diesel engine instruction>.

(2) Water radiator should be filled up with cooling water.

(3) Check fuel tank volumn, use oil filter gauze when filling oil.

(4) When checking transmission oil level after engine started, the vehicle must be stopped on flat road and check
if oil level is in range.

(5) Check hydraulic fuel tank level and keep it around upper scribed line.

(6) Open air drum water drain valve, screw up after water exhausted.

(7) Check if tire pressure is normal.

(8) Fill lubricating grease to every lubrication point according to the lubrication Fig..

(9) Check if there is any joint part that is loose.

After started, check the following:

(1) Check if gauge reading normal, engine charged.

(2) Listen to the engine running voice when running in low speed and intermediate speed.

(3) Check illumination, steering indicating lamp, horn, wiper and braking light.

(4) Rotate steering wheel and check steering system.

(5) Check foot braking and park braking.

(6) Check working device motion.

(7) Check if there is leakage in every oil tube and water tube.

*Daily check the vehicle before driving it, maintain the vehicle every day according to the technical maintenance
regulations.

2. Driving of loader

(1) Starting

a. Engine should not be started after completing the above checking process.

b. Place direction control handle and hydraulic control handle in middle position, and place brake handle in
braking position.

c. Insert electric switch key, and turn it clockwise to “ON” position.

d. Half press the acceleration pedal, turn the switch key clockwise to “start” position, and then start motor, and
diesel engine will be started.

- 15 -
☆ When the engine started, loose the starting switch immediately, in order to avoid damaging the gear and burn
down the starting motor.

e. The starting time should not exceed 10 seconds, starting interval is 2 minutes. If starting failed several times
continuously, check the problem and find the reason, and don't restert it before eliminating the fault.

f. Speed up gradually after starting, make engine run at 800~1000 r/min, and conduct preheating run and charge
the air drum.

☆ When engine is heating and meter reading is normal, don’t run it in high speed and full load. Pay particular
attention when it is in winter.

(2) Start to drive

a. After engine started, idle run for 5 minutes, then preheat it. When water temperature and oil temperature is
above 45℃, check every gauge reading, and then start the loader.

☆ Don't start the loader before braking pressure reaches 0.6Mpa, that is（6kg/cm2）.

b. Lift bucket or gripper to carriaging positon (400mm from ground).

c. When air pressure reaches 0.4Mpa, press parking brake handle to release parking brake.

d. Adjust the gear control lever to required gear according to ground and working condition.

e. Pull direction control lever to forward or backward position.

f. Ring the horn, and start to drive.

(3) Shift gear

a. This loader adopts hydraulic torque converter which enables continuously variable transmission. When run
into obstruction or steep slope, the loader can automatically decelerate, and enhance tranction power to
overcome the obstruction; therefore it is not needed to shift frequently. On the contrary, in order to reduce
abrasion and power cutoff, avoid unnecessory shifting.

b. When running on flat road, choose gear Ⅲ. When running on mountain areas, it is suggested to choose gear
Ⅱ. And when in cross-country or operating, and running on mal-conditions as steep hill, sharp turn, it should
be run at gear Ⅰ.

c. The loader adopts hydraulic shift, when shifting, decelerate to about 1000r/min to ensure stable shifting.

d. When changing forward/backward direction, decelerate to 1000r/min, press brake pedal, and change
direction when the vehicle stops, otherwise transmission will be violently impacted.

e. When changing gear, observe the clutch pressure gauge, confirm the gauge value is normal.

(4) Steering

The full hydraulic steering gear used in the loader is similar to general mechanical steering. However, please
notice that when engine speed lower down, steering fuel pump fuel supply volumn will reduce, and steering speed
will also be influenced, perticularly, engine flameout, steering fuel pump not supplying fuel, at that moment,
steering control will be invalid. Therefore, when it is taking a suddern turn, it is required to use low speed gear
(gear I), and engine speed should not be over-decelerated, and particularly prevent engine flameout.

(5) Stop and flameout

a. Lower down engine speed and pressure braking pedal to stop the vehicle.

b. Pull the direction control lever to the middle position, pull parking brake handle upwards.

- 16 -
c. When flameout is needed, engine speed should be reduced to 500~800r/min, and run for a while, then turn
the electric switch key to “OFF” position, so that engine will be flameout.

d. After engine flameout, place bucket or gripper on the ground, and control handle in the middle position,
return electric switch key to “OFF” position and pull out the key.

e. When air temperation is lower that -10℃, don’t stop during interval time.Drain completely the cooling water
after vehicle stopped.

3. Loader operation

Due to the loader working range and working objects are quite extensive, this instruction book is impossible to
cover everything in detail, drivers should aquire more experiences in real operation. Here we just list some
common examples for user’s reference. Before operating, clean the working site, flat the ground; get away big
rocks or obstacles, and keep the site clean and flat, so the loader operation will be smoothy and safe.

(1) Use bucket to loading from stockpile.

When loading, according to site and road condition, loader numbers and parking position, and loader route, there
are several working methods as follows: single vehicle loading, V-type loading and sequence loading. The purpose
of choosing the appropriate working method is to ensure shortest running distance and minimun the steering angle,
in order to improve loading efficiency.

The operation of bucket loading:

a. Lower down the bucket to the ground; keep a 3o～5o angle of bucke bottom and horizontal. Pull the lifting
handle to “middle” position, drive forward to stockpile in gear Ⅰ, if the ground is hard, ig. Cement floor,
then push lifting handle to headmost “fluctuating” position (Fig. 3.4-1).

b. Once the bucket insert into stockpile, pull swing arm control lever to “lifting” position, press acceleration
pedal to the bottom, cut into the pile, meanwhile quickly push and pull the bucket control lever back and
forth to fill the bucket full (Fig. 3.4-2).

c. After bucket is filled full, return the control lever to “middle” position, and loder quickly draw buck (Fig.
3.4-3). If transportation distance is long, control the lifting handle to keep the bucket at about 350mm from
ground, ensure better stability of the loader. And if cargo truck is near, the bucket can also be lifted to proper
“unloading” height.

Fig. 3.4-1 Fluctuation Fig. 3.4-2 Full fill Fig. 3.4-3 Draw back after loaded.

The operation of unloading materials to truck

a. Lift swing arm to make the clamping jaw or bucket higher than truck bed.

b. Loader approach the truck in gear Ⅰ, when the clamping jaw or bucket reaches the unloading site, press
braking pedal, push forward rollover control lever, slowly unloading materials to the truck bed.

c. If there are adhesive stuff in the bucket, push the rollover control lever back and forth several times to unload
the materials completely.

- 17 -
d. Draw back bucket or clamping jaw. When loader is exiting backward, drop down swing arm, and continue
next loading operation.

(2) Wood log loading and unloading

When using wooden log gripper, besides increasing the clamping jaw, other operations are basically the same with
bucket operation.

a. Insert quickly into the pile in gear Ⅰ.

b. Gripper rollover backward, and control the clamping jaw, and clamp the wooden log.

c. Lift upward and draw back from stockpile.

When unloading, if is is automobiles, press the clamping jaw close to trunk bed as far as possible, rollover gripper
downward, slowly loose gripper to let the wooden log roll in, avoid damage to the vehicle.

For fragmentaries, the loading is difficult; the operator can use gripping method.

If the pile is high, it can be gripped from the top or shovel from the middle.

(3) Short distance operation:

Under the following condition, the loader will perform self-loading and self-transporting.

a. Ground is too soft, site in not flat, and truck in enable to be used.

b. Transportation distance is in 500m, using truck is a waste of time.

When transporting, rotate the gripper or bucket to its limitation, and keep them 354mm away from ground.

(4) Spading operation

a. Put the bucket on the ground, and make it slightly slope down（3o～5o）.

b. When driving loader forward, meanwhile control the swing lever lowering position, to make the shovel edge
cut into the ground.

c. When the shovel edge reaches certain depth, pull the lifting handle to "middle” position, continue driving the
loader forward. Meanwhile use rollover handle to adjust the digging depth to adapt to the ground change.

d. When bucket is fully filled, or reaches expected position, rollover the bucket backward to the limited position,
and lift swing arm to the transportation position at the same time.

e. Transport the soil to the appointed position.

☆ The bucket slanting angle should not be higher than 10°when digging.

(5) Bulldozing and flating ground

This loader adopts multi-purpose bucket or mould board with the help of connecting rack. Mould board can lean
left or right for 25o, lifting control handle can be used for height adjusting, and rollover control lever can be used
to adjust mould board cutting edge angle. But this loader is not wheeled bulldozer; therefore, the bulldozing
operation is only used for assisting operations such as ground flatting, hollow filling, and deposite cleaning, etc.

(6) Other assisting operations

Used for transporting big rocks, winching packing boxes, trailler tracting, and cleaning branches. Other operations
can refer to the above mentioned operation.

(IV) Loader fuel comsumption

1. Precautions:

- 18 -
(1) When filling oil, fuel torque converter oil, hydraulic system working oil, lubrication oil and lubrication gease,
clean the lubricator and container, and clean the filling port to prevent moisture, dust and other stuff mixed
with the oil.

(2) When filling various oil or checking oil volumn, ensure the loader is in horizontal position. Except for the
sections that can be indicated by dipstick or oil level indicator, other sections such as the front/rear axle and
hub, fill them until oil overflow, notice that the wheel is in the wheel arrowdown direction(Fig. 3.5-1), (Fig.
3.5-2).

(3) When filling lubrication gease, stop filling when the gease overflow from the filling position, and wipe off
the overflowing gease.

Oil filling hole

Shell filling hole

Oil discharging hole

Fig. 3.5-1 Wheel guard oil filling hole Fig. 3.5-2 Front/rear axle oil filling hole

(4) When changing oil, discharge dirty oil as quickly as possible when it’s hot, fill cleaning oil and make the
engine run in idle for several minutes, and control tipping bucket and lifting swing arm to the top. After
engine stopped, discharge cleaning oil, and add fresh oil, make engine run in low speed, then fill fresh oil to
required oil level.

(5) Under different working condition, low temperature or high temperature, change working oil and lubrication
oil according to actual condition and requirement.

