PREFACE

Thank you for purchasing LONKING’s wheel loader !

This Manual briefly describes the safety, operational and maintenance requirements of
LG876N wheel loaders for the use and reference by operators, maintenance and
technical management personnel.

User Manual is a guide for proper use and maintenance of this machine. Please carefully
read and understand the contents of this Manual before operating this machine.

Please put this Manual in driver’s cab for convenience of reference at any moment. If you
lose this Manual, please contact our sales department for buying a new one.

Many failures arise as a result of operator’s failure to carefully read this Manual and other
human reasons. A high sense of safety and good maintenance enable the safe and
efficient operation of this machine, thus bringing you more benefits. Therefore, please
read and understand safety instructions before operating this machine and fully comply
with them. Improper operation, lubrication, maintenance and repair of this machine are
dangerous and may result in human casualties.

We will continue to increase the working efficiency of the machine by improving product
design and endeavoring to improve the comprehensive product performances. The
parameters and configurations of the machine in this Manual are subject to change
without notice. The technical parameters contained herein shall not serve as the basis for
any inspection or test.

In order to offer better services to you and improve product and service quality, you are
expected to timely inform us of any problem identified during your use of LONKING
products and this Manual, along with any corresponding improvement opinions.

This Manual is its first version.

Best wishes for your business!

LONKING Holdings Limited

September 2020

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 CONTENTS

PREFACE ............................................................................................................................ 1
CONTENTS ......................................................................................................................... 2
CHAPTER I SAFETY PRECAUTIONS .......................................................................... 7
1.1 DESCRIPTION OF SAFETY SIGNS .............................................................. 7
1.2 DESCRIPTION AND LOCATIONS OF SAFETY SIGNS ............................... 7
1.2.1 WARNING SIGN OF REVERSING ...................................................... 8
1.2.2 WARNING SIGN OF THE ANTI- FREEZE FLUID............................... 8
1.2.3 WARNING SIGN OF MAINTENANCE AND TRANSPORTATION ..... 8
1.2.4 WARNING SIGN OF LIFT ARM ........................................................... 9
1.2.5 SAFETY WARNING SIGN OF HINGE ................................................. 9
1.2.6 WARNING SIGN OF FAN .................................................................. 10
1.2.7 WARNING SIGN OF NO TRAMPLE.................................................. 10
1.2.8 DISTRIBUTING DIAGRAM OF GREASE NIPPLE AND
LUBRICATING POINTS .............................................................................. 10
1.2.9 MACHINE NAMEPLATE .................................................................... 11
1.2.10 LIFTING AND BINDING SIGN ......................................................... 11
1.2.11 HYDRAULIC OIL SIGN .................................................................... 12
1.2.12 SCHEMATIC DIAGRAM OF USE OF TRIANGLE IRON ................ 12
1.2.13 FUEL SIGN ....................................................................................... 12
1.2.14 WARNING SIGN FOR SCRAPING .................................................. 13
1.2.15 ATTACHMENT NAMEPLATE .......................................................... 13
1.2.16 SIGN OF FLUSHER CONTAINER ................................................... 13
1.2.17 WARNING SIGN OF PREVENTING SINKING MOVEMENT .......... 14
1.2.18 SAFETY EXIT SIGN ......................................................................... 14
1.2.19 SCALDING WARNING SIGN AT HIGH TEMPERATURE PLACE 14
1.2.20 REMARKS FOR LONG TIME STANDSTILL .................................. 15
1.2.21 SIGN OF BATTERY CONNECTING WIRE ..................................... 15
1.2.22 COMBINATION OF WARNING SIGNS ........................................... 16
1.3 UNAUTHORIZED MODIFICATION .............................................................. 17
1.4 GENERAL SAFETY PRECAUTIONS .......................................................... 17
1.4.1 SAFETY REGULATIONS ................................................................... 17
1.4.2 PROTECTIVE DEVICES .................................................................... 18
1.4.3 SAFETY PRECAUTION FOR INTERNAL CAB ................................ 18
1.4.4 WORKING CLOTHES AND PERSONAL PROTECTIVE
EQUIPMENTS ............................................................................................. 19
1.4.5 GETTING ON AND OFF THE MACHINE .......................................... 20
1.4.6 FIRE PREVENTION OF OIL PRODUCTS ......................................... 21
1.4.7 PRECAUTIONS WHEN OPERATING AT HIGH TEMPERATURE ... 22
1.4.8 PROTECTION OF ASBESTOS DUST HAZARD .............................. 22
1.4.9 FACE MASK AND EARPLUG ........................................................... 23

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 1.4.10 FIRE EXTINGUISHER AND FIRST-AID KIT ................................... 23
1.4.11 PREVENTION OF ROLLING INJURY OR CUT OFF ...................... 23
1.4.12 ETHER (IF YOUR MACHINE IS EQUIPPED WITH ETHER COLD
STARTING DEVICE) ................................................................................... 24
1.4.13 MAKE SURE A GOOD VENTILATION WHEN OPERATING IN AN
ENCLOSED SPACE .................................................................................... 24
1.4.14 PIPELINE, HARD PIPE AND FLEXIBLE PIPE ............................... 25
1.4.15 COOLANT ........................................................................................ 26
1.4.16 PROTECTION FROM FALLING OR FLYING OBJECTS ............... 26
1.5 SAFETY PRECAUTION OF OPERATION ................................................... 27
1.5.1 SITE SAFETY ..................................................................................... 27
1.5.2 CHECK BEFORE ENGINE START-UP ............................................. 28
1.5.3 ENGINE START-UP ........................................................................... 30
1.5.4 CHECK AFTER ENGINE STARTING UP AND BEFORE MACHINE
OPERATION ................................................................................................ 31
1.5.5 PRECAUTIONS WHEN THE MACHINE BEGINS TO TRAVEL ....... 32
1.5.6 PRECAUTIONS WHEN THE MACHINE IS TRAVELING ................. 32
1.5.7 CHECK WHEN CHANGING DIRECTION ......................................... 33
1.5.8 PROHIBITED OPERATION ............................................................... 34
1.5.9 PRECAUTIONS WHEN TRAVELING ON THE SLOPE .................... 34
1.5.10 BEWARE OF HIGH VOLTAGE CABLES ........................................ 36
1.6 PRECAUTION FOR OPERATION ............................................................... 37
1.6.1 METHODS OF USING A BRAKE ........................................................ 38
1.6.2 PRECAUTIONS WHEN OPERATING ON SNOWY DAYS ................. 38
1.6.3 PRECAUTIONS FOR OPERATION IN COLD AREAS ....................... 38
1.6.4 DO NOT OPERATE THE MACHINE ON SOFT GROUND ................. 39
1.6.5 PRECAUTIONS WHEN PARKING THE MACHINE............................ 40
1.6.6 PRECAUTIONS WHEN LOADING THE MACHINE ........................... 40
1.6.7 PRECAUTIONS OF MACHINE TRANSPORTATION ......................... 41
1.6.8 PRECAUTIONS FOR DRAG ............................................................... 41
1.6.9 PRECAUTION FOR USE AND MAINTENANCE OF THE BATTERY 42
1.6.10 PRECATUTION FOR START-UP WITH BOOSTER CABLE ............. 43
1.6.11 PRECAUTIONS FOR BATTERY CHARGE ........................................ 44
1.7 MAINTENANCE PRECAUTIONS ............................................................. 44
1.7.1 FAULT NOTIFICATION ........................................................................ 44
1.7.2 CLEANING BEFORE REPAIR AND MAINTENANCE........................ 44
1.7.3 KEEP CLEANNESS OF WORKPLACE .............................................. 45
1.7.4 DESIGNATION OF RESPONSIBLE PERSON ................................... 45
1.7.5 CHECKING WATER LEVEL OF RADIATOR ...................................... 45
1.8 OPERATING BEFORE REPAIR AND MAINTENANCE............................. 45
1.8.1 SUPPORT OF WORKING DEVICE ..................................................... 46
1.8.2 APPROPRIATE TOOLS....................................................................... 46
1.8.3 REGULAR REPLACEMENT OF CRITICAL SAFETY PARTS ........... 46
1.8.4 ILLUMINATION .................................................................................... 46