2. Specification of Oils and Fluids for Loaders

Season Ambient New Standard Oils and Fluids

Type and Temperature Remarks
Standard Code Fuel/Oil Trademark
Climates ℃
Extreme
-29～0/-44～0 -35 -50
cold
GB252-2000
Fuel -14～10/-5～ Fuel tank
Winter Light diesel -20 *-10
10
Summer 4～40/12～40 *0 10
Vehicles
Extreme SAE Mobil Delvac1 exported to
Diesel engine oil

-40～40
cold API CF-4 cold regions
Extreme
-30～10 GB11122-1997 5W/30 Domestic
cold
Diesel engine oil made engines
Full year -10～40 *15W/40
(CD)
Summer 0～40 30
Extreme Torque
converter oil

-40～40 8D converter and

cold
Torque

transmission
Hydraulic oil
Full year -15～40 *8# Hydraulic
system

- 19 -
 (Optional for
Extreme export
-40～40 Mobil ATF Dexron III
cold vehicles)

Kunlun anti-wear hydraulic

-38～0 L-HS
oil 32
Extreme Mobil DTE 11M ISO VG
cold 15
Hydraulic oil

-38～0
(Optional for export Working
vehicles) hydraulic
Winter -10～10 GB11118.1-94 *32 system
Mineral oil type and
synthetic
Summer 0～40 hydrocarbon type *46
hydraulic oil (L-HM)
Extreme GB13895-1992
-40～40 75W/90
cold Gear oil for Domestic
Full year -10～40 heavy-duty vehicles *85W/90 made axles
Summer 0～40 GL-5 90
Gear oil

Extreme Mobilube 1 SHC Imported axles

-40～40
cold (Optional for
SAE exported
API GL-5 Mobilube HD 80W/90 vehicles with
Full year -20~40
domestic made
axles)
GB10830-1998
Brake
fluid

Full year -20~40 (719 synthetic brake fluid) Brake system

(DOT-3, SAE J1703)
SH/T0380-1992 Rolling
Lubricating

ZL-2H bearings and

grease

Composite
Full year -20~40 various hinge
lithium-based ZL-3H
lubricating grease pins

-45 full-functional Export

-40~40 anti-freeze vehicles
Anti-freeze

SH/T0521-1999
Full year -15~40 Automotive glycol -18 full-functional Domestic
anti-freeze vehicles with
coolant
air conditioner
or heater

Notes: Those items with “*” marking indicate the recommended trademarks.

3. Attachment notes

General precautions

a. In winter, choose different brand of diesel and oil according to different areas and temperatures. For example,
in cold areas which are -40℃, use -50 light diesel and 10W/30 diesel.

Diesel tank oil should be supplemented in time to prevent dryness. Check once every month if the diesel is
polluted or if there are deposit sediments. And clean the filter as well.

Diesel oil must be changed regularly, because the mechanical impurities in the oil will increase gradually, and the
reason is: there are resultants when accessories are oxidative worn, and combustion residual in cylinders, and dust
from outside. When these impurities reach 0.4-0.5%, oil will be black, and physicochemical index will degrade.

- 20 -
Changing oil should be performed under thermal state.

b. Check regularly the cleanliness of hydraulic oil.Method is: take a drop of oil from tank, drop it into 240 filter
papers, if the paper appears a light yellow cycle, it proves the oil can be used. If the slight yellow cycle is
obvious but the center of cycle is black, then the oil is polluted, and needs to be changed. When adding fresh
oil, it is required to use a filter, and don’t fill the tank directly, mixture of several kinds of hydraulic oil is
absolutely prohibited.

c. When using 719-synthetic brake fluid, the sealing component material in brake system is EPDM rubber, if
utilizing alcoholic brake fluid, the braking system seal components should be pure rubber, mixture of
different type of brake fluid is absolutely prohibited.

d. In order to protect gear, save engine fuel, the driving axle internal transmission and hub reduction gear
should choose heavy load vehicle gear oil, equal to AP1 classification GL-5 level.

☆ Fuel Precautions:

Performance and work life of the loader is closely related to oil, therefore, users should pay special attention when
choosing oil for use, especial diesel oil and torque converter oil that are used in high temperature and high speed
working conditions.

Due to continuous research and production of fresh oil, the above mentioned substitute oil is not comprehensive,
and for reference only.

(V) Lubrication
Correctly lubricate the machine will greatly reduce abrasive resistance of every part and abrasion of accessories,
which ensures the machine's good performance and extent its work life.

Please pay attention to the fuel precautions of the above section 5 when lubricating the machine.

Lubrication parts and cycle:

Notice:

1. Daily checking and oiling before driving should be according to the checking regulations mentioned in the
above section 4. Besides, the lubrication cycle is devided into four schedules: weekly (or every 50 hours),
monthly (or every 200 hours), quarterly (or every 600 hours) and annually (or every 1200 hours). Users can
refer to this cycle lubrication according to specific operation conditions.

2. Detail method for engine lubrication please refers to engine instruction book.

3. Symbols: △Initial fuel change for new vehicle after test-run. ⊙Fuel change of spring and summer; ○ Check
fuel level and supplement fuel;● Change fresh oil

- 21 -
 Fig. 3.6-1 Loader lubrication

Table 3.6-1 Lubrication parts and cycle

Lubrication cycle
Number of
Lubricat-ion oil Monthly Anually Lubrication
Lubrication parts Lubricati-on Weekly Quarterly
type or or drawing
points or 50h or 600h
200h 1200h Serial NO.
Crank case 1 △ ○ ● ⊙ 3
diesel
Fuel injection pump 1 ● 4
oil
Engine

Speed adjustor 1 ● 5
Water pump and fan
1 Lubrication ▲ 1
bearing
gease
Charging engine 2 ▲ 2
Torque converter and
Torque
transmission hydraulic 1 △ ○ 6
converter oil
system
△ ⊙
Front/rear

Main drive 2 ○ 19、29

axle

Hub reduction gear

4 △ ○ ⊙ 18、29
gear

- 22 -
Brake system brake master
2 Braking oil ○ ● 17、30
cylinder
Hydraulic fuel tank 1 Hydraulic oil △ ○ ● 7
Lifting fuel cylinder
2 ▲ 11
top bearing
Tipping bucket
Working device and its hydraulic system

cylinder two ends 2 ▲ 10、12

bearing
Upper arm front
2 ▲ 16
pivot
Rocker shaft 1 ▲ 13
Lubrication
Draw-bar two ends
2 gease ▲ 14、15
hinge joint
Upper arm rear hinge
2 ▲ 8
joint
Lifting cylinder and
2 ▲ 9
frame hinge pin
Steering fuel
cylinder front/rear 4 ▲ 21
bearing
Front/rear frame hinge joint
2 ▲ 24
bearing
Rear axle frame bearing 2 ▲ 31、32
Hydraulic torque
converter to 2 ▲ 33
transmission
Universal steering axle

Transmission to rear Lubrication

2 ▲ 26、27
axle gease
Transmission to
2 ▲ 23、25
middle bearing
Middle bearing to
1 ▲ 20
front axle
Extension driving
1 ▲ 22
axle
Driver cab and joint of the
several
following Lubrication oil ▲
.
Control lever system

- 23 -
 V. Main parts structure, adjustment and maintenance
(I) Engine system

Fig. 4.1-1 Engine system

1. Acceleration pedal control 2. Flameout device 3.Diesel tank 4. Diesel 5. Air filter 6. Air bleeding tube
7. Water tank inlet tube 8.Water tank radiator assembly 9. Water tank outlet tube 10.Diesel engine return tube

The power of the loader is Dongfeng Cummins 6BT5.9-C130 engine, its performance, structure and maintenance
instruction book is included in the shipping list.

(1) Air filter

The loader adopts KW2139A2 air filter. (See Fig. 4.1-2)

KW air filter is a double paper filter, airflow enter from intake air tube (2), pass the blade ring and whirl to first
filter (3), and generate high speed whirling. Under the function of centrifugal force, dust will enter into the ash
pan (8), and be auto exhausted through rubber dust exhausting bag. Initial filtering air will pass filter element (5)
and safe filter element (6), after filtration, at last purify air enter into engine through exiting pipe (1).

Fig. 4.1-2 Air filter

1. Outlet tube 2. Intake air tube 3. Blade ring whirl first filter 4. Shell 5. Main fiter element
6. Safe filter element 7. Pull frame assembly 8. Ash pan assembly 9. External rubber dust exhausting bag

- 24 -
Maintenance and precaution:

① Stop and maintain the machine once when air filter is working for 50 hours. Loose clamp bolt, take off
clamp and ash pan, and clean the dust in the ash pan. Take out main fiter element, blower from inside to
outside by compressed air, and tap the cover for maintenance, prohibit using water-oil fiter element.

② After maintenance of main filter element, check carefully, if filter paper leakage, end closure degumming or
other fault is found, or after normal maintenance for 5-6 times, please change a new filter element. Put the
main filter element into hot water when changing the filter element, and take out the rubber blade ring and
wipe it dry. If there is no damage, press it into a new main filter element without rubber blade ring for
continuous use; if rubber blade ring disabled, change a filter element with rubber blade ring.

③ Safe filter element does not need maintenance, if main filter element is split, or there are lots of dust adhered
to the safe filter element, or the element is used normally for 1 year, please change it.

④ Install correctly after maintenance without leaving out any part. And don’t aquash the filter shell, screw up
the clamp outside ash pan, ensure it is well sealed. And make rubber dust exhausting bag vertically
downward; strictly prohibit work without rubber dust exhausting bag.

(2) Diesel tank: fuel tank is integrated as a whole with the working hydrauic tank, and be placed in the back of
driver cab, and linked together with rear frame by 4 bolts. Oil storage volumn is about 130L. There is oil
filling port on top of the fuel tank, oil dischargeing tube in lower part of the tank, and there is filter gauze in
the bottom oil suction pipe joint for filtering dirt in diesel. The kay problem of fuel is cleaning, so the filter
should be cleaned regularly.

(3) Radiator bank: composed of water tank and fan, and installed in the front of engine. Cooling system needs to
be checked for leakage regularly, fill fresh water into the radiator to keep it clean, and regularly check the
tensioning of fan belt, and make neccessory adjustment.

(4) Adjusting mechanism: connected by acceleration pedal, pilot joint and acceleration soft axle and diesel
acceleration pedal control handle. When adjusting, there is an angle of 50o between the acceleration pedal
and driver cab floor, diesel engine acceleration pedal control handle angle shift from left to right, and from
idle to highest speed.

(II) Hydraulic torque converter

(1) Structure and function:

Hydraulic torque converter is mainly composed of pump wheel 4, guide wheel 5, turbo 7, pump shell and other
accessories (Fig. 4.2-1). Three working wheel (pump wheel, turbo, guide wheel) are installed in pump shell that is
filled with oil. Every bending blade on the blade wheel is casted by aluminium alloy and blade wheel. Pump
wheel is connected with pump shell by bolt; pump shell is connected with flexible disc by bolt. Flexible disc is
fixed with engine flywheel by bolt.Turbo is sheathed in turbo axle 14 by spline hub. While guide wheel is
connected with guide wheel base 2 by bolt, guide wheel base is fixed firmly with tank body. Hydraulic torque
converter original structure (Fig. 4.2-2), pump shell pass main driving axle 14, gear is connected with inner gear
of the gear ring. Gear ring is fixed with engine flywheel by bolt.