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 1.8.5 FIRE PREVENTION ............................................................................. 47
1.8.6 PERSONS FOR REPAIR AND MAINTENANCE ................................ 47
1.8.7 ATTACHMENTS ................................................................................... 48
1.8.8 MAINTENANCE UNDER MACHINE ................................................. 48
1.8.9 MAINTENANCE WITH THE FRAME SUPPORTED UP ................... 48
1.8.10 MAINTENANCE ON THE TOP OF THE MACHINE ............................ 49
1.8.11 MAINTENANCE WHEN ENGINE IS WORKING................................. 50
1.8.12 NO LEAVING OF FOREIGN MATTER INSIDE MACHINE ................. 50
1.8.13 PRECAUTIONS IN THE USE OF HAMMER ....................................... 50
1.8.14 WELDING REPAIR .............................................................................. 51
1.8.15 PRECAUTIONS FOR BATTERY MAINTENANCE ........................ 51
1.8.16 TREATMENT OF ABNORMAL STATUS ............................................. 51
1.8.17 FILL OF FUEL OR LUBRICATING OIL............................................... 52
1.8.18 HANDLING OF HIGH-PRESSURE HOSE .......................................... 52
1.8.19 PRECAUTIONS OF HIGH-PRESSURE OIL ....................................... 52
1.8. 20 PREVENTION MEASURES OF MAINTENANCE IN HIGH
TEMPERATURE OR HIGH PRESSURE............................................................ 53
1.8.21 WASTE DISPOSAL ............................................................................. 53
1.8.22 PRECAUTIONS OF TIRE MAINTENANCE ........................................ 54
1.8.23 PRECAUTIONS OF TIRE STORAGE ................................................. 55
1.9 CATALOG AND REPLACEMENT CYCLE OF CRITICAL SAFETY PARTS
56
CHAPTER II OPERATION AND CONTROL ................................................................ 58
2.1 MAIN PERFORMANCE PARAMETERS AND SPECIFICATION ................ 59
2.2 OUTLINE DRAWING OF CDM860I.00II WHEEL LOADER ........................ 62
2.3 PURPOSE ..................................................................................................... 63
CHAPTER III OPERATION INSTRUCTIONS ................................................................ 64
3.1 STEERING WHEEL..................................................................................... 64
3.2 NEGATIVE-POLE SWITCH OF BATTERY .................................................. 64
3.3 STARTER SWITCH ...................................................................................... 65
3.4 SERVICE BRAKE PEDAL ........................................................................... 66
3.5 ACCELERATOR PEDAL AND INSTRUMENT PANEL ADJUSTING
MECHANISM ...................................................................................................... 67
3.6 ELECTRICALLY CONTROLLED SPEED-SHIFT HANDLE........................ 67
3.7 PILOT JOYSTICK......................................................................................... 67
3.8 LAMPS AND THEIR SWITCHES ................................................................. 68
3.9 INSTRUMENT ASSEMBLY AND HORN SWITCH ................................. 71
3.9.1 INSTRUMENT ASSEMBLY................................................................ 72
3.9.2 HORN SWITCH .................................................................................. 74
3.10 SWITCH OF AIR CONDITIONING SYSTEM ............................................. 74
3.10.1 WARM WATER VALVE .................................................................... 75
3.11 SEAT ADJUSTMENT.................................................................................. 75
3.12 SAFETY BELT ............................................................................................ 77
3.13 CAB DOOR LOCK ...................................................................................... 77

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 3.14 USE OF LOCATING LOCK ........................................................................ 78
3.15 ADJUSTMENT TO REAR-VIEW MIRROR ............................................. 78
3.16 TURNING LAMPS AND FULL-BEAM/LOW-BEAM HEADLIGHTS ......... 78
3.17 CHARGING DOCK ..................................................................................... 79
3.18 SUNSHADE ................................................................................................ 80
3.19 PLAYER ...................................................................................................... 80
CHAPTER IV OPERATION ......................................................................................... 83
4.1 NOTICES ON OPERATION OF NEW LOADER ........................................ 83
4.2 RUNNING-IN OF NEW LOADER................................................................ 84
4.2.1 REQUIREMENTS ON RUNNING-IN OF NEW LOADER ................... 84
4.2.2 OPERATIONS TO BE CARRIED OUT AFTER EIGHT HOURS OF
RUNNING-IN ....................................................................................................... 84
4.2.3 OPERATIONS TO BE CARRIED OUT AFTER EXPIRATION OF
RUNNING-PERIODS .......................................................................................... 85
4.3 OPERATION OF LOADER.......................................................................... 85
4.3.1 INSPECTION BEFORE STARTUP OF ENGINE ................................. 85
4.3.2 STARTUP OF ENGINE ...................................................................... 86
4.3.3 TRAVELLING OF LOADER ............................................................... 87
4.3.4 PARKING OF LOADER ..................................................................... 89
4.4 WORKING OF LOADER ..................................................................................... 91
4.4.1 PREPARATION BEFORE WORKING ................................................. 91
4.4.2 GENERAL TECHNIQUES ................................................................... 92
4.4.3 WORK METHOD .................................................................................. 95
4.5 TRANSPORTATION OF LOADER ...................................................................... 96
4.5.1 HOISTING OF LOADER ...................................................................... 97
4.6 OPERATION IN COLD WEATHER ........................................................... 100
4.6.1 PRECAUTIONS FOR OPERATION AT LOW TEMPERATURE ....... 100
4.6.2 OPERATIONS TO BE CARRIED OUT AFTER COMPLETION OF
WORKS IN EACH DAY .................................................................................... 101
4.6.3 AFTER COLD WEATHER HAS ENDED ........................................... 101
4.7 OPERATION UNDER SPECIAL CONDITIONS ....................................... 101
4.7.1 OPERATION UNDER EXTREMELY COLD CONDITIONS............... 101
4.7.2 OPERATION UNDER EXTREMELY HOT WEATHER ...................... 102
4.7.3 PERATION IN DUSTY OR SANDY AREA ........................................ 103
4.7.4 PERATION IN RAINY AND HUMID ENVIRONMENT ....................... 104
4.7.5 PERATION IN SALT WATER ............................................................. 104
4.7.6 OPERATION AT HIGH ALTITUDE .................................................... 104
CHAPTER V MAINTENANCE AND REPAIR ............................................................. 105
5.1 PREPARATION BEFORE MAINTENANCE ............................................. 105
5.2 REGULAR MAINTENANCE ................................................................ 105
5.3 LUBRICATION CHART .............................................................................. 114
5.4 THE CHINESE AND FOREIGN OIL TYPE LIST FOR WHEEL LOADER 115
5.5 OIL INFORMATION .................................................................................... 116
5.6 UNIVERSAL TORQUE TABLE ................................................................. 117

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 5.7 MAINTENANCE OF THE ENGINE COOLANT ........................................ 117
5.7.1 COOLANT COMPOSITION ............................................................... 118
5.7.2 ADDING COOLANT ........................................................................... 119
5.7.3 INSPECT COOLANT LEVEL REGULARLY ..................................... 120
5.7.4 CLEANING OF COOLING SYSTEM ................................................. 121
5.7.5 ENGINE AIR FILTER MAINTENANCE.............................................. 122
5.7.7 CLEAN DUST COLLECTION CUP OF THE AIR FILTER .............. 124
5.8 USE OF FUEL SYSTEM AND RELATED MAINTENANCE ...................... 125
5.8.1 FUEL TANK ...................................................................................... 125
5.8.2 CLEANING OF FUEL TANK ............................................................ 125
5.8.3 FUEL OIL LEVEL INSPECTION .................................................... 125
5.8.4 APPLICATION AND REPLACEMENT OF FUEL FILTERS ............ 126
5.8.5 APPLICATION AND REPLACEMENT OF FUEL PRE-FILTERS ... 126
5.8.6 MAINTENANCE OF ENGINE OIL ................................................... 127
5.8.7 REPLACEMENT OF ENGINE OIL .................................................. 127
5.8.8 REPLACEMENT OF ENGINE OIL FILTER ..................................... 128
5.9 INSPECT ELECTRICAL SYSTEM ............................................................. 128
5.9.1 INSPECT BATTERY ......................................................................... 128
5.9.2INSPECT ELECTRICAL DEVICES .................................................. 129
5.9.3 SOLDERING ...................................................................................... 131
5.10 TRANSMISSION OIL MAINTENANCE .................................................... 131
5.10.1 INSPECT OIL LEVEL OF GEARBOX ............................................... 131
5.10.2 TRANSMISSION OIL REPLACEMENT ............................................ 132
5.11 MAINTENANCE OF DRIVE AXLE OIL..................................................... 133
5.11.1 INSPECT OIL LEVEL OF DRIVE AXLE ............................................ 133
5.11.2 REPLACEMENT OF THE DRIVE AXLE OIL .................................... 133
5.12 INSPECTION AND REPLACEMENT OF TIRE ........................................ 134
5.13 MAINTENANCE FOR LONG TIME PARKING ......................................... 134
5.14 MAINTENANCE UNDER SPECIAL CONDITIONS .................................. 135
5.15 MAINTENANCE OF HYDRAULIC OIL ........................................................... 136
5.15.1 INSPECT THE OIL LEVEL OF THE HYDRAULIC OIL ............... 136
5.15.2 REGULAR REPLACEMENT OF HYDRAULIC OIL .................... 136
5.16 BUCKET MAINTENANCE ........................................................................ 138
5.16.1 REPLACE BUCKET O-RING .......................................................... 138
CHAPTER VI COMMON FAULTS AND TROUBLE-SHOOTING ............................ 140
VII. MAINTENANCE AND SERVICING OF AIR-CONDITIONING SYSTEM ................. 144
CHAPTER VIII ENVIRONMENTAL PROTECTION REQUIREMENT ............................ 145
APPENDIX: REFERENCE TABLE OF PROPORTION OF COMMON MATERIALS ... 146

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 CHAPTER I SAFETY PRECAUTIONS

Warning!

Please read and understand all the safety precautions before operation. Failure to do so
may result in severe bodily injury or death.

1.1 DESCRIPTION OF SAFETY SIGNS

Danger!

1) There exists danger that may affect your personal safety.

2) Don’t operate the machine without permission. Any operation may affect the
machine’s normal conditions and cause machine damage or dangerous accident.

Warning!

1) There exists potential danger that may affect the safety of you and others.

2) Don’t operate the machine without permission. Any operation may affect the
machine’s normal conditions and cause machine damage or dangerous accident.

Caution!

1) There exists potential danger that may affect your personal safety.

2) Please operate this machine according to instructions. Any improper operation or no

operation may affect the machine’s normal working conditions and cause machine
damage.