When working, three working wheel blades of hydraulic torque converter form a closed loop circuit. Power
coming from engine passes from gear ring, pump shell to pump wheel. After working oil enter into pump wheel,
due to the rotation of pump wheel and the function of centrifugal force, oil will flow outward along the pump
wheel blade, and outflow from pump wheel outer edge, and then enter into turbo wheel, impact the turbo and
causes the turbo to rotate, thus to drive the turbo axle to rotate, and ouput power. Oil flow from turbo and then
impact the guide wheel. Because guide wheel is fixed, it gives certain restoring torque to working oil, and the
torque joined together with the torque that pump wheel gave to the working oil, and all torque is transferred to
turbo, therefore torque force gained from turbo is stronger than the torque inputted by engine, thus it place a part

- 25 -
in increasing torque, that is to say, torque convert. Oil continues cycle flow and impact when working, the
temperature will rise, meanwhile, working wheel itself will leak, and therefore, you should input working oil of
certain pressure to conduct working wheel compensation. Part cyclic working oil pass from return valve to
radiator for cooling.

Torque converter compensation fuel pump is installed in torque converter tank body, and driven by gear 3, gear 11,
and connection cover 12. Return valve 1 controls torque converter back pressure, connector on tank body connect
with torque converter fuel gauge.

Fig. 4.2-1 Hydraulic torque converter

1. Return valve 2. Torque converter tank 3. Sun gear 4. Pump wheel 5. Guide wheel 6. Pump shell
7. Turbo 8. Connection shell 9. Flexible disc 10. Flexible disc body 11. Planetary gear
12. Connection cover 13. Guide wheel base

- 26 -
 Fig. 4.2-2 Hydraulic torque converter
1. Return valve 2. Torque converter tank 3. Sun gear 4. Pump wheel 5. Guide wheel 6. Pump shell 7. Turbo wheel
8. Connection shell 9. Engine flywheel shell 10. Planetary gear 11. Connection cover 12. Guide wheel base
13. Turbo axle 14. Driving axle.

(2) Oilway system:

Torque converter and transmission combines an oilway system, see Fig. 4.2-4.

Oil pump working oil flow in from fuel tank (transmission bottom), pass from oilway (7) secondary filter (9) and
oilway (10) and then enter into inlet valve, and divided into two way from inlet valve, one way is to the
transmission distribution valve, the other is passing the torque converter tank body into the pump wheel. After
cyclic work, part of the oil will flow from oil valve and pass oilway (4) to the radiator, after cooling down; work
oil will flow into every gear clutch of the transmission to cool abrasive friction. Oil in torque sheel flow from
return pipe (8) return tank, and flywheel end oil pass from oilway (5) return tank. Torque converter oilway system
before improving, see Fig. 4.2-3.

- 27 -
 Fig. 4.2-3
Torque converter and transmission oilway system
1. Oilway of inlet valve to transmission
2. Oilway of radiator to transmission
3. Hydaulic torque converter
4. Oilway of return valve to radiator
5. Flywheel shell oilway
6. Oilway of first fileter to oil pump
7. Oilway of secondary filter to inlet valve.
8. Torque oil return pipe.
9. Secondary filter.
10. Oilway from oil pump to secondary filter.

- 28 -
 Fig. 4.2-4 Oilway system of torque converter and transmission
1. Oilway of inlet valve to transmission 2. Oilway of first filter to oil pump 3. Hydraulic torque converter
4. Oilway of return valve to radiator 5. Oilway of radiator to transmission 6. Radiator 7. Torque oil return pipe.
8. Fuel pump to secondary filter 9. Secondary filter 10. Oilway of secondary filter to inlet valve 11. Fuel pump
12. Inlet valve 13. Return valve

(3) Maintenance

① Notice: after engine started, check the oil dipstick in the transmission frequently; ensure oil level is above the
minimum line. Strictly follow regulations and supplement or change with the specified brand oil.

② Working oil must be kept clean, prevent impurity and water mixed with oil, secondary filter element should
be cleaned regularly, change work oil in 500h working cycle according to the regulations, ensure oil level
system is normal.

③ Observe the torque converter oil gauge value when working, once the value exceeds 110℃, make engine idle,
or stop the vehicle to cool it down.

- 29 -
 ④ Compensation oil pressure should ensure torque converter working pressure in 0.39-0.49Mpa (4-5 kgf/cm2),
back pressure is 0.196-0.245MPa（2-2.5 kgf/cm2). If pressure too low, it will cause working wheel cavitation,
efficiency reduced; if pressure too high, it will cause heavy leakage, temperation rise up rapidly, and sealing
components disabled easily. The pressure is controlled by return valve, and is adjusted when it leave the
factory, users should not change it.

⑤ Check sealing condition of every connecting part to prevent air inlet and oil leakage.

⑥ When re-installing after overhauling, fill certain volumn of work oil into the work wheel. Unscrew the bolt
on torque converter case near the inlet valve, and crew it up after oil filled.

(III) Transmission
(1) Overview of transmission:

ZLM30E-5 adopts parallel shaft common engaged hydraulic shifting transmission. Because every drive gear in
the case is commonly engaging, it extents the work lift of the gear. Hydraulic shifting makes the case strain in
structure, quick in shifting and convenient, stable, voiceless in using.

Transmission structure is shown in Fig. 4.3-1, it is composed of tank lid ○12, tank body ⑧, forward and reverse
axle assembly ①, middle axle assembly ③, gear 2,3 shaft assembly ④, gear 1 clutch ⑨, gear 2, 3 clutch ⑩,
output axle assembly ⑥, reverse axle assembly ②, and gear valve etc.

When shifting, hydraulic torque-transmission oilway system fuel pump supplies a pressure of 1.47-1.86 Mpa
<15-19 kgf/cm), and the pressure pass from distribution valve, gear valve and enter into clutch of every gear, to
realize clutch gear shifting. <Refer to Fig. 4.3-1>.

(2) Transmission power transfer process (Fig. 0-3, P3)

Transmission can change three types of forward, backward speed, the following is power transfer route (refer to
transmission system Fig. 0-3).

Power from torque converter to main driving axle:

Drive gear 1, transmission input axle drive gear clutch joint →Z1→Z2→Z7→Z4→gear 1 clutch joint
→Z11→Z12（output）.

Drive gear 2, transmission input axle drive gear clutch joint →Z1→Z2→Z8→Z10→gear 2 clutch joint
→Z9→Z12（output）.

Drive gear 3, transmission input axle drive gear clutch joint →Z1→Z2→Z3→gear 3 clutch joint →Z9→Z12
（output）.

Reverse gear 1, transmission input axle reverse gear clutch joint →Z5→Z6→Z8→Z7→Z4→gear 1 clutch joint
→Z11→Z12（output）.

Reverse gear 2, transmission input axle drive gear clutch joint →Z5→Z6→Z8→Z10→gear 2 clutch joint
→Z9→Z12（output）.

Gear 3, transmission input axle drive gear clutch joint →Z5→Z6→Z8→Z2→Z3→gear 3 clutch joint →Z9→Z12
（output）.

(3) Hydraulic clutch structure and working principle:

There are 5 hydraulic shifting clutches in transmission, with the same structure, see Fig. 4.3-1. Clutch is composed
of cylinder, valve, drive plate, slaving plate, press plate, lid plate, wave spring, gear ring etc. When handle control
gear valve and pressure oil enter into cylinder to push the valve to joint the clutch drive abrasive plate and slaving
abrasive plate, and transfer torque, power will be transfored from gear. When cutting off pressure oilway, valve
will be reset by wave spring, and the drive and slaving abrasive plates will be seperated.

- 30 -
There are 8 drive abrasive plates and 8 slaving abrasive plates in the drive clutch and reverse clutch respectively.
Gear 1 clutch has 13 drive abrasive plates and 13 slaving abrasive plates, gear 2 has 11 drive abrasive plates and
11 slaving abrasive plates, gear clutch has 6 drive abrasive plates and 6 slaving abrasive plates; the materials of
the drive abrasive plates is 20 steel, while slaving plates has 0.5mm copper-base power metallurgy on their
surfaces.

Fig. 4.3-1 Transmission structure

1. Drive/reverse gear axle assembly 2. Reverse gear assembly 3. Middle axle assembly 4. Gear 2, 3 axle assembly
5. Gear 1 axle assembly 6. Output axle assembly 7. Braker 8. Tank body 9. Gear 1 clutch 10. Gear 2, 3 clutch
11. Drive, reverse clutch 12. Tank lid

- 31 -
 Fig. 4.3-2 Gear valve
1. Valve 5. Pressure gauge connector 9. Brake lever spring 18. Plunger 17. Rubber bowl 21. Ball limiting cone
2. Gear valve 6. Gasket 10. Gasket 14. Valve lever 18. Intake linking lid 22. Gear ring 3. Direction valve lever
7. Brake lever connector sheath 11. Bolt 15. Valve lever guide bushing 19. Direction lever 23. Gear lever
4. Brake unloading valve lever 8. Stop collar 12. Plunger bushing 16. Valve lever return spring 20. Spring

(4) Gear valve

Distribution valve and gear valve is overlying installed on the right side of transmission top; pressure oil of
1.47-1.86MPa（15-19kgf/cm2）from torque converter inlet valve enter into distribution valve firstly. Distribution
valve controls the flow and stable pressure. Gear valve is composed of valve body, direction control valve lever,
gear control valve lever, brake unloading valve lever, intake connection disc etc., see Fig. 4.3-2. When operating
direction or gear valve lever, according to the location of the valve lever, pressure oil enter into valve body will
enter into drive/reverse gear clutch respectively or into every gear clutch, push the valve, connect the clutch, and

- 32 -
perform such functions as loader drive/reverse or speed change. When braking, brake air pressure acts on cutoff
valve cylinder, make it shift, and the direction gear clutch oilway is cutted off, and connected with oilway, clutch
pressure dispeared, drive/slaving abrasive plate disengaged, so as to realize brake.( Refer to Fig. 4.3-3) torque
converter and transmission oilway principle

Drive
Reverse

Gear
valve

Fuel supply valve

Gear Ⅰ

converter
Torque
Gear Ⅱ

Secondar
y filter
Gear Ⅲ

pump
Fuel
Return valve

Strainer
Distribution

Lubricating circle
valve r

Fig. 4.3-3 Torque converter and transmission oilway principle

(5) Transmission maintenance:

① Maintain the transmission regularly according to maintenance regualtions, check the oil level, fill oil and
change oil, use specified brand of hydraulic transmission oil.

② Wash filter of the case regularly, if find oil polluted, change oil in time, for example, if too much metal
impurity is found in oil, Should be caution, and check carefully to see if any accessory disabled.

③ If speed change pressure deceased too much, say, lower than 1.28 Mpa (13 kgf/cm2), check outlet pressure of
adjusting valve, see if there is any channel or sealing ring disabled, and if the gear valve banked and other
problems, eliminate faults once being found.