1.2 DESCRIPTION AND LOCATIONS OF SAFETY SIGNS

There are a number of safety signs on the machine. This section will give a detailed
description of their locations and meanings. Please familiarize yourself about these safety
signs before any operation.

If these signs are damaged, lost or illegible after cleaning, please replace them in a timely
manner.

If any part bearing any safety sign has to be replaced, a new safety sign must be affixed
onto the replaced part.

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 These safety signs must be kept clean. If the
figures and words on these signs are unclear or
illegible, please replace or clean them with soft
cloth, water or soapy water. No solvent, gasoline
or other irritating chemical agent may be used for
this purpose.

1.2.1 WARNING SIGN OF REVERSING

 Sign location: rear counterweight

 Contents: when driving the car backwards,

the driver must pay attention to maintain a
certain distance between the machine and
surrounding staff to avoid accidents. When
driving the car backwards, the driver must pay
attention to the surrounding pedestrians and vehicles
to avoid accidents.

1.2.2 WARNING SIGN OF THE ANTI- FREEZE FLUID

 Sign location: on the engine hood.
 Contents: this sign reminds the user to
operate the machine according to this
sign. Otherwise, it may cause machine
damage or personal injury.

1.2.3 WARNING SIGN OF MAINTENANCE AND TRANSPORTATION

8
 Sign location: left side of frame hinge joint

 Contents: it reminds the users to lock the

frame with fixing rod before transportation
and maintenance of machine, to avoid
accidents. Dismount the fixing rod before the
loader recovers its work, and place it in fixed
location.

1.2.4 WARNING SIGN OF LIFT ARM

 Sign location: front end of lift arm
 Contents: this sign reminds user that never
permit persons to stand below the moving lift
arm when operating lift arm to avoid
accidents.

1.2.5 SAFETY WARNING SIGN OF HINGE

 Sign location: in the front and rear hinging

positions at the left side of the front frame
 Contents:
1. Dangerof crushing! Do not stand here when the
loader is turning, because the crushing may lead
to serious injury or death.
2. Dangerof crushing! During the transport of
loader or the maintenance of hinge, the front and
rear frames of the loader shall be locked in order
to avoid dangers.

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1.2.6 WARNING SIGN OF FAN

 Sign location: at both left and right sides of

the engine hood

 Contents: this sign reminds the user to open

engine hood only when the engine stops in
order to avoid severe injury

1.2.7 WARNING SIGN OF NO TRAMPLE

 Sign location: upper side of splash guard of

front frame

 Contents: due to the limitation of bearing

capacity of steel panel on splashguard, keep
off here to avoid accidents.

1.2.8 DISTRIBUTING DIAGRAM OF GREASE NIPPLE AND LUBRICATING

POINTS

 Sign location: left side of the frame hinge

 Contents: distribution diagram of lubricating
points by hourly calculation based on the
requirements of machine. This sign reminds
user to fill and change different lubrication
oils at each lubricating point at scheduled
time.

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1.2.9 MACHINE NAMEPLATE

 Sign location: left side of the frame hinge

 Contents: description of basic information of
特 征
the machine
额定载重量 发动机型号

发动机功率

THE PEOPLE'S REPUBLIC OF CHINA

1.2.10 LIFTING AND BINDING SIGN

 Sign location: rear end of frame, near tire

 Contents:
1. This sign reminds the user of the hanging
position of the hook when the loader is
lifted.
2. This sign reminds the user of the binding
position when the machine is shipped.

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1.2.11 HYDRAULIC OIL SIGN

 Sign location: on oil tank at the left side of the

hydraulic oil tank on the top
 Contents: this sign reminds the user that
filled hydraulic oil shall be the oil product
designated by LONKING or the hydraulic oil
of the same type.

1.2.12 SCHEMATIC DIAGRAM OF USE OF TRIANGLE IRON

 Sign location: on the triangle iron fixing

bracket of front fender
 Contents: this signs reminds the user that if
the machine stops on the slope or tires need
to be fixed to prevent tires from moving, it is
required to comply with the contents of this
sign. Otherwise, it may cause personal injury.

1.2.13 FUEL SIGN

 Sign location: oil tank at left side of the frame

 Contents: this sign reminds the user that the
left side of the frame is fuel tank. Please fill
the clean fuel commensurate with
environment temperature.

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1.2.14 WARNING SIGN FOR SCRAPING

 Sign location: on the bucket

 Contents: this sign reminds the user that the
permitted capacity of the bucket is less than
the figure as shown on the sign. Otherwise, it
will cause accidents.

1.2.15 ATTACHMENT NAMEPLATE

 Sign location: on the bucket

 Contents: the description of the basic

information of machine attachments. 型 号

属具重量

属具容量

属具宽度

系统压力

1.2.16 SIGN OF FLUSHER CONTAINER

 Sign location: on the engine hood of the cab

 Contents: this sign reminds the user that this

position is for flusher container. Please fill
washing liquid as required after the machine
is running for a period of time.

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 1.2.17 WARNING SIGN OF PREVENTING SINKING MOVEMENT

 Sign location: lift arm

 Contents: this sign reminds the user

to operate the machine according to
this sign. Otherwise, it may cause
machine damage or personal injury.

1.2.18 SAFETY EXIT SIGN

 Sign location: on the glass of the right door of

the cab

 Contents: this sign reminds user that if the

main exit is blocked, unhinge the latch and
escape from the right door.

1.2.19 SCALDING WARNING SIGN AT HIGH TEMPERATURE PLACE

 Sign location: left and right sides of the

engine hood

 Contents: because the working engine gives

out large quantities of heat (maximum
temperature of exhaust pipe is up to 500℃),
the user must be careful when opening the
engine hood so as to prevent damage to
human body due to high temperature. If
possible, wear the high temperature-resistant
gloves so as to avoid scalding.

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 1.2.20 REMARKS FOR LONG TIME STANDSTILL

 Sign location: on rear hood

 Contents: this sign reminds the user to

operate the machine according to this sign.
Otherwise, it may cause machine damage or
personal injury.

1.2.21 SIGN OF BATTERY CONNECTING WIRE

 Sign location: rear side of engine hood

 Contents: this sign gives a description of
method and precaution for battery wiring.
Please install battery wiring according to the
instructions of this sign.

15
1.2.22 COMBINATION OF WARNING SIGNS
·Sign location: on the right front column in the cab
·Content of signs:
1. This warning sign reminds the user to
read all items described in this
instruction book. Violating this
instruction book or ignoring the warning
may lead to casualties, and the driver
must strictly obey the operating
specification.
2. This warning sign reminds the user to
rotate the fan support while turning on
the heating supply in cold weather. Turn
on the fan to blow at the front windshield
to prevent blurred vision due to
formation of mist on the glass.
3. This sign reminds the user to operate
the machine in strict accordance with
the contents of the sign; otherwise the
machine may be damaged.
4. This sign reminds the user to turn off the
cathode switch of storage battery while
performing the welding operation on the
machine; unplug the plug connector
linking the wire harness to the engine
controller before unplugging the plug
connector of the electrically-controlled
transmission control system; since the
operation involves numerous factors,
the user is advised not to perform
welding operation on the machine
arbitrarily; such operation shall be
performed under instructions of
professional personnel for fear of an
accident.
5. The warning reminds the user to operate
the machine in strict accordance with
the contents of the sign; otherwise
machine damage or personal accident
may occur.
6. This warning sign reminds the user to
use parts dedicated for Lonking loaders
during replacement of parts; otherwise
machine damage or personal accident
may occur.
7. This warning sign reminds the user to
use oil dedicated for Lonking loaders or
equivalent oil recommended in this
instruction book during oil replacement;
otherwise machine damage or personal
accident may occur.

16
1.3 UNAUTHORIZED MODIFICATION
Any modification of this machine not authorized or approved in writing by LONKING may
cause safety accidents. The owner shall bear all the consequences.

For the sake of safety, please use correct grade and genuine fitting and oil. If without
correct fittings or periodically fasteners change, the parts may exceed safety use
limitation.

1.4 GENERAL SAFETY PRECAUTIONS

1.4.1 SAFETY REGULATIONS

Only those who experienced special training or

got equivalent qualification can operate or
maintain this loader.

Strictly follow the requirements of safety

regulations, warnings when operating or maintain
this loader.

Never operate or maintain the loader when you

feel bad, tired due to dose, after drinking, or do
not adapt to environment, because it may reduce
you emergency reacting capacity and
commission error, which may cause accidents.

When working with operators or site traffic

commanders, make sure all persons are familiar
with the using sign language.

17
Observe the surrounding safety influence factor
at any instant.

Follow related safety regulations.

1.4.2 PROTECTIVE DEVICES

Make sure all protective devices and engine hood

is in proper location, if there is damage, timely
repair it.
Please correctly use protective devices such as
joystick locking device, safety belt etc. never
demount protective devices and make sure they
are in good working condition. Incorrect use of
protective devices may cause casualty accidents.

1.4.3 SAFETY PRECAUTION FOR INTERNAL CAB

Before entering cab, remove mud and oil dirt

sticking to shoes bottom. Otherwise, it may cause
an accident due to skidding when trampling the
accelerator pedal or brake pedal.

Do not adsorb suction cup stick on the cab glass,

for the lens action of suction cup may cause fire
accidents.

Do not randomly lay the lighter or match inside

the cab, for it may cause lighter blasting if the cab
temperature is high.

18
Do not use mobile phone when operating the
loader, because distraction may cause accidents.

Do not take any flammable and explosive

hazardous article into the cab.