(IV) Front axle and rear axle

Power from transmission output axle, pass from front/rear transmission universal alxe to front/rear axle. Because
of the need of steering, there is one extension transmission shaft in the front transmission shaft.

This loader adopts 4WD drive, and front/rear axle are both drive alxe, so as to increase the traction force of the
loader. And its performance is also improved.

The difference of front/rear axle lies in: the front bolt is fixed on front frame, while the rear axle bolt is fixed on
the roker, and can swing for ±12. When the loader is running on rough road, it can also be 4 wheel grounding, and
to play strongest driving force. The front axle drive spiral bevel gear is rightward rotation, while the slaving spiral
bevel gear is leftward rotation, and the situation of rear axle is converse. Other structions are basically the same.

Driving axle is composed of shell, main transmission, semi-axle, rub reducation gear and rim etc., as is shown in
Fig. 4.4-1, the function of Driving axle is to further increase the engine torque and change the direction to vehicle

- 33 -
wheel.

The main transmission is stage 1 spiral bevel gear deceleration; the differential is composed of cross axle, straight
semiaxis bevel, straight planetary bevel, and differential shell. The slaving spiral bevel gear is fixed on differential
shell by bolt, differential plays different roll on the speed of left and right wheel. Through torque rise deceleration
from main transmission stage 1, power pass from left and right semiaxis to rub reduction gear.

Rub reduction gear is planetary, inner gear ring is connected by inner ring bearing and rim bearing, and the rim
bearing is fixed on the shell. Power pass from semiaxis to sun gear, and drive the planetary wheel and planetary
frame to rotate, since the planetary wheel is connected with wheel shell, the vehicle also rotate.

This loader adopts 17.5-25 low pressure wide base tires, with large section width, and good flexibility, low
grounding pressure rate, which is smooth when running on soft ground, and with good buffering performance
when running on rough and hard road.

Front/rear axle maintenance and adjustment:

1. Oiling and change oil regularly according to the lubrication regulation section one, and fill lubrication gease
to universal joint and rear axle swing bearing. Particularly notice to keep stretching transmission shaft in
good lubrication condition, otherwise, the stretching transmission shaft skiving will severely damage the
transmission shaft and driving axle.

2. Regularly check and maintain every connecting bolt, venting, running voice, tire pressure and abrasion or
change parts when neccessory in accordance with the regular technical maintenance regulations section one.

3. When overhauling and installing or changing universal joint axle, level the universal joint fork on two ends
of the transmission shaft. When changing new stretching universal joint fork, the fork top internal should be
modified, to ensure swing angles in four directions are higher than 22o, and avoid of interruption to fork top
on lesser curvature.

4. When maintaining and overhauling, if vehicle wheel needs to be dismantled, please ensure wheel air is fully
bleeded to avoid accidents.

5. Check all gear, shaft, spline, and whorl to see whether there are flaw, nick, depression, spalling and abrasion,
change the parts if neccessory.

6. The differential must be flexible in rotation, no stuck, and gear backlash is 0.15-0.35.

7. Check the abrasion of semiaxis gear cushion and planetary gear cushion, change the cushions if neccessory,
it’s better to change the two simultaneously to ensure inconsisdence of gear backlash. Clearance between
semiaxis bevel gear bearing surface and abrasive cushion ring (both left and right sides), should be in
0.2-1mm, the clearance difference of the same gear should not exceed 0.2mm.

8. Drive spiral bevel gear should be changed pairingly, they are matched when producing. Semiaxis bevel gear
and planetary gear should also be changed pairingly.

9. Check all bearings to see whether there are burning-out, decrustation, spalling, depression, inflexibility, or
abnormal voice, change parts if necessary.

10. During the service and installation, make sure to apply certain preload onto the conical roller bearings.

- 34 -
 1．Rear supporting ring
2．Copper bush
3．Fixed flange
4．Rear axle sheel
5．Semiaxis
6．Hub bearing axle
7．Braking disc
8．Connector sheath
9．Wheel shell
10．Inner gear ring bearing
11．Inner gear ring
12．Planetary wheel
13．Planetary wheel axle
14．Planetary wheel frame cover palte
15．Sun wheel
16．Planetary wheel frame
17．Steel ring
18．Wheel
19．Sub axle
20．Braker block
21．Main axle
22．Differential right shell
23．Adjusting cushion
24．Bearing seat
25．Flange plate
26．Active spiral bevel gear
27．Rear lid
28．Active bevel spiral gear
29．Differential left shell
30．Bracket
31．Bearing seat
32．Semi-axle gear
33．Spherical washer
34．Planetary gear
35．Cross axle
Fig. 4.4-1 Rear axle structure

Overhauling and installing conical roller bearing must be able to bear certain pretensioning force. For main
transmission conical roller bearing, after pretensioning, the return spiral bevel gear should have a torque of
0.98-3.43 N.m. Drive spiral bevel gear bearing pretensioning force is adjusted by increasing and decreasing
adjusting shim on one terminal of spacer bush. Then screw up the castle nut with a screwing force of 1960 N.m.
When screwing up the nut, rotate driving bevel gear to make the bearing roller located in a proper position on the
surface of bearing internal and external cone.

11. Slaving bevel gear is fixed on differential shell by bolts and nuts with a force of 118N.m.

12. In main transmission bevel gear, the engaging interval should be adjusted to 0.25-0.35 mm, its contacting
imprint is higher than 50% along the gear length and gear height, and is in the middle of the gear face,
slightly closer to the small terminal, it is not on one side or on top of the gear. The adjustment of interval and
contacting imprint can be done by increasing and decreasing the adjusting cushion 23 on the bearing base, or
by increasing and decreasing the cushion on both sides of the differential. The adjustment of contacting area
is every important to the performance and work life, so it must be carefull when operating.

For incorrect imprint adjusting methods, please refer to the table bellow：Incorrect imprint of the slaving spiral

- 35 -
bevel gear and the adjusting method

Imprint position
Adjusting method Adjusting direction
Forward Backward

Move slaving bevel gear to drive bevel gear, if the interval is too
small, move outwards the drive bevel gear.

Move slaving bevel gear away from drive bevel gear, if the interval
is too big, move inwards the drive bevel gear.

Move drive bevel gear to slaving bevel gear, if the interval is too
small, move outward the slaving bevel gear.

Move drive bevel gear away from slaving bevel gear, if the interval
is too big, move inwards the slaving bevel gear.

(V) Steering system

ZLM30E-5 type loader adopts full hydraulic steering system, the system features are as follows:

(1) Follow the requirement of steering oilway, regardless of the load pressure, steering wheel speed, the single
stable valve distribution can ensure sufficient oil supply, therefore, the steering action can be stable and
reliable.

(2) Component is in small size, and structure is firm.

(3) All components are lubricated by pressure oil, with long work life.

* Once engine is flameout, steering system will loose pressure oil supply, it is every difficult to realize steering
under such circumstances, therefore, users should pay particular attention to it.

ZLM30E-5 type steering system is composed of fuel tank 6, steering fuel pump 5, one-way steady flow valve 1,
steering wheel 2, redirector 3 and steering cylinder 4. (See Fig. 4.5-1)

Fig. 4.5-1 Steering system layout drawing

Steering hydraulic tank is shared with working hydraulic system. The fuel pump is CBG2050 gear pump, and is
installed under torque converter shell, and driven by the power coming from engine to torque converter. The fuel

- 36 -
pump transfers the pressure oil to one-way overflow cushion valve bank through one-way steady flow vavle.

One-way overflow cushion valve is composed of valve body and the one-way valve, overflow valve, double-way
cushion valve that are installed in the valve body. When steering an vehicle wheel is blocked, the steering oil
pressure in oil cylinder will rise dramatically, when the pressure is higher than working pressure, the one-way
valve will prevent oil flow back To the oil transfer pump, and make the direction offset. Two-way cushion valves
are installed in the oil hole leading to two sides of oil cylinder, in fact they are two safe valves which is used to
protect oilway system from damage caused by severely crash when it is rapidly steering and the resistance is too
high. The two-way suchion valve is unadjustable; the overflow valve is installed in the whole between inlet hole
and outlet hole. The adjusting pressure is 13.7MPa（140kgf/cm2）, it is mainly used for protecting pressure stability,
preventing overload, and meanwhile when turning steering wheel, it plays a function of unloading overflow.
One-way steady flow valve (FLD-D30H) is to ensure when the engine speed changes, ensure the stable flow that
the steering gear required, to meet the needs of hydraulic steering performance.

Fig. 4.5-2 Hydraulic steering system principle

1. Gear fuel pump 2. First filter 3. Secondary filter 4.fuel tank 5. Steering cylinder 6. Overflow one-way cushion valve
7. Steering gear 8. Channel

The overflow valve is adjusted in producing, don’t adjust it when operating.

Steering cylinder is two-way cylinder, its structure is similar with the working cylinder, and joint bearing is
installed in piston rod pin. Steering cylinder is connected with vehicle front/rear frame. When turning steering
wheel, oil cylinder stretch and pull the hinged frame to realize steering.

Hydraulic steering gear is a key part of the steering system; it is mainly composed of valve body 4, valve bushing
5, valve plug 3, linkage 6, oil distribution plate 7, stator cover 9, rotor 8, plug pin 13, and return spring14, etc.

- 37 -
 Fig. 4.5-3 Hydraulic steering gear
1. Steering shaft 2. Upper cover 3. Valve plug 4. Valve body 5.Valve bushing 6. Linkage 7. Oil distribution plate
8. Rotor 9. Stator cover 10. Needle gear 11. Cushion block 12. Lower cover 13. Plug pin 14. Return spring

Valve cover 5 is inside valve body 4, it is driven by rotor 8 through linkage 6 and plug pin 13, and can rotate in
valve body 4. Valve plug 3 is inside valve bushing 5, and is driven by steering wheel through steering shaft. Rotor
bushing 9 and rotor 8 form the metering pump. Stator is fixed, it has 7 gears, rotor has 6 gears, and they form a
pair of swing needle engaging gear. When steering wheel don’t work, valve plug and valve bushing is in the
middle position by the function of return spring 14. There are 4 nut holes installed with oilway connector, and
they are connected with inlet, return as well as steering oil cylinder.

Working process:

Stator stand still, when steering, rotor can rotate synchronously with the steering wheel, and revolution around
rotor center by the semidiameter of eccentricity e. It forms 7 sealing gear chambers at any moment.

Volumns of the 7 gear chambers are changing as the rotor is rotating. Oil is distributed to these 7 gear chambers
through 7 holes that are uniformly distributed on valve body 4, and 12 holes uniformly distributed on valve
bushing 5; let the pressure oil enter into half of the gear chambers, and the other half of gear chambers will
transfer oil pressure to cylinder.

When steering wheel not work, valve bushing 5 and valve plug 3 will be in the middle position by the function of
return spring 14, Channel from rotors, stators and steering cylinders will be closed, pressure oil enter into valve
plug inner chamber from the small holes on valve plug and valve bushing top, and then return to fuel tank through
valve body return port. While the oil in the chamber of steering cylinder is not able to get in or get out, valve is

- 38 -
not able to move, loader will run at the original direction.

When steering wheel is rotating toward one direction, it drives the valve plug through steering shaft, valve
bushing 5 is not able to rotate temporarily because of the braking of rotor, therefore, it makes a relative rotation
between the valve plug and valve bushing, and gradually open a channel to the chambers of rotor and stator
bushing and steering cylinder, meanwhile, the holes in valve plug and on top of the valve bushing will be
gradually closed. The pressure oil enter into rotor, stator bushing chambers push the rotor to rotate, and through
linkage 6 and plug pin 13 and drive the valve bushing 5 to rotate together with the steering wheel. When steering
continues to rotate, Valve bushing 5 is always rotating synchronically with valve plug 3 (follow the direction of
steering wheel), and keep a relative angle. The relative angle ensures the oil channel that is needed for rotating
toward the direction to enter into the rotor. Stator bushing chamber pressure causes the rotor to rotate, meanwhile
press the oil to one chamber of the cylinder, and oil in the other chamber passing from return channel of inner
steering gear to the return tank. When the wheel continues to rotate, steering gear will send the proportional oil
volumn with the steering wheel angle to the steering cylinder, and to drive the valve, push the frame to turn, so as
to complete the steering action. At this moment, rotor and stator play a function of metering pump.

Steering wheel stops rotating, that is valve plug 3 stops rotating, due to the function of valve bushing 5 and return
spring 14, the relative angle of valve plug and valve bushing disappeared immediately, and steering gear is back to
the middle position. Loader runs along the controlled direction.

Steering system doesn’t need to be maintained frequently, just add lubrication gease to the two ends of the fuel
cylinder regularly. In addition, please notice when installing, splined tooth coincident with linkage and plug pin
seat should be installed in tooth slot that is right opposite to the rotor. (See Fig. 4.5-3), otherwise oil distribution
will be damaged; steering wheel will be out of control.

2. Steering hydraulic system main parts performance parameter

2.1 Steering fuel pump: CBG2050, displacement: 50 ml/r

2.2 Load sensor full hydraulic steering gear BZZ1-400：Nominal displacement: 400ml/r, maximum inlet pressure:
14Mpa.

2.3 One-way steady flow valve FLD-D30H, steady flow 30l/min, maximum allowed inlet pressure 20Mpa.

2.4 Cushion oil compensation valve block: FKA-143020 is composed of the two-way oil compensation cushion
valve and a one-way oil inlet cushion valve. Cushion valve protects the overload between steering gear and
steering cylinder systems. At the same time, when one chamber of steering cylinder oilway is overloaded, and
cushion valve unloading, the two-way compensation valve will compensate oil to the other chamber, to prevent
system corrosion. Valve block rated pressure is 14Mpa.

Two-way cushion valve rated pressure is 20 MPa, two-way compensation valve starting pressure is 0.1 MPa, and
these are adjusted when the loader left the factories and canot not be changed, otherwise it will affect the stability
of system.

2.5 Steering cylinder: cylinder diameter: φ70mm, lever diameter: φ40mm, minimum installation size: 650mm,
maximum installation size: 986mm， stroke: 336mm, working pressure: 14mpa。

3. Steering system maintenance

3.1 Steering system working oil shoud be kept clean, and change once every half a year according to actual
working conditions.

3.2 In order to keep system clean, filter should be cleaned once every month.

3.3 According to actual working conditions, in half a year or one, overhaul and clean every part of the steering
system once.

- 39 -
 (VI) Breake System
ZLM30E-5 loader is equipped with driving brake system and emergency brake syste (parking brake system) (see
Fig. 4.6-1 brake system)

Shift gear valve

Fig. 4.6-1 Brake system

1. Braker 2. Brake chamber 3. Three-way valve 4. Two-position three-way directional valve 5. Manual control valve
6. Pressure gauge 7. Air drum 8. One-way valve 9. Air compressor 10. Brake valve 11. Brake sensor (switch)
12. Brake booster 13. Brake

1. Emergency brake system (parking brake system):

The system shares one air draum with driving brake syste, and is composed of manual control valve (5), two
position three way directional valve (4), three way valve (3), brake chamber (2), and braker installed in front of
transmission output shaft, the braker is internal expanding type.

When air pressure is lower than 0.4 MPa, manual control valve will automatically pop up by the spring, and
compressor air coming from air drum will be cutted off, braker will also automatically return to braking status.
When air pressure is higher than 0.4 MPa or above, manual control valve can be pressed, and compressor air
coming from air drum will pass the valve and enter into braking chamber. The valve will push top lever to drive
braking braking shoe, release the braking, and preparing for starting. When air pressure is higher than 0.4 MPa,
manual valve can be pull up to realize braking, meanwhile, by the function of return spring, the two-position
three-way directional valve will transfer the air from air drum passing from three-way valve into gear cutoff valve
to block the power and protect the vehicle, and avoid misoperation. When the loader needs to be parked on hill for
a long time, or needs to be braked on flat ground, this system can be used. It can also be used in emergency
conditions.

2. Driving brake system

Driving brake system is air over hydraulic clamping disc type; it is composed of air pump (9), air drum (7),
braking valve (10), braking booster (12), and braker (13). Air pump is installed in the engine, when engine works,
it drives the air pump, and compressed air enters into air drum. The air drum is equipped with safe valve, the safe
valve control system pressure is 0.833-0.9 MPa, when pressure exceeds, the safe valve will be open automatically,
and exhaust part of compressed air.

Brake valve is connected with air drum through channel. When pressing brake pedal, outlet valve will open, and
compressed air from air drum will be pushed by brake valve into the two brake boosting cylinders installed in
front & rear frame. And then push cylinder valve, and push the brake master cylinder valve by roof bar, and make

- 40 -
the braking oil generating high pressure in cylinder, and thus flow from outlet. Because air cylinder valve area is
large, when oil cylinder valve area is smaller, and inputed air pressure is 0. 784Mpa（8kgf/Cm2）, the output oil
pressure will increase to about 11.96 Mpa (122 kgf/cm2）, that means the pressure increased to about 15.3 times of
the original value, see Fig. 4.6-2).

Braker is installed in two ends of front and rear axles. It is composed of main/sub axle, valve, dome, brake block
etc. When braking, the high pressure oil in brake master pump will enter into main/sub axle cylinder to push the
valve, dome, and make braking block firmly clinch the braking disc that is rotating with vehicle wheel, and plays
a function of braking.

3. Brake system maintenance and adjustment

To ensure the braking is reliable, brake system should be carefully maintained. Eliminate leakage in the braking
parts, oiling and changing oil frequently, and bleeding air of the braking hydraulic parts.

A. Check every day before driving the vehicle to see if there is leakage. Oil leakage check and be done by
observing directly; air leakage check can be done by observing the air gauge. In normal conditions, when the
loader started, if air pressure rise gradually, while the engine stops, air pressure decreased quickly, then it indicates
that the leakage is serious. In this case, dressing some soap water in the connector of every tube, and check the
brake valve outlet vent, eliminate the leakage.

Inlet Outlet

Fig. 4.6-2 Booster profile fig.

1. Valve 2. Y-type sealing ring 3. Dome 4. Oil cup 5. Sealing ring 6. Air bleeding nut

B. Fill up brake oil in oil pool of the brake master pump, during the whole working time, oil should be kept
above half of the pool capacity. The brake oil cannot be substituted by other mineral oil or degenerative oil;
otherwise the brake system rubber sealing will be disabled. If the brake oil darkening, moisture, smelly or
lack of lubrication when feel it with fingers, then the oil needs to be changed. When changing oil, clean and
purge all hydraulic brake channels as following steps:

a. Loose air bleeding valve of the braker.

b. Start engine and charge air continuously, pressure brake pedal several times untill there is no oil flowing out
of the air bleeding hole.

c. Add alchol into brake master pump oil pool. Press brake pedal again, and purge channel and braker, untill
fluid completely flowed out from every air bleeding hole.

d. Add fresh brake oil; use the same method to purge the channel.

e. At last fill with brake oil and bleed air.

- 41 -
C. Brake hydraulic system air bleeding

When system is leaking or oil level is low in master pump, it will cause air intaking and mixing with brake oil.
When air is mixing with brake air, it will cause malfunction of braking, braking disc will be heating, in this case,
air bleeding is needed. Air bleeding needs to be done by two persons, one presses the brake pedal, the other opens
air bleeding valve. The operation steps are as follows:

a. Start engine and make the air drum filled with compressing air, then turn off the engine.

b. Wipe the lid of brake master pump, take off the lid, and fill in fresh brake oil.

c. Press braking pedal, loose air bleeding valve, bleed air repeatedly for several times, untill no air bubble
coming out; compensate brake oil continuously when bleeding air.

d. Screw up bleeding air, fill in brake oil full.

D. Keep the brake block and brake disc clean withou greasy dirt, when the brake block lining thickness is
abrasive and lower than 5mm, it needs to be changed.

E. Looses the water drain valve after every working cycle, drain the water completely.

(VII) Working device and its hydraulic system

(1) The working device is installed in the front frame of the vehicle (Fig. 4.7-1), and is mainly composed of
swinge arm 4, swing arm 3, draw bar 2 and tools (log grapper, bucket 1, mould board ……). When the tools
are placed on the ground flatwise, they can be kept flat during the lifting process; when buckets are folding,
they can be kept folding during the lifting process.

Fig. 4.7-1 Working device and its hydraulic system

The whole working device is composed of hydraulic control, gear fuel pump installed on torque converter shell by
hydraulic system 9, working fuel tank with filter and oil mark 10, control handle in the driver cab 8, multi-channel
directional valve 6, lifting oil cylinder 7, and rollover oil cylinder 5 etc.

Fuel tank is as shown in Fig. 47-2. There are filling hole and filter gauze above the tank, and the underneath outlet
venting is connecting to gear fuel pump; upper front of the tank is return channel. The secondary filter is located
in return channel whole for eliminating impurities and dirts. When the filter gauze is dismantled for regular
cleaning, only uncrew 6 bolts on the filter lid, and take off the lid, the secondary filter assembly will be pulled out
easily. There is oil draining plug for regular oil change and cleaning, change the oil at least once every year. The
tank is working under the principle of syphon. Therefore, when overhauling the hydraulic system, just loose the
fuel tank lid to avoid hydraulic oil flowing out.

The fuel pump is CBGj2100 gear pump; its working pressure is 15.7 Mpa (160kgf/cm2).