Do not wear earphone or headphone when

driving or operating the loader, otherwise it may
cause accident. Do not put head or hand out of
windows.

Before leaving the loader, lower the working

device down to the ground, lock up the protective
devices, shut down the engine, lock all devices,
unplug keys and take with them.

1.4.4 WORKING CLOTHES AND PERSONAL PROTECTIVE EQUIPMENTS

Avoid wearing loose clothes and ornaments or

other things that may hook control level or other
machine parts, for they may be blocked or
engulfed in control system or moving parts, and
cause severe injuries or casualties.

Do not wear greasy clothes to avoid catching a

fire.

Wear safety helm, glass, shoes, mask and gloves

before operating or maintaining the machine.

Wear safety dust goggles, Safety Helmets and

thick gloves when working in conditions of metal
pieces or slight sundries, especially when nail pin
with hammer or clean air filter impurities with
compressed air, and make sure no person
approaches the machine.

Compressed air may cause human injuries;

19
therefore, it is important to wear mask, protective
clothes and safety shoes before using the
compressed air. The maximum pressure of
compressed air using clean shall be under
0.3MPa.

Check whether all protective equipment are in

normal work conditions.

1.4.5 GETTING ON AND OFF THE MACHINE

Before ascending or descending machine, clean

oil dirt, lubricant or mud, furthermore, repair
damaged parts and tighten loose bolt.

Do not jump on or off the machine, either when it

is at rest and when it is moving.

When ascending or descending the machine, you

shall face to the machine, hold armrest, step on
ladder and keep three points contact (two feet
and a hand or two hands and a foot) to make sure
body balance and stable.

It is prohibited to hold control level when

ascending or descending the machine.

It is prohibited to cab from back of machine or

descend machine by stepping side tires.

When ascending or descending machine, it is

prohibited to take any tools or other things.

20
1.4.6 FIRE PREVENTION OF OIL PRODUCTS
Please use fuel, oil and hydraulic oil used in
hydraulic system to fill diesel engine of this
loader, hydraulic transmission oils and gear oils
used in transmission system and brake fluid used
in brake system and antifreeze used in engine
water tank can be lit by open fires, in particular,
fuel is flammable and dangerous, therefore, the
following Safety and accident prevention must be
noted:
Be sure to keep flame away from the flammable
liquid.
Fill these flammable liquids in a well-ventilated
place, shut down the engine, and do not smoke.
Tighten storage lid of above combustible liquids.
Store the above flammable liquids in containers
marked with corresponding logos and lay them in
a specified place to give a classified storage and
prevent non-staff person use them.
Lay the rags stained with oil or other flammable
materials in a protective container and put them in
a safe place.
Do not use electric weld or flame cut pipeline or
container containing flammable liquids. Prior to
electric weld or flame cut, use non-flammable
liquids clean the welding or cutting place.
Clean up the combustible materials accumulated
on the machine such as fuel, lubricants, or other
debris.
Do not lay the machine in flame, burning bushes
places.

This wheel loader is ordinary construction

machinery; do not operate it under flammable and
explosive environment.

21
1.4.7 PRECAUTIONS WHEN OPERATING AT HIGH TEMPERATURE

When the operation of machine has just

completed, temperature of hydraulic oil, oil and
water inside engine and radiator is still high, and
the pressure still exists. At this moment, open fuel
tank cap, radiator cap, pour oil or replace filter are
likely to cause serious burns. Therefore, carry out
those operations according to specified
procedures after the temperature dropped.

In order to prevent hot water spray out, the

engine should be close to make the water cool
down, release the pressure slowly when opening
the engine cover. (Check whether the water
temperature has reduced by testing the air
temperature with hand close to oil radiator. Be
careful not to contact with radiator.)

In order to prevent hot oil spray out, the engine

should be shut down so as to let the oil cool
down, slowly loosen the cap to release the
pressure when opening the engine cap. (Check
whether the oil temperature has reduced by
testing the air temperature with hand close to the
front of the oil radiator. Be careful not to contact
radiator.)

In order to avoid scald, do not touch relay when

the engine is hot.

Do not detach temperature sensor of engine oil,

water sensor, torque converter sensor and A/C
pipelines to avoid burnings.

1.4.8 PROTECTION OF ASBESTOS DUST HAZARD

Inhalation of asbestos dust may be harmful to
body health.

The products produced by LONKING Holdings

Limited do not include asbestos, but if you contact
with materials containing asbestos fibers, please
follow the below rules:

It is protective to use compressed air for cleaning.

Please use water to clean so as not to stir up the

dust.

It is dangerous if the air containing asbestos dust,

22
if possible, operate the machine in the uptake.

If necessary, use qualified dust mask.

1.4.9 FACE MASK AND EARPLUG

Never ignore the dangerous factors that may not be harmful to body health at present.
Exhaust gas and noise is unseen, but it may cause disability or permanent injury.

1.4.10 FIRE EXTINGUISHER AND FIRST-AID KIT

In case of personal injury or fire, please take aid

actions according to the following measures:

Fire extinguishers must be equipped. Read

carefully the instructions for use, and know how to
operate it.

First aid kit must be equipped in site, periodically

check it and timely added medicines. Know what
to do when a fire or injury happened.

Some staff’s phone numbers (such as doctors,

first aid center, fire station, etc.) are well
prepared, so that you may contact them in case
of emergency. Stick those phone numbers to a
specified place to make sure all staff are aware of
those numbers and know the correct
communication methods.

If fire breaks out during the operation of machine,

please follow the below requirements for danger
escape: turn off the starter switch, shut down the
engine, if condition permits, take fire extinguisher
for quelling a fire. Escape from machine through
the escalator.

1.4.11 PREVENTION OF ROLLING INJURY OR CUT OFF

It is protective to enter or place your hands or any

other body parts between movable parts, such as
between working device and oil tank and between
machine and working device. With the movement
of working device, the space of connecting rod
may increase or decrease, it may cause serious
injury accidents if you close to it. Therefore, if you

23
want to get close to the moving parts of the
machine first shut down the engine and lock up
working device.

Properly support equipment or accessory when

working underside the machine. Do not relay on
hydraulic cylinder for supporting. If the control
mechanism moves or hydraulic pipeline leaks,
any attachment will fall off.

Unless otherwise specified, make no adjustment

when the machine is operating or the engine is
starting.

Be sure to keep away from all rotating and

moving parts.

Be sure that there is no debris in the engine fan

blades.

1.4.12 ETHER (IF YOUR MACHINE IS EQUIPPED WITH ETHER COLD

STARTING DEVICE)

Ether is toxic and flammable, inhalation of ether

vapor or frequently contact it with skin may cause
injury. When using ether, make sure the place is
in good ventilating conditions and pay attention to
prevent fire. Do not smoke when replacing ether
cylinder.

Do not store ether cylinder in living areas or

inside the cab. Do not put ether cylinder in an
area of direct sunlight or the place where the
temperature is more than 39℃(120°F).

Please put the waste ether cylinder in a safe

place, do not perforate or burn it.

Lay the ether cylinder away from non-staff areas.

1.4.13 MAKE SURE A GOOD VENTILATION WHEN OPERATING IN AN

ENCLOSED SPACE
If it needs to start the engine or handle fuel, clean parts or paint in an enclosed or bad
ventilated place, open the doors and windows to ensure that this is adequate ventilation to
prevent gas poisoning.

If the opening doors or windows still cannot offer an adequate ventilation condition, please
install a fan.

24
1.4.14 PIPELINE, HARD PIPE AND FLEXIBLE PIPE

Do not bend or hammer high-pressure pipeline,

do not install abnormal bending or damaged pipe
or tube on the machine. Repair loose or damaged
fuel and lubricant pipeline and pipe or tube
installed in hydraulic system.

Leakage may cause fire. For repair or

replacement, please contact the designated
dealer of LONKING Holdings Limited.

Please carefully check all pipelines, hard pipes

and flexible pipes, tighten all joints according to
specified tightening torque. Do not check the
leakage with bare hands, but check them with
board or cardboard.

Even a pinhole size pressure liquid leakage may

penetrate muscle and cause death. If the solution
sprays out to the skin, please contact with
surgeons who is familiar with this injury for cure
within a few hours. If the following faults
happened, the parts should be replaced:

1) connector damaged or leaked; 2) outer layer of

the tube worn or cut and strengthening steel wire
bare; 3) local uplift of the tube; 4) the tube has
obvious torsion or deflection; 5) strengthening
steel wire of the tube embedded in outer layer; 6)
end connector dislocation.

Make sure that they has been installed correctly

such as all pipe clamps, protecting plates and
heat resistant cover to avoid shock or overheating
due to the friction with other components.

When removing connecting pipe of A/C

compressor, no open fire closing, otherwise it will
produce toxic gases and cause poisoning.

25
1.4.15 COOLANT

When operating, the engine coolant temperature

and pressure are high. All pipelines leading to
radiator or engine has hot water and steam, touch
them will cause serious burn.

When checking coolant level, the engine should

be shut down and add cold water to let it cool until
the bare hands can be used to open the outlet
cover.

Slowly screw the filler cap of cooling system to

release pressure.

Because the coolant of cooling system containing

alkali, it is forbidden to contact with skin or eyes
and drink.

Cool the coolant before exhausting it.

1.4.16 PROTECTION FROM FALLING OR FLYING OBJECTS

When there is falling or flying objects hit the cab

at site, it will cause danger, please select the
protective device that is suitable to operating
condition to protect driver.