(2) The multi-channel directional valve is two-way or three-way slide valve (Fig. 4.7-3), there is safe valve in it

- 42 -
 for controlling the work pressure of the whole hydraulic system. The pressure is adjusted aready, users
should not change it.

(3) Working device hydraulic system working principle

When engine is working, it drives the working fuel pump to rotate and output pressure oil, and the oil is
distributed into oil cylinder through multi-channel velve to stretch the oil cylinder, so as to realize working device
motion.

Control handle a has 4 controlling poistions: “lifting”, “middle”, lowering”, and “fluctuating" (Fig. 4.7-5), control
the swing arm’s “lifting”, “keeping”, “lowering” and “fluctuating” states manually.

When pulling control handle a backwards, and pull the lifting valve lever in the multi-channel valve rightwards by
a soft axle in lever system. Pressure oil flow into swing arm cylinder big chamber through multi-channel valve,
and pull upwards the valve. At the moment, the small chamber of swing arm cylinder will be connected with fuel
tank through multi-channel valve, and swing arm plays a function of “lifting”.

When pulling control handle a forward, and pull the lifting valve lever in the multi-channel valve leftwards by a
soft axle in lever system. Pressure oil flow into swing arm cylinder small chamber through multi-channel valve,
and pull downwards the valve. At the moment, the big chamber of swing arm cylinder will be connected with fuel
tank through multi-channel valve, and swing arm plays a function of “lowering”.

Push control handle a forward to “lowering” position, and push forward continuously, it will reach the
“fluctuating” position. Meanwhile the multi-channel valve connects the fuel pump, fuel tank, big and small
chambers of swing arm cylinder; and the big and small chamber of swing arm are also connecting with each other,
therefore, the position of swing arm cylinder can be fluctuating in the cylinder without any limitation. And the
bucket can make the swing arm lifting freely in accordance with the ground condition.

The control handle has three controling positions: “rolling up”, “middle”, and “rolling down” for controlling the
bucket’s states of “rolling up” (drawing back bucket), “maintaining” and rolling down (putting down bucket).

When pulling control handle b backwards, and pull the bucket valve lever in the multi-channel valve rightwards
by a soft axle in lever system. Pressure oil flow into bucket cylinder big chamber through multi-channel valve,
and pull forwards the valve. At the moment, the small chamber of swing arm cylinder will be connected with fuel
tank through multi-channel valve, and the bucket plays a function of “rolling up”.

When the handle b is in middle position, bucket valve lever will back to middle position by the spring, and make
the big and small chambers in bucket cylinder locked, and bucket is in “maintaining” status.

- 43 -
 Oil outlet

Fig. 4.7-2 Hydraulic fuel tank

1. Fuel tank body 2. Magnetic block 3. Secondary filter assembly 4. Secondary filter cover 5. Filling hole

6.Vacuum bolt

Simillarly, when pushing control handle b forward, bucket will play a function of “rolling down”.

The loader adopts two-way working cylinder, their structures are basically the same; see Fig. 4.7-4.

Middle locking of control handle:

When control handles a, b are in “middle” position, roll down the locking lid on top of control tank inwards, the
slot in locking plate happens to lock the control handle, and lock the handle so it is not able to swing back and
forth.

(4) Working device hydraulic system main parts structure and performance

A. Working pump: gear pump GBGj 2100, displacement 100ml/r

B. Fuel tank: working devices hydraulic system shares a fuel tank with capcacity of 120L with the steering
hydraulic system.

C. Filter: both the first and secondary filters are placed inside the fuel tank. First filter uses filter gauze; while
secondary filter combines filter gauze and magnetic corn, which ensures the cleaness of the oil.

D. Multi-channel valve: entire multi-channel valve DF32, main safe valve adjusting pressure 15.7 Mpa, nominal
flow 250r/min.

- 44 -
 Fig. 4.7-4 Bucket fuel cylinder
1. Valve lever 8. Shaft bushing 3. Bearing ring 4. Cylinder head 5. Cylinder body 6. Bearing cup 7.valve
9. Dustproof ring 10. 11. 0-type ring 12. Glyd ring 13. Nut

Multi-channel valve includes rotating bucket and swing arm valve (one more assisting valve is allowed to be
added when necessory). The motion of rotating valve lever can be used to control the length of rotating cylinder to
realize the “rolling up”, “maintaining” and “rolling down” of the bucket. Also, the motion of swing arm valve
lever can be used to realize the swing arm in any of the states of “lifting”, “maintaining”, “lowering” and
fluctuating” to meet the requirements of the operation.

E. Bucket fuel cylinder

- 45 -
Cylinder diameter: φ150，lever diameter: φ70，minimum installation size: 1034mm maximum installation size:
1468mm

Clamping jaw fuel tank

Rotating bucket
cylinder
Lifting cylinder
Swing
arm
control
Float Lower Neutral position Lift

Rotati
ng
bucket
Upward rotate control
Lower Neutral position

Clamp
ing
jaw
Clamp Multi-way
Neutral control
position
reversing valve

Oil tank

Fig. 4.7-5 Hydraulic system principle

F. Swing fuel cylinder

Cylinder diameter: φ125, lever diamter: φ70, minimum installation size: 1163mm

Maximum installation size: 1860mm

(5) Working device and its hydraulic system repairing and maintenance precaution:

Most hydraulic system faults are caused by pollution of the oil, therefore, it is vital important to keep the oil lever
cleaness, prevent the oil from being polluted by dust, impurity, moisture, etc. The followings are the precautions
that should be noticed when operating:

A. The oil change period should be in accordance with this instruction, the methods are:

a. Drain the exhausted oil before the temperature is lowering down, so that dust and deposits will be exhausted.

b. When control bucket rolling up and swing arm lifting to the highest position, turn off the engine, then use
swing arm and bucke rolling down to exhaust the oil in cylinder completely.

c. Loose the nut in bottom of the fuel tank and fuel cylinder. Exhaust dirty oil, and clean the chamber of fuel
tank. Dismantle the filter; ensure the chamber of the tank is clean without any dirt, pollution and impurities.

B. When filling in fresh oil:

a. Change new oil once half a year.

- 46 -
b. Fresh oil should be precipitated for 48 hours.

c. When filling oil, use filter for filtering, don't pour the oil into the tank directly without filtering.

C. Working hydraulic system daily maintenance

a. Clean the filter once in a month.

b. According to working conditions, clean these working hydraulic system parts annually: multi-channel valves,
fuel cylinders, and connectors. When dismantling, be carefull of damaging the accessories, and clean the
accessories.

c. When conducting daily check or maintenance, do notice the cleaness; don't put randomly the pipe units,
connectors and other hydraulic accessories on the ground, otherwise they will be dirty and carries impurities
to the hydaulic system.

D. Check frequently the fastness of every connection in the working units to see if there is any crew loosed and
cutted off, if any of the bolts disabledm repair it immediately.

E. Check the load-carrying parts, if there is out part out of shape or with weld failure, repair it immediately.

F. Fill lubrication gease regularly according to the lubrication Fig. indicates.

G. Regularly fill oil into the tank as required, change oil and clean the oil filter. When change oil, drain the oil in
the tank, cylinder and tube as soon as possible when the oil is hot.

H. The working temperature should be kept among 35-80℃. Run the engine for a while when it is in cold
weather, start operating when oil temperature rised. While in summer, stop for a while when oil temperature
is too high, don't keep it working continuously.

I. Working pressure is not allowed to be adjusted randomly. If it does need to be adjusted because of safe valve
fault or overhauling, please connect pressure gauge in the valve inlet tube, and then adjust the pressure from
low to high till it reaches 15.7MP（160kg/cm2）.

J. Naturalsettling check

Load capacity: 3 tons.Rotate the bucke backward to the bottom, lift the upper arm to the top, engine run in idle,
keep for 5 minutes, and then check the lowering distance of the upper arm cylinder valve lever, the distance
should not exceed 18mm, otherwise check the inner leakage and oil sealing conditions

☆It is prohibited to run into the piles when the loder is operating at high speed.

(VIII) Electrical system

Electrical system is shown in Fig. 937H.18

The electric system is a 24V system with engine, engine rated power is 1000W, and battery capacity is 120AH.
The two batteries are installed on two sides of the rear frame, inside the frame, cutoff power switch is installed.
The fuse box, relay are installed in the meter, turn on the power switch, the whole system power can be cutoff.
Turn on the battery switch before overhauling, and cutoff power.

The electric system adopts single line system, with negative pole grounding.

System instruction
(1) Accumulator battery bank

The loader adopts two banks of maintenance free type 12V battery with series connection. The negative pole of
bank1 battery is connected with the positive pole of bank 2 battery. Negative pole battery switch is grounded, and

- 47 -
positive pole of bank 1 is connected with fuse box through key switch controlling relay, and reaches the electric
devices. Battery positive pole also connected directely with starting engine through lead. When colse the power
closing switch, and turn on electric switch, power is supplied to the electric devices.

Notice the following precautions when using the battery:

A. Battery installed in frame rear sides should be fixed firmly to prevent bumping and disabled when running,
connectors connecting with battery pole should be tight.

B. Keep battery external clean, avoild of electric leakage.

C. Check discharging level of battery, when the discharging is out of range, charge it immediately.

D. Don’t start engine continuously, every starting time should not exceed 5s, if the engine cannot be started once,
stop starting for at least 15s before starting again.

E. Don’t put metal stuff on the battery, avoid of short circuit. It is prohibited to use metal tools like screw or
lead to connect directly with battery pole to see if there is spark and thus to judge if the battery is normal, which
will burn down the battery pole and wast battery capacity.

- 48 -
937H.18 Electrical system

- 49 -
F. Before electric system working, or when dismantling battery wire, please turn off battery switch to prevent
short circuit or firing.

(2) Silicon rectification generator and adjustor:

The load installs silicon rectification generator, which is matching products for diesel engine. Generator voltage is
28V, power is 1000W, and voltage adjustor is equiped inside. In normal condition, engine working and charging
the battery at the same times, and charge the electric devices as well.

Silicon rectification generator precautions:

A. As engine requires, battery negative pole must be grounded, don’t connect inversely, if so, battery will
discharge in short circuit by diode, and the diode is in “engine” will be burned down, relative circuits will
also be burned down.

B. When engine is running, it is prohibited to short connected the engine “armature” binging post with the outer
shell to see if there is spark and thus to judge if the engine is normal, which will burn down the diode.

C. Don’t make engine “magnetic field” binding post grounding, avoid of damaging the adjustor.

D. When checking the engine isolating property, if using 220V alternator or megohm meter, should depart the
connection of diode with other parts. Or use other universal meter of high resistance for checking.

E. When engine is used for 1200 hour or so, dismantle the engine, exam and repair it. Contents:

a. Clean the external and internal of the engine.

b. Clean and check the bearing and slipping ring. If the bearing is loose, change for other one, the slipping ring
should be polished by “00” gauze.

c. Check the abrasion of the carbon brush, if it is seriouly brasive, change for other one.

d. Check if the carbon brush holder is good, and if the shell is isolation. If the carbon spring is not flexible,
change for other one.

e. Check the diode one by one with universal meter of high resistance. The normal state is: positive resistance
should be about 10ohm, and negative resistance should be 10,000ohm. If the two valves are similar or of
great difference, it can be considered the diode is disabled, and should be changed.

f. Check the contact stability of internal connectors.

(3) Starting motor

The starting motor is matching products for diesel engine. Starting motor is used to realize the diesel starting
through the starting relay controlled by key switch.

Starting motor operation precautions:

A. Check frequently if the wire is good, and if the connecting bolt is tight.

B. Keep it clean and waterproof.

C. Starting motor should be maintained regularly. The maintaining can be performed when repairing the loader.
Use gas to wipe the internal oil dirt, and use “00" gauze to polish the commutator and contat point of
magnetic switch.

(4) Lighting units:

The loader is equiped with front/rear headlight, working lamp, front signal light, and taillight, front/rear steering
lamp, braking light, reversing buzzer, cab dome lamp, steering indicating lamp, brake indicating lamp, etc.

- 50 -
 V. Regularly technical maintenance
Under general working conditions, regular maintenance includes: daily maintenance (8~10h), weekly maintenance
(about 50h), monthly maintenance (about 200h), quarterly maintenance (about 600h), semiannually maintenance
(about 1200h), and annually maintenance (about 2400h). Users can maintenance the loader according to the
working time, specific working conditions and actual technical status of the loader.

(I) Daily technical maintenance

1. Chech engine oil level, refuel oil if the level is below dipstick line; if the level too high and the oil gradually
turns lean, check the reason and eliminate the fault.

2. Check fuel tank oil level, and fill it as full as posible.

3. Check the torque, transmission, fuel pump, and hydraulic steering gear for the fixation, sealing and
overheating problem.

4. Check leakage of oil, water, and air channel.

5. Check if the connecting bolts of driving axle and hinge pin lost or loose.

6. Do some necessory cleaning work, clean the oil dirt, dust and impurities etc.

7. Check if there is abnormal voice in the running of every part.

(II) Weekly technical maintenance

Except or daily technial maintenance, there are weekly items as below:

1. Fill oil and change oil according to the lubrication Fig.;

2. Clean engine oil filter and first filter;

3. Check the tightness of fan belt and make necessory adjustment;

4. Check battery oil level and connector, dress thin layer of Vaseline oil in the connector;

5. Check the disk braker linings and air bleeding conditions.

6. Check the control lever system including acceleration pedal, brake, and shifting, etc., and check the pedal
stroke and clearance.

(III) Monthly technical maintenance

Except for the daily and weekly maintenance, there are monthly maintenance items as below:

1. Clean air filter;

2. Check tire pressure and abration, tire pressure is 0.275-0.294MPa（ 2.8-3.0 kg/cm2）,

The pressure is lower as the ground is softer;

3. Clean working hydraulic oil and transmission filter.

4. Apply lubrication gease into the water pump bearings, driving axles and control levers;

5. Check the oil lever of front/rear axle main driving and rub reduction gear, keep it in specified level;

6. When working for 150 hours, please dismantle brake mater pump vlave and sealing rubber cup, check if
there is mechanical damages, and slots in sealing edge, if so, change the faulty parts.

7. Check and fix the rocker, front/rear axle wheel hub, and braker bolts;

8. Check front/rear frame, load-carrying weld joints in working positions.

- 51 -
 (IV) Seasonal technical maintenance
Except for the daily, weekly and monthly maintenance, there are quarterly maintenance items as below:

1. Clean engine cooling system;

2. Lubricate charging engine and starting motor;

3. Check engine valve clearance, and make necessory adjustment;

4. Check the injection volumn and injection pressure of the injection pump;

5. Check and clean venting hole of the brake master pump and front/rear axle, transmission, torque converter;

6. Apply lubrication gease to tretching Driving axle;

7. Change diesel crank case and injection pump oil;

8. Check air leakage of the pressure pump, air drum, brake valve and air channel.

(V) Semiannually technical maintenance

Except for the daily, weekly, monthly and quarterly maintenance, there are semiannually maintenance items as
below:

1. Lubricate, clean and change oil according to the lubrication Fig.;

2. Check braker abrasion and change it when necessory;

3. Check all meters and lights.

4. Check and change brake master pump sealing rubber cup.

(VI) Annually technical maintenance

1. Exam and repair the diesel engine according to engine instruction book;

2. Dismantle and check the transmission, torque converter, front/rear axle, differential, and hub reduction gear
according to actual conditons, repair and change the disabled parts.

3. Check steering gear and steering angle, idle clearance and make necessory adjustments;

4. Dismantle and check brake system, repair and change disabled parts;

5. Check multi-channel vavle and cylinder sealing by checking the working cylinder naturalsettling. If the
naturallsettling exceeds 20mm/min, it means that the inner leakage is serious, and should dismantle and
check the cylinder and multi-channel valve.

6. Check working devices and vehicle frame to see if they are out of shape, disengaged or disabled, if so, repair
the faults in time.

- 52 -
 VI. Common fault and elimination methods
Parts Faulty features Possible reasons Elimination methods
1. Change electricity
1. Accumulator battery low.
2. Supplement fresh oil
2. Fuel tank lack of diesel.
3. Dismantle the motor to check and adjust
Diesel engine is 3. Starting motor fault or gear not rotate or no
the starting motor, or change a new one.
not able to start power supply.
4. Check and connect the circuit connector.
4. Electric circuit connector disengaged.
5. Refer to the diesel instruction book of the
5. Diesel engine fault
faulty elimination methods.
1. Push the directional lever and gear lever
The entire machine fault

1. Not put into gear.

to the connection position.
2. Transmission lack of oil, oil level lower than
2. Supplement fresh oil
tipstick line.
Diesel engine run, 3. Change new oil sealing ring.
3. Clutch axle oil sealing ring disabled.
Vehicle don’t 4. Dismantle and check if the O-shape ring
4. Braking unloading valve lever in the gear valve
move too tight, and if the sealling cup rolling
is not able to return.
up.
5. Oil pump disabled.
5. Change fuel pump.
Ⅰ.

6. Emergency braking not released.

6. Release the emergency braking.
1. Check and eliminate the fault according
to instruction book.
Driving power 1. Engine lack of power.
2. Loose manual braking and bleeding the
insufficient, 2. Braking not loose or braking disc.
wheel braking.
running speed is 3. Transmission oil pressure low, clutch slipping.
3. Check the transmission clutch and adjust
low. 4. Transmission fuel volumn insufficient.
the torque converter inlet valve pressure.
4. Supplement fresh oil
1. Off-loading or stop working for a while.
1. Continuous working time too long.
Oil temperature 2. Discharge or charge oil according to the
Torque and

2. Transmission oil level too high or too low.

transmission

too high, torque tipstick line.

3. Oil radiator blocked.
converter 3. Clean radiator.
4. Clutch friction plate out of shape, and not fully
transmission oil 4. Change clutch friction plate.
disengaged, frict and heating.
Ⅱ.

too hot. 5. Dismantle the part and clean it. Reset the
5. Gear valve cannot be totally resetted.
valve or change it when necessory.
1. Supplement fresh oil
1. Transmission oil level low.
2. Dismantle the first and secondary filter
2. Oilway not clean, first and secondary or
and distribution valve. Use pure oil for
distribution valve is blocked, distribution valve
purging, discharge the oil in the tank
plug stucked.
completely, and then fill in fresh oil.
3. Distribution valve stable pressure valve stucked
Torque and transmission

Gear no pressure, 3. Dismantle the part and clean it.

or throttle hole blocked.
no gear, or gear 4. Adjust inlet valve end nut. Press the
4. Torque converter inlet valve pressure too low.
pressure too low. spring to increase pressure.
5. Distribution valve slaving valve plug stucked,
5. Clean distribution valve, change O-shape
O-shape ring disabled.
ring.
6. Gear valve chamber leakage.
6. Change valve body.
7. Clutch axle oil sealing disabled.
7. Change oil sealing ring.
8. Oil pump disabled.
Ⅱ.

8. Change fuel pump.

Gear pressure
waving 1. Oil system indrawing too much air, which form 1. Check if the channel splitted or if air
dramatically, hydraulic impacting and waving. needs to be exhausted completely.
running unstable.
Digging lack of 1. Relative position is incorrect between the gear 1. Adjust the relative position between the

- 53 -
Parts Faulty features Possible reasons Elimination methods
power, gear controling handle and gear valve lever. controling handles and gear valve lever,
incorrect, running 2. Oil temperature too high. screw up the nut.
unstable. 2. Handle the problem according to the
elimination method to overtemperature.
1. One of the gear clutches drive/slaving friction
plates stucked.
Break down when 1. Dismantle and check transmission,
2. Oil sealing ring of one clutch shaft disabled,
operation or change friction plate.
forming two gears intaking oil pressure
running. 2. Change oil sealing ring.
simultaneously, or oil entering gear entering
into cooling hole.
1. Adjust clearance, wheel hub should be
1. Wheel hub bearing clearance too large.
Wheel deflected able to rotate freely.
2. Tire installation not good.
Front rear drivin axle

when running. 2. Re-install the tire correctly.

3. Wheel hub fasting bolt loose.
3. Fasten it.
1. Bearing assembling clearance too small. 1. Adjust the clearance.
2. Lubrication oil too much or too little. 2. Properly discharge or charge oil.
Heating.
3. Venting hole blocked. 3. Clean venting hole. Change sealing parts,
4. Sealing part disabled, oil leak. charge oil.
Ⅲ.

1. Bolt, nut lost or loose. 1. Fix or change bolt or nut.

Abnormal noises
2. Lubrication oil insufficient and cause abrasion. 2. Apply lubrication oil.
exit.
3. Lubrasion oil unqualified or impurified. 3. Change for qualified lubrication oil.
4. Adjust it, contacting imprint should be
4. Main slaving spiral bevel gear clearance
above 50% along gear length and gear
incorrect, gear surface not well engaged.
height direction.
Front rear drivin axle

Oil leakage in
driving end top,
wheel edge
bearing 1. Bolt loose. 1. Fix it.
combining 2. Frame work oil seal disabled. 2. Change the frame work oil seal.
surface, hub 3. Combining surface fluffing and rough. 3. Flat the surface.
Ⅲ.

reduction and 4. O-shape sealing ring out of shape or disabled. 4. Change the O-shape sealing ring.
wheel hub
combining
surface.