When working at mines, tunnels, deep pit, soft or

wet surface, it may exist hitting danger of falling
rocks or flying objects. It is necessary to install
protective devices in the cab, and the installation
must comply with the requirements of FOPS
(falling objects protective devices) and glass
protection.

Prohibit the use of strengthening devices, such as

drilling and welding on the protective device.

If the protection device is seriously impacted or

damaged, its strength is lowered and its normal
functions cannot be reached, please contact the
designated dealer of LONKING Holdings Limited
for consultation repair method.

When using breaker for operation, install a

protective device on the front windshield. Please
contact the designated dealer of LONKING
Holdings Limited for recommendations.

26
If any glass of the machine is damaged, please
replace with a new one immediately.

1.5 SAFETY PRECAUTION OF OPERATION

1.5.1 SITE SAFETY

Before starting the engine, carefully check whether there is any abnormal condition
around the engine leading to dangerous situation.

Check the site landform and ground condition; determine the best and safest operation
method.

Shovel and level the ground into a solid and plane state before the machine is in operation,
in case of heavy dust at site, spray water before operating.

In case of operating at a street, there should be a special person to direct traffic, or set a
fence or put up a sign of ―no entry‖ around the site.

Any objects around lift arm are potentially dangerous, or make the driver unprepared that
may cause accidents. When operating in bridge, cable lines, or there are scaffoldings or
other barrier accessories, need the special commander.

Insurance coverage, operating license or certification, minimum standard protection or

limitation of operating hours of obstacles around working environment that may be
authorized or decided by government authorities. Please follow local required regulations,
guidelines, standards or equipment limitation conditions and relevant provisions of
implementation of specified work. If you want to know whether your machine and site
circumstance is compliance with environmental laws and regulations, please consult the
local authorities or relevant departments.

Soil piled on the ground or on the side of ditch is very soft and sloppy; the vibration of the
machine may collapse the soil, causing tip-over accidents.

For the place with buried facilities, such as water

pipe, gas pipe, telephone line or high voltage line,
please contact the responsible company to
determine the location of buried facilities, and
note that do not damage these facilities during
construction.

27
First, check ground conditions, water depth and
flow rate when operating on water or sandy
embankment. Do not exceed the allowable water
depth.

Do not drive or run the machine on the soft road,

otherwise, the machine may be difficult to leave.

Avoid operating on the cliff edge, suspended

material or deep pit, if the ground collapsed, the
machine crashed or upset, which may cause
serious casualties. Especially after raining, do
blasting operations or after earthquake, the soil is
very soft and sloppy and prone to cause danger.

Please install head protection devices for

operation on dangerous areas where there are
falling stones.

1.5.2 CHECK BEFORE ENGINE START-UP

Prior to operation, check the following items before the engine start-up. Otherwise, it may
cause serious injuries or damages.

Check whether there are leakages of fuel, oil or hydraulic oil.

The operator shall not leave parts and tools around seat, because those things may fall
and cause damage to joystick or switch due to the machine’s traveling and vibration
during operation, or it may lead to joystick moving or working devices running and cause
an accident.

Before ascending the machine, the operator shall remove all sludge and fine sand stuck
on the shoes, because the sludge may accumulate on the accelerator pedal and brake
pedal that will affect the reset of pedal. If these places accumulate sediment on the pedal,
you should remove it immediately.

28
Check the level of coolant, fuel and oil of engine oil pan, check whether air filter is blocked
and cable is damaged.

Adjust the operator’s seat to the location where is convenient to operate machine, check
whether the positioning device of seat belt and safety belt is damaged. Service lift of the
safety belt is over 3 years and replaced

Check whether the instruments are in normal working condition, and whether the joystick
is in parking position.

Clean the window glass and light in the cab to ensure a good visibility.

Adjust the location of rearview mirror to ensure the operator has best vision when setting
down the cab seat. Clean the surface of the rearview mirror. If the rearview mirror glass
has damaged, replace it.

Check whether the front lamp and working lamp are in normal working conditions. If they
are not in normal conditions, repair them.

Check whether there are flammable materials

around engine or battery

Check whether the rearview mirrors, armrests

and ladders have stained by fuel.

Make sure there is fire extinguisher, and the

operator must be familiar with use methods.

Do not place the machine close to a place where

there is open fire.

29
1.5.3 ENGINE START-UP

Before ascending the machine, visible inspect your machine, check whether there are
persons and objects on, off, or near the machine or on the working area.

If the machine has not used for a long time or the operating temperature is extremely low,
please maintain your machine before start up.

Check whether all instruments and monitor displays are in normal condition before
starting the engine. Note whether there is noise and potential unsafe factor when running
the engine.

You can start the engine only in the cab. Strictly prohibit starting the engine with starter
motor short-circuiting. Otherwise, it may cause damage to the machine’s electrical system,
and this operation itself is very dangerous.

If there is a sign of ―do not operate‖ on the

joystick, do not start the engine or pull the joystick

When starting the engine, please ring the horn for

warning.

Only when the operator sitting down to the seat

that can start and operate the engine. Make sure
there is nobody in the cab except the operator. It
is not allowed that anyone sit down on the
body of the machine.

30
If a reversing alarm device is installed, make sure
it is in normal working condition.

1.5.4 CHECK AFTER ENGINE STARTING UP AND BEFORE MACHINE

OPERATION
If there is no proper and timely check after the engine starts up, it is likely that the
abnormal condition of the machine cannot be identified in time, thus causing personal
injury or machine damage.

Check work shall be performed in a spacious place where there is no obstruction. No

other person is allowed to approach the machine during checking.

Check whether the instruments and equipment, bucket, lift arm, brake system, power train
system and steering system are in normal working conditions.

Check whether the sound, vibration, heat, smell or instrument are in abnormal conditions;
check the leakage of hydraulic oil, lubricant, gas or fuel.

If any abnormal condition has been identified, please immediately adjust or repair it to
normal condition. Otherwise, it may cause injury accidents or machine damage.

Before the machine is traveling or working, check the frame fixing rods that are used to
lock front and rear frames, the frame fixing rods should be in a position of ―release‖.

Before operating the machine, heat the oil of engine, hydraulic tank and torque converter
to normal working temperature.

Remove all obstacles on the machine’s running path.

Keep window clean, and make sure all windows are in a safe opening or closing position.

Adjust the rearview mirror to the best field vision, make sure horns, alarms and other
warning devices are in a good working condition.

31
1.5.5 PRECAUTIONS WHEN THE MACHINE BEGINS TO TRAVEL

Before operating the machine, again check the

states around the machine, make sure there is
nobody and obstacle there.

When the machine is running, sound the horn for

warning.

Only when the operator sitting down to the seat

that can start and operate the engine. Fasten the
safety belt.

Nobody except operator shall enter the cab.

Nobody is allowed to sit on the external body
of the machine.

It must be made sure that the back-up buzzer

works properly.

1.5.6 PRECAUTIONS WHEN THE MACHINE IS TRAVELING

Do not turn the starter switch to the ―OFF‖ position when the machine travels. If the engine
suddenly stops during the traveling, it is very dangerous, because it will cause hard
steering. If the engine stops, perform braking to stop the machine.

If the machine is detected having any abnormal conditions during operating (abnormal
status of noise, vibration, smell and instrument display, gas or oil leakage), immediately
drive the machine to a safe place for check.

Do not suddenly turn the steering wheel, because the sudden turning will make the
working device collide with the ground that may cause the machine to lost its balance, or
damage the machine or buildings around it.

Lower speed when running on an uneven road and do not suddenly turn the steering
wheel.

Try to avoid running over barriers, if it is necessary for the machine to moving across a
barrier, lower speed and let the working device close to the ground.

Keep distance with other machines or building structures to avoid collision during traveling
or operating.

32
Right and left glance is dangerous when
operating the machine; therefore, the operator
shall concentrate on his work.

Too fast traveling, sudden start, sudden stop,

sudden turn or zigzag traveling is dangerous.

Adjust the height of working device below the lift

arm and keep a clearance of 500-600mm
(20-24in) from the hinge pin and ground, let the
machine walking on the level ground. Do not
operate the pilot joystick during running. If it is
necessary to operate the pilot joystick of working
device, first stop the machine, and then operate
the pilot joystick.

If the working condition is in water condition, it

shall not exceed a permitted depth.

When passing through a bridge or private

structures, check whether their bearing capacities
can support this machine. When walking on
public road, firstly it shall be in comply with the
provisions of related authorities and traffic laws
and regulations. The speed of this loader should
lower than normal speed of a car. Walking in the
aside road, leave the center of the road to other
vehicles.

If this machine has run for a long time, its tire will
be overheated, and its internal pressure becomes
extremely high. It may cause tire to blow up and
produce great destructive power, and then may
cause serious injuries or accidents.

1.5.7 CHECK WHEN CHANGING DIRECTION

In order to prevent injury or death, even though the machine is equipped with a backup
alarm and rearview mirror, you must comply with the following rules before moving the
machine or its working devices.

33
Sound the horn to warn the staff and person in
the field.

Check the vicinity of the machine to ensure that there is nobody. Pay special caution to
check the back area of the machine, for this area is unclear to see from the operator’s
seat.

It is necessary to designate a person to direct site traffic when the operating place is
danger or has bad visibility.

It is not allowable to enter in the turning area or in the walking area of the machine.

Do not change direction when the machine is walking at high speed.

1.5.8 PROHIBITED OPERATION

In order to prevent machine upset or working

device damage due to overload, the load of the
machine must maintain within the specified
maximum value. Do not exceed the specified
capacity.

It is not allowable to dig the operation surface

beneath the upland; otherwise, it may cause the
upland collapse and smash the top part of the
machine.

It is not allowable to dig the ground deeply in front

of the machine, the collapsed soil may cause the
machine crashed.

It is dangerous to work on the soft, uneven or

cracked road, and may cause the machine
crashed. It is also dangerous to walk with
imbalanced load and non-load.

1.5.9 PRECAUTIONS WHEN TRAVELING ON THE SLOPE

Be careful that the machine may dump or skid to one side when traveling on the slope.

When an emergency happens, lower the bucket to the ground to help to stop the machine.

Do not travel on grass, fallen leaves or wet steel plate surface at a high speed. Even a
small slope may cause the machine to skid to one side. Therefore, it is required to drive

34
machine at a low speed. The machine must move straight up and down when traveling on
the slope.

When the machine travels downhill, never shift gear or place the gear in a ―neutral‖
position. It is dangerous not to use the braking force of the engine. When the machine
begins to travel downhill, the gear has to be placed in a ―low‖ position.

When the machine travels downhill, the braking force of the engine has to be used so that
the machine travels at a low speed. If necessary, when the braking force of the engine is
used, the braking pedal is also used to control the travelling speed.

If the engine stops during traveling on the slope, immediately step full brake pedal to exert
braking, lower bucket down to the ground, and then use parking brake to fix machine’s
present position.

If the bucket is loaded when ascending or descending, you should make the bucket
toward uphill direction (that is, forward for uphill traveling, backward for downhill traveling).
Otherwise, the machine may have a risk of tip-over.

Keep a clearance of 20-30cm from the bucket to

the ground when traveling on the slope.

Do not turn direction or walk transversely on the

slope, to complete this operation, the machine
should be driven down to the even ground.

35
1.5.10 BEWARE OF HIGH VOLTAGE CABLES

Do not let the machine touch the overhead

cables, even near the high voltage cable can
cause electric shock. Keep a safe distance
between the machine and cable as shown in the
following table.

For the prevention of accidents, please perform

the following tasks:

When there is a danger of touch the cable during

operation on site, consult the power company
before the start of operation, examine the
feasibility of this operation based on the existing
relevant laws and regulations.
Wear rubber boots and gloves. Lay a rubber mat
on the operator’s seat and be careful not to let
any part of the body touch the exposed part of the
metal chassis. Designate a signal commander
who sends warning signal if the machine is too
close to the cable.
If the working device touched the cable, the
operator shall not leave the cab.
When operating near the high voltage cables, do
not let anyone close to the machine.
Prior to operation, consult the local power
company for inquiring about cable voltage.

Voltage value (kv) Minimum safe distance (m)

0.1-0.2 2

6.6 2

22 3

66 4

154 5

187 6

275 7

500 11

The minimum safe distance listed in this table is for reference only. Rainy or high voltage
conditions will greatly reduce the safe distance.

36
1.6 PRECAUTION FOR OPERATION
When the machine shoves the soil descending a cliff or onto the peak of the slope, the
load will suddenly become lighter. In such case, due to a sudden increase in walking
speed, it is dangerous; therefore, it is important to reduce the speed.

When the bucket is full, do not give the machine a sudden start, turn or stop.

Do not get close to the edge of a cliff.

When loading unstable objects, such as round or

cylindrical objects, layered plates, if the working
device lifts, the loading objects may fall down to
the top of the cab, and cause serious injuries or
damages. Therefore, note that do not lift the
working device too high or heavy tilt bucket
backward.

If the working device suddenly dropped or stopped, its reaction force may cause the
machine overturning. Be careful to operating the working device, especially when it is
loaded.

For a good visibility, please pay attention to the following tips:

 When operating in a dark place, turn on the switch of working lamp and headlamp; if
necessary, install illumination equipment on site.

 Do not operate the machine in fogy, obscure, snowy or heavy rainy days or other poor
visibility conditions until there is sufficient visibility for operation.

For collision prevention of working device with other objects, please pay attention to the
following tips:

 When operating in tunnel, under the bridge, wire or other height limitation places, pay
caution not to let the bucket hit anything.

 When use dump truck to load, check whether there is anybody around the dump truck,
pay caution not to let the bucket of dump truck hit driver’s cab. In order to prevent
collision with other objects, and cause accidents, the machine shall operate at safety
working speed, especially in limited spaces indoor and other areas with many
vehicles.

37
1.6.1 METHODS OF USING A BRAKE

Do not put your feet on the brake pedal unless it is necessary.

Do not frequently step the brake pedal unless it is necessary.

When walking down hill, take the engine as a brake, never use gear shifting or place the
gearbox in neutral position.

1.6.2 PRECAUTIONS WHEN OPERATING ON SNOWY DAYS

When the machine working on the snowy or icy road, even a small slope can make the
machine slide aside, therefore it is important to low the walking speed and avoid a sudden
start, stop or sharp turn, because it has danger of sliding, especially when the machine is
in uphill or downhill status.

On the freezing road, when the temperature rises, the ground will become soft, so the
walking condition will become unstable, in this case, be careful to operate the machine.

After heavy snow, the objects on the road shoulders and roadside were buried in the snow
and unclear to see, so be careful to wipe the snow.

When walking on the snow-covered slope, it is not completely exert a sudden brake. To
slower the speed, it is correct to use engine as a brake, meanwhile, step the brake pedal
for several times. If necessary, lower the bucket down to the ground to stop the machine.

The adhesion force of the ground may greatly change with the effects of the snow.
Therefore, it is necessary to adjust loading capacity to avoid machine sliding aside when
walking.

The machine shall be equipped with anti-skid tire

chains when walking on the snow-covered road.

1.6.3 PRECAUTIONS FOR OPERATION IN COLD AREAS

After the completion of operation, clean off the water, snow or mud that clung to wires,
cable connectors, switches or sensors, as well as covering parts.

Totally preheat the machine. Prior to the operation of joystick, the machine will response
slowly if it is not totally preheated, this may lead to unexpected accidents.

Operate all joysticks to circulate hydraulic oil in hydraulic system (increase the system
pressure to a specified value, then release the pressure, drain the oil to hydraulic oil tank)
which can warm the hydraulic oil to ensure that the machine is sensitive and prevent
function failure.

38
If the electrolyte of the battery has frozen, it is dangerous to charge the battery and use
other power supply to start the engine, because it may cause fire. If it is necessary to
charge or use the other power supply to start the engine, unfreeze the electrolyte of the
battery and check whether there is any leakage.

1.6.4 DO NOT OPERATE THE MACHINE ON SOFT GROUND

Do not operate the machine on soft ground.

Do not let the machine close to the edge of a cliff

or its hanging parts and deep pit.

When there is danger of falling rocks and

potential turnover trend at site, tie the safety belt
and install falling objects protection device
(ROPS).

Soil piled on the ground or beside canals is soft and sloppy. The weight or vibration of the
machine may collapse the soft soil that cause machine turnover.

When there is danger of falling rocks at site, the machine shall be equipped with falling
objects protection device (FOPS).

39
1.6.5 PRECAUTIONS WHEN PARKING THE MACHINE

Park the machine on the even ground, and then

lower working device down to the ground where
there should no falling rocks or sliding danger,
and there also should no flood if it is low terrain.

If it is necessary to park the machine on the

slope, place a wedge under the wheels to prevent
the machine moving, and then drop the working
device down to the ground.

When parking the machine on the road, it is

necessary to set up fences, signals, flags or
warning lights and other necessary signals to
ensure the machine can be seen clearly.
However, the machine, fences and flag shall not
affect other vehicles passing through the road.

Before leaving the machine, fully lower the bucket

down to the ground, lock up joystick with locking
device, shut down the engine, and pull up the
parking brake switch to the ―brake‖ position. Lock
all equipments with keys, and remove and carry
the keys.

1.6.6 PRECAUTIONS WHEN LOADING THE MACHINE

When loading or unloading machine, the engine

should be ran at low speed, while the machine
should walk at low speed.

Loading or unloading of the machine should

progress on solid and even ground, and keep a
safe distance from the roadside.

Fix the carrying truck when loading or unloading

the machine, and place a pad block under the
springboard.

Use inclined plates with enough strength, width

and length to provide a safe loading or unloading
slope. The oblique angle between slant plate and
ground shall not exceed 15°. The distance
between the slant plates shall be compatible with
machine’s wheelbase

Firmly fix the position of slant plate, and make

40
sure they have the same height.

Make sure the surface of the slant plate is clean,

no lubricants, grease, ice and loose materials.
Clear the tires.

Do not turn direction on the slant plate. If

necessary, let the machine leave the slant plate,
and then adjust the wanted direction before
turning.

After loading materials, wedge the machine tires

and tighten the machine with cord.

1.6.7 PRECAUTIONS OF MACHINE TRANSPORTATION

When carrying this machine with trailer, it is necessary to comply with national and local
laws and regulations for the weight, height, and length of heavy objects and comply with
all relevant traffic laws and regulations.

Take machine’s weight, height, width and length

into account when determining transportation
route.

Check whether its loading capacity can support

the weight of the machine when passing through
a bridge or a structure.

When the machine travels on the public road, first check whether it is in comply with the
provisions of relevant authorities and follow those provisions.

The machine may need to divide into several parts for the convenience of transport. For
the division of this machine, please consult the designated dealer of LONKING Holdings
Limited.