1. Working hydraulic fuel tank oil level too low.

1. Fill in oil as specified.
Too much 2. Channel leak, sealing disabled. 2. Change sealing part, fix the connector.
steering ring, 3. Cylinder inside leakage, flow insufficient. 3. Change oil sealing ring.
system

steering torque 4. Steering gear rotor abrasive. 4. Change the abrasive steering rotor.
insufficient. 5. Temperature low, oil sticky, or using the 5. Change oil as specified.
Steering

improper oil. 6. Adjust pressure to 14Mpa.

6. Steering valve pressure low.
Ⅳ.

1. Rotor and stator locked, valvel plug, valve 1. Dismantle and check, clean and reset the
Not able to steer body, valve bushing locked with each other. malfunction parts. Or change the part.
or steering 2. Linking plug break. 2. Change the malfunction part.
malfunction. 3. Spring disabled. 3. Change the malfunction part.
4. Steering fuel pump invalid. 4. Change the malfunction part.

- 54 -
Parts Faulty features Possible reasons Elimination methods
1. Rubber sealing ring disabled.
1. Change rubber sealing ring.
Oil leakage. 2. Combining surface rough or cushion ring
2. Flat or change cushion ring.
disabled.
1. Air pressure too low. 1. Check air leakage and eliminate the fault.
2. Accerator rubber sealing cup abrasive. 2. Change the faulty part.
3. Braking vale intaking air delayed. 3. Check and adjust the size of the inlet
4. Braking valev exhausting valve leakage. valve hole of the brake valve.
5. Braking hydraulic channel and disc braker 4. Repair the faulty part.
Break system

Braking power
leakage. 5. Check and repair the faulty part.
insufficient.
6. Air entered into braking hydraulic tube. 6. Bleed air.
7. Brake master pump oil inlet hole blocked. 7. Clean the hole.
8. Brake oil insufficient. 8. Fill oil.
Ⅴ.

9. Brake block abrasive. 9. Change the brake block.

10. Brake block saturated by oil. 10. Change the brake block.
Step missed
occassionally 1. Master pump rubber sealing cup edge is
1. Change rubber sealing cup.
when pressing the abrasive and slotting.
2. Change master pump valve.
brake pedal, but 2. Inflexible, aging.
3. Change rubber cup sealing layer.
return normal 3. Rubber cup sealing layer rolling up.
after a while.
1. Braking valve exhausting hole blocked. 1. Clean the hole.
Braker is not able 2. Booster motion not good. 2. Check the booster.
to loose normally. 3. Air entered into braking hydraulic system. 3. Bleed air.
4. Braker rubber sealing cup roll-up valve stucked. 4. Check and clean oil sealing or change it.
1. Check air compressor.
Pressure rise 1. Air compressor is not working normally.
Break system

2. Fix the connector, Change sealing part if

slowing when 2. Channel connector loose.
necessory.
engine is running. 3. Air drums leakage.
3. Check every part of the air drum.
1. Check and repair or change the faulty
Ⅴ.

part.
Air pressure drop 1. Air drain valve and safe valve in the air drum is
2. Change the channel and sealing part, fix
down quickly not well sealing.
the connector.
when engine 2. Channel splitted or connector loose.
3. Press brake pedal several times, blow
stops. 3. Braking valve inlet valve stucked or disabled.
away the dirt. Change the faulty part if
necessory.
1. Adjust to rated pressure.
2. Change oil pump or adjust slipping valve
1. Safe valve pressure adjusting improper.
and valve body clearance.
system

Working device 2. Gear fuel pump and valve clearance are leaking
3. Clean the filter.
motion speed is seriously.
4. Fill in qualified oil to the specific oil
low, lifting force 3. Feul tank filter blocked.
Working hydraulic

level.
insufficient. 4. Fuel level low, using improper oil.
5. Check the sealing part according to
5. Cylinder inner leakage.
natural settlement volumn. Change oil
sealing part.
Too much
1. Oil quality is poor. 1. Change oil.
hydraulic oil
Ⅵ.

2. Oil level is low. 2. Fill oil.

foam.
1. Inlet channel or filter blocked. 1. Clean fuel tank and channel.
Oil pump is noisy.
2. Too much foam in oil. 2. Fill oil or change oil.

- 55 -
Parts Faulty features Possible reasons Elimination methods
Hydraulic
cylinder running 1. Oil level low or air enters into the system. 1. Fill oil, bleed air.
unstable and 2. Feul tank filter blocked. 2. Clean or change the filter.
shaking.
1. Tight the belt.
system

Generator fault or 2. Check diesel engine ir running in low

charging current speed, short connect the “ignition” and
is very low. (In the 1. Driving belt loose or slipping. “magnetic field” of the two terminal of
Electric

condition of 2. Adjustor fault. adjustor. Observe the spark, if spark

battery not fully appears, and current gauge indicating
Ⅶ.

charged.) charging, it proves that adjustor is fault,

and need to be changed.
3. (1) Check if generator supplying power
by DC voltage meater. Connect voltage
meter (+) with generator “armature”
binding post, Connect voltage (-) with
generator sheel. When engine is running,
the voltage meter indicates the battery
voltage rise to 28V, this means generator
is working normally; if voltage meter
reading not changed, it indicates that the
generator is not supplying power.
(2) Check if engine supplying power by
3. Generator fault. bulb.First, dismantle the lead connecting
to engine “armature” binding post. And
then connect the live line of the bulb on
board (ig. Panel light) with the
“armature” binding post, not need to
system

connect the other terminal (grounded).

When engine runs in low speed, bulb
Electric

on, it indicates the generator is supplying

power. If the bulb is not lighting,
generator is not supplying power.
Ⅶ.

When the engine is fault, dismantle it

for repairing.
1. The key is not in “ON" position for long time 1. Turn the key to “ON” position.
Battery voltage when driving the vehicle. 1. Conduct some assisting work to change
comsumption is 2. Working cycle time too short and battery not the battery or dismantle it for charging.
fast. fully charged. 3. Check and repair the circuit, keep clean
3. Circuit electricity leakage. of the battery surface.
1. Accumulator battery low. 1. Charge electricity or change battery.
2. Starting motor circuit connector loose. 2. Fasten the nut.
Disel starting
3. Carbon brush abrasive or connection not good. 3. Repair or change a new carbon brush.
difficult.
4. Starting switch disabled. 4. Change switch.
5. Circuit open or not good. 5. Check and repair the faulty part.
Ammeter pointer 1. Engine carbon brush is not well connected. 1. Dismantle and repair it.
swinging angle 2. Adjustor contacting point not well connected. 2. Dismantle and repair it.
too large. 3. Connector loose. 3. Check and screw it up.
Charging current 1. Adjustor adjusting voltage too high. 1. Re-adjust it to the specific range.

- 56 -
Parts Faulty features Possible reasons Elimination methods
too high. 2. Adjustor contacting point burned down. 2. Dismantle for repairing or change a new
3. Adjustor coil terminal disengaged or not one.
functioning. 3. Open the adjustor and weld it again.

Parts Faulty features Possible reasons Elimination methods

1. Horn relay contacting point burned down. 1. Change a new horn.
Horn not sound. 2. Horn coil burned down. 2. Repair or change a new horn coil.
system

3. Circuit fault. 3. Check and repair the faulty part.

Steering lamp not
Circuit fault. Check the fuse flasher and bulb.
lightening.
Electric

Other
illumination 1. Check the fuse.
Ⅶ.

lightings and Circuit fault. 2. Check the bulb.

indicating lamp 3. Check the circuit and repair it.
not lightening.

Compressor Check the fan connector to see if it is disengaged or is

Cooling fan works it well grounding, check if fan is disabled.
Evaporating doesn’t work. Compressor Check temperature controlled switch, relay, and relay
fan rotate. doesn’t work. connector.
Cooling fan Compressor Checke if clutch is disabled, if connector is
works. doesn't work. disengaged, if belt is loose or slipping.
Cooling fan
works.
Check speed adjusting switch, fan circuit and fan grounding circuit.
Not Compressor
cooling. Evaporating works.
fan stopped. Cooling fan
Ⅷ. Air Conditioning system

doesn’t rotate, Check if fuse burned out, check if relay working normally, and if
compressor circuit loose.
doesn’t work.
Evaporating fan R-134a in the system is charging too much, use voltage meter to check
Compressor and cooller if it is coincide with specific value.
normal working Not use for a long time, system R-134a leak, check with voltage meter,
normally. to see if R-134a exits.
Evaporating fan
and cooling fan
Liquid reservoir inlet and outlet reverse.
are both
Check if expansion valve blocked by ice or dirt, or change the
working
expansion.
Cooling normally,
Compressor Change R-12.
volumn evaporator,
normal
low cooller normal.
Fan and other
parts are
Check the cooller surface.
working
normally.

- 57 -
 VII. Loader transportation and storage
1. Transportation

Long distance transportation of this loader can be done by railway freight car. Should abide by the regulations of
the transportation department and ensure the following:

(1) Apply anti-corrosive oil to the exposed moving parts to prevent corrosion.

(2) Use triangle wood to fix the front and rear of the vehicle; lock the front/rear frame by frame lock; better to
use rope or iron wire to fix the vehicle body.

(3) Pull up manual braking valve handle, and make it in braking status.

(4) Lower down the swing arm to lowest position; lay the bucket or gripper on the floor of the trunk.

(5) Turn off the battery main switch, put every handle in middle position, and wrap the electric devices and
meters for dampproof.

(6) Drain all the coolant, coil and fuel when transporting the loader to cold areas.

2. Hoisting

(1) When the loader is to be hoisted, use the frame lock to lock the front/rear frame of the vehicle.

(2) When crossing the front/rear hoisting ring by a rope, pay attention to the center of gravity of loader, prevent
damage to the body by the rope.

Fig. 7-1 Hoisting

3. Storage

For long depositing loaders, abide by the following regulations:

(1) Place the loader in dry and venting garage, if it is open storage, put up the loader, tirée hang in the air, and
covered with rainp-roof tarpaulin.

(2) Clean the oil dirt and soil on the loader, and make an overall check of it, keep clean of every lubrication point
and fill with fresh lubrication oil.

(3) When running the engine in low load, drain the oil as soon as possible when it is hot, and drain all the

- 58 -
 coolant.

(4) Put all the control handles in the middle position, lower down the swing arm to the lowest position, put the
bucke or clamp on the floor.

(5) Apply anti-corrosion oil on expose moving parts.

(6) Starting once in a month during storage time, run it idle for 5-10 minutes.

4. Reusing of the loader

After long period of storage, follow the regulation below when using the loader again:

(1) Clean anti-corrosion oil on the surface.

(2) Install charged battery, adjust the fan belt.

(3) Close all the water draining port. Check and fill oil and water as specified.

(4) Check the tire and charge it to the specified pressure.

(5) Start and test-run the loader according to the regulations of test-run and preparations before starting in
section Ⅲ of this instruction book.

- 59 -