1.6.8 PRECAUTIONS FOR DRAG

If the machine dragged with incorrect ways or wrong steel wires, it may cause injuries or
casualties; therefore, it is important to abide by the follow precautions:

41
Wear protective leather gloves when touch the
steel wires.

Agree on a common signal before dragging the machine together with other workers.

If there are some problems such as failing to start the machine or braking system, please
contact the designated dealer of LONKING Holdings Limited for repair.

It is dangerous to drag the machine on the slope, therefore it is right to choose a flat
gradient place, if this place is not available, choose a place as small angel as possible to
drag the machine.

If another machine drags the failed machine, the strength capacity of the used steel wire
must bear the weight of failed machine.

Make sure that the steel wire is no cutting trace, twist or shrunken diameter.

Do not divide your two feet and stride over the steel cable or rope.

Make sure there is nobody stands between the dragging machine and failed machine.

Make sure the dragging machine and failed machine are in the same straight line and in
place.

1.6.9 PRECAUTION FOR USE AND MAINTENANCE OF THE BATTERY

Because the battery electrolyte contains sulfuric acid

and can produce hydrogen gas, incorrect process
may cause serious injury or fire. Therefore, please
strictly abide by the following precautions.

It is not allowable to put lit cigarette or open fire close

to the battery.

Wear safety glasses and rubber gloves when it is

necessary to contact with battery.

If the electrolyte of battery splashed on your clothes

or skin, immediately rinse with plenty of clean water.

If the electrolyte of battery splashed into your eyes, it

may cause blindness. Therefore if it happens,
immediately rinse your eyes with plenty of clean
water, and see a doctor at once.

If accidentally drink the electrolyte, you must drink

plenty of water or milk, raw eggs or rape oil, at the

42
same time call the emergency center for help.

Please shut down the engine before operating the

battery. Avoid metal objects (such as tools)
unexpected contact with the battery, because it may
cause short-circuit between the positive (+) and
negative (-) terminal.

When installing battery, first connect positive (+)

terminal, while demounting battery, first disconnect
negative (-) terminal (ground side).

When amounting or demounting battery, first identify

which is positive (+) terminal and which is negative (-)
terminal, and tighten the nuts firmly.

Clean the top surface of battery with wet cloth instead

of gasoline, solvent, or any other organic solvent and
cleanser.

Tighten the top cover of the battery.

If the electrolyte of battery has frozen, it is dangerous

to charge the battery or start the engine with other
power supply, for is may cause battery fire.

Unfreeze the electrolyte and check whether there is

leakage before charging the battery or starting the
engine with other power supply.

Demount battery from the machine before charge it.

1.6.10 PRECATUTION FOR START-UP WITH BOOSTER CABLE

If the connection method of booster cable is wrong, it may cause fire; therefore, it is
necessary to abide by the following methods:

It requires two operators to start the machine (one of them sitting down the operator’s
seat)

It is not allowable the two machines contact each other when starting another machine.

When connecting the booster cable, turn off the two starter switches of normal machine
and failed machine.

When installing the booster cable, first connect the positive (+) pole cable, while
demounting the booster cable, first disconnect negative (-) pole cable (ground side).

The final earth connection means connect the earth cable to the engine of failed machine,
but it will produce sparks, therefore, make it keep away from the battery.

When demounting the booster cable, do not let the clips of booster cable touch each other
or touch the machine.

43
1.6.11 PRECAUTIONS FOR BATTERY CHARGE

If use the wrong method to charge the battery, it

may cause battery explosion. Therefore, it is
important to abide by the related charge
regulations and instructions stipulated in the
manual and note the following tips.

Choose a well-ventilated place to charge the

battery. Remove the battery cap to release
hydrogen gas and prevent explosion.

Set the charger voltage value to be consistent

with battery voltage value. If the voltage is
wrongly set, it may cause charger overheating or
fire and explosion.

Connect the charger’s positive (+) clip to positive

(+) terminal of battery, correspondingly, connect
negative (-) clip to negative (-).

IF the charge rate of the battery is less than 1/10,

give high-speed charging and set the values into
the rated capacity of the battery. If the charge
current is too large, it may cause electrolyte
leakage or evaporation, which may catch fire or
cause explosion.

1.7 MAINTENANCE PRECAUTIONS

1.7.1 FAULT NOTIFICATION

If processing maintenance has not mentioned in User Manual, it can lead to unexpected
fault. Then please contact to designated dealer of LONKING Holdings Limited for repair.

1.7.2 CLEANING BEFORE REPAIR AND MAINTENANCE

It needs to clean up the machine before repair

and maintenance. This ensures that no waste
enters into the machine, as well as the smooth
and safe process of maintenance

When performing cleaning, pay attention to the

following items:

1. Wear non-slip shoes to prevent falling down

from the wet or oil surface.

2. When using high-pressure water to wash

machine, please wear protective clothing to

44
 avoid the impact of the high-pressure water,
such as hurting the skin or wastes, mud
splashed into the eyes.

3. Prohibit water spray onto components of the

electrical system (like sensor, wiring plug
connector), in case that water goes into
electrical system that causes malfunctioning.

1.7.3 KEEP CLEANNESS OF WORKPLACE

Do not leave any maintenance tool around in the workplace. Please wipe out all the
grease, lubricants, or other things that may make people slip completely.

Do keep clean and tidy of the workplace in order to work safely, in order to avoid danger of
tripping, slipping, falling and alike, resulting in injuries.

1.7.4 DESIGNATION OF RESPONSIBLE PERSON

During repair of machinery, loading and unloading equipments, or cooperation with others,
one principal should appoint whose order the others should obey, which will avoid
misunderstanding that resulting in serious accidents.

1.7.5 CHECKING WATER LEVEL OF RADIATOR

When checking water level in radiator, be sure to stop engine, wait until the cool down of
engine and radiator before checking water level check in the water tank.

If you need to open the radiator cap, comply with the following methods:

 Check water temperature before the compressor down.

 When the filler cap is cool enough to be open by bare hand, loose the radiator filler
cap to release its inner pressure and then open the top cap.

1.8 OPERATING BEFORE REPAIR AND MAINTENANCE

Before repair and maintenance, park the machine

on the level ground where there is no falling
stones or landslides. If parking in a lower position,
there should be no danger of suffering flood, and
then shut down the engine.

After stopping the engine, shift the pilot joystick to

the position of up and down in order to release
the left pressure within the hydraulic oil circuit.
Then lower the working device to the ground, and
lock up the joystick with locking kit.

45
Pull up the parking brake switch, perform braking
and put wedge down the tire.

Lock up the front and rear frames with the frame

fixing rod. During maintenance, be careful not to
be touched or to be hooked by moving parts.

1.8.1 SUPPORT OF WORKING DEVICE

Be sure to lock safety support up to the piston rod

of the lift arm cylinder to restrict the retraction of
lift arm cylinder, to prevent the falling down of
working device. In addition, shift the joystick to
neutral position; lock up the joystick with lock kit.

1.8.2 APPROPRIATE TOOLS

Be sure to use appropriate tools designated to the task. Using damaged, inferior, defective
or temporary tool can lead to personal injury.

1.8.3 REGULAR REPLACEMENT OF CRITICAL SAFETY PARTS

Fuel, tubes of hydraulic system and braking system and other parts is critical to ensure
safety, be sure to replace them regularly.

Certain technology is necessary to replace the critical safety parts. Please contact the
dealer of LONKING Holdings Limited to do so.

Critical safety parts will go aging with time and oil leakage will lead to serious accident;
during their use, if any problem is discovered, they shall be replaced or repaired in time,
even if the specified interval is not reached; no matter whether critical safety parts have
any failure, these parts shall be replaced at regular intervals with new ones.

Regular replacement of critical safety parts is shown in Catalog and Replacement Cycle
of Critical Safety Parts.

1.8.4 ILLUMINATION

When checking fuel, lubricant, battery electrolyte, or window glass detergent, make use of
explosion-proof lighting equipment to avoid risk of explosion.

46
If work in the dark without lighting, there would be the risk of injury, so to install the
appropriate lighting equipment.

Even in the darkness, it is not allowed to use lighters or open flame to illuminate. This has
the danger of catching fire, for gas from the battery may produce an explosion.

When using the machine as a lighting source, be sure to comply with the guidance of
User Manual.

1.8.5 FIRE PREVENTION

Gas from fuel and battery may be ignited during maintenance, so it is necessary to comply
with the following precautions during maintenance or repair:

Fuel, lubricant and the other inflammable should

be stored far away from open fire.

Do not use diesel or gasoline, for it has risk of

lighting; use incombustible material as detergent
for cleaning the parts.

Smoke at the designated place. Smoking is

prohibited when overhaul or maintenance is
performed.

Use explosion-proof feature of the lighting

equipment to check fuel, lubricating oil, or battery
electrolyte, Prohibit use lighters or matches to
light.

When do grinding or welding operation on the

frame, move all the flammables to a safe place.

There should have a fire extinguisher in repair

and maintenance work site.

1.8.6 PERSONS FOR REPAIR AND MAINTENANCE

Only personnel with relevant qualifications can repair or maintain this machine. Personnel
unrelated with work of repair and maintenance is not allowed to enter working site. If
necessary, designate a person keep guard.

Pay special caution to keep your personal safety during grinding, welding or using of a
sledge-hammer and other operations.

47
1.8.7 ATTACHMENTS

Designate a person in charge when demounting or amounting a component.

It is not allowed for any non-staff to close to the

machine or components.

Put the demounted components into a safe place

and make sure they wound not fall. Encircle the
demounted components with a fence and put up
a sign of ―no entry‖ to avoid prohibitive person
entering this area.

1.8.8 MAINTENANCE UNDER MACHINE

Before maintenance or repair, stop the machine on a solid flat ground, lower the working
device to the ground and fix the tires with wedges;

Working under the poorly supported machine is prohibited. If the tires are off the ground
and the machine is only supported by the working device, maintenance under the
machine is very dangerous.

1.8.9 MAINTENANCE WITH THE FRAME SUPPORTED UP

When the frames are maintained with the working device lifted, it is necessary to lock up
the front and rear frames with the frame fixing rods. Set the joystick to the ―neutral‖
position, lock up joystick with locking equipment, and then support the working device with
supporting rods.

48
Before lifting, wedge the wheel from the opposite
side. After lifting, place a block under machine

1.8.10 MAINTENANCE ON THE TOP OF THE MACHINE

When conducting maintenance on the top of the machine, make sure your standing point
is clean and no barrier, as well as comply with the following items for the prevention of
falling:

Spilled lubricant or grease is not allowable.

No tools or spare parts displayed around.

Pay attention to your walking steps

Prohibit jumping from the machine. Be sure to

use ladder and handrail when up and down the
machine, and always maintain a three-point
contact (two-foot one-hand or two-hand one foot).

If necessary, use protective equipment.

Top of the engine hood and top of tire are smooth

and dangerous; and it is prohibited to stand on
them.

49
1.8.11 MAINTENANCE WHEN ENGINE IS WORKING

To avoid hurting, do not conduct maintenance

when the engine is running.

Be sure to comply with the following items for

maintenance when the engine is running:

To arrange one worker sitting in the operator seat,

and ready to shut down the engine at any
necessary moment. All workers must keep
contact with others.

When the operating point close to the rotating

components, extra care should be taken for there
is the danger of being involved by rotating parts.

Avoid any tools or any part of the body touching

the fan blades or fan belts.

When clearing the inner of radiator, it is

necessary to lock up joystick with lock equipment
to prevent movement of working device. In
addition, pull up the parking brake switch to
implement braking.

Do not touch any joystick. If it is indispensable to

operate joystick, you must notify other workers to
walk away to safe place.

1.8.12 NO LEAVING OF FOREIGN MATTER INSIDE MACHINE

When opening the repair windows or refueling port of fuel for repair, pay caution not to let
any foreign objects drop (such as nuts, bolts, cotton, or tools) into the hood. If there is
thing falling within the machine, it will cause damage to the machine, operational failures
and other
faults.

If there is any foreign object falling into the machine, make sure to remove it from the
inside of the machine.

During maintenance, do not carry any unnecessary tools and spare parts in the pockets.

1.8.13 PRECAUTIONS IN THE USE OF HAMMER

When using a hammer, be sure to wear safety glasses, safety helmets and other
protective clothing, and place a brass rod between the hammer and area being
hammered.

50
When hammering hard parts, such as a pin or a
bearing, there will be the injury risk of debris flying
into the eye.

1.8.14 WELDING REPAIR

Welding operation should be performed by qualified welders, and conduct in place fitted
with appropriate equipment. Welding will produce gas, so there is hazard of causing fire
and electric shock when doing welding. Therefore welding must comply with the following
notes:

 Disconnect the connection of the battery terminals to prevent

battery explosions.

 Clear the paint of welding parts to prevent harmful gases.

 When welding on the hydraulic device or pipe, or near them, it will

produce combustible vapors and sparks that have risk of ignition.
Thus, it is necessary to avoid welding in such a place.

 If the welding sparks flying directly onto rubber hoses, wires or pipes with pressure,
these tubes may suddenly rupture and wire insulation skin may be damaged, so it is
necessary to cover these things with fire flapper.

 Wear protective clothing during welding operation.

 Keep the welding work site well ventilated.

 Clean all flammable materials before welding, and equip with fire extinguishers on the working site.

1.8.15 PRECAUTIONS FOR BATTERY MAINTENANCE

The negative pole (-) of the battery must be disconnected when the electrical system is
repaired or electric welding operation is performed on the machine, so as to prevent
current flow.

1.8.16 TREATMENT OF ABNORMAL STATUS

If any abnormal status is found during overhaul, repair it. Especially that when the
machine is in operation, there is any irregularity in braking system, steering system or
working device system, which can lead to serious accidents.

Please consult the designated dealer of LONKING Holdings Limited for repair according
to the fault types.

51
1.8.17 FILL OF FUEL OR LUBRICATING OIL

Fuel, lubricating oil, hydraulic oil, antifreeze,

brake fluid, window glass detergent can be
ignited by flame. Therefore please comply with
the following provisions:

When filling fuel or lubricating oil, close engine

No smoking.

Overflowed fuel, lubricating oil, hydraulic oil,

antifreeze, and brake fluid or window glass
detergent should be cleaned up immediately.

All top caps of container of the fuel, lubricating oil,

hydraulic oil, antifreeze, braking fluid and window
glass detergent should be tightened firmly.

Place of filling or storing of fuel, lubricating oil,

hydraulic oil, antifreeze, brake fluid or window
glass detergent should be well-ventilate.

1.8.18 HANDLING OF HIGH-PRESSURE HOSE

If the high-pressure hose leaks, it may lead to malfunction, personal injury or equipment
damage. If find that the hose is damaged or bolts loose, stop working, and contact with the
designated dealer of LONKING Holdings Limited for repair.

Replacement of high-pressure hose needs superb skills. Installation torque should be

determined by the type and size of hose. So this work should not be done by the user,
please contact the designated dealer of LONKING Holdings Limited for replacement.

1.8.19 PRECAUTIONS OF HIGH-PRESSURE OIL

When repair or replace line in hydraulic system, it

is needed to make sure that system pressure has
been released. If there is pressure left in the line,
this may lead to serious injury or damage,
therefore, please comply with the following
measures:

 Never perform any repair or replacement

ahead of the complete release of the
pressure.

 Wear safety glasses and leather gloves.

 If the line leaks, then the line and its

surrounding will be wet, it’s time to check

52
 whether there is crack in the steel pipe or in
the hose，or there is blister in the hose. If the
leaking place is difficult to identify, please
contact with the designated dealer of
LONKING Holdings Limited about repair
issues.

 Do not use bare hands to check for leakage,

but to use the board or cardboard to check for
leakage.

 If shot by the sprayed high-pressure oil, be

sure to contact the doctor for treatment
immediately.

1.8. 20 PREVENTION MEASURES OF MAINTENANCE IN HIGH

TEMPERATURE OR HIGH PRESSURE

When the machine just stops working, cooling water and oil of all parts of engine is in high
temperature and high pressure. If now open the engine hood to do drain of oil, water or to
replace filter, this may lead to burn or other injuries. It is needed to wait for the
temperature drop, and then conduct repair according to requirements in the User Manual.

1.8.21 WASTE DISPOSAL

In order to prevent pollution, especially in place lived with people or animals, must comply
with the following requirements:

 Prohibit waste oil to dump into drainages and

rivers and other places.

 Discharged oil from the machine should be

placed in containers, do not discharge the oil
directly onto the ground.

 When dealing with hazardous substances

such as lubricants, fuel, coolant, solvents,
filters, batteries and other substances, it is
necessary to comply with relevant laws and
regulations.

53
1.8.22 PRECAUTIONS OF TIRE MAINTENANCE

Tire filled with gas explodes for the inner gas is

overheated, commonly due to heat from welding
or wheels rim, external fire or brake too often. Tire
explosion is so powerful which can cause tire,
wheel rim, and eventually transmission parts
flying 500 meters away from the machine.
Explosive force and fragments of the explosion
can lead to casualties and property damage.

Equipments and staff are needed to avoid

over-inflation. Leakage or rim damage is due to
the incorrect or improper use of inflatable
equipment. When inflating tire, you should stand
on the side and use automatic working clamp.

Danger may exist during maintenance and replacement of tire or wheel rim, as a
result it requires trained personnel to operate strictly according to operation
specifications provided by maintenance personnel of tire or wheel rim or the dealer.

If the operation of the tire or wheel rim goes wrong, tires may burst or rupture, wheel rim
may be damaged and spread around, may result in serious injury or death.

In order to ensure the security of maintenance work, the following precautions should be
complied with:

 Maintenance, demolition, repairs and installation of tire and rim requires special
equipment and expertise, so it is necessary to have it done in the tire repair shop.

 Use only the specified tires, charge to the required pressure.

 During tire inflation, other unrelated persons are not allowed to enter the work area.

 Stand by the side of the tire and use automatic working clamp, check the inflation
pressure occasionally so that it will not be too high.

 If the rim is not installed correctly, when the tire inflated, the wheel rim may be
damaged or spread about. Therefore, it is necessary to place shield around the tire,
and do not work in the front of the rim but beside the tire.

 When the abnormal decline in tire pressure or irregular match of the rim and the tire,
which indicate there is problem in tire or wheel rim. In this case, it is necessary to seek
help from the tire repair shop.

54
 After high-speed driving or heavy-load operation, do not adjust inflation pressure.

 Tire filled with gas can explode because of heat and robust to the inner gas of the tire.
This heat always comes from warm-up or welding to the wheel rim, external flame, or
brake too often, which cause inflation or robust of gas suffered from heating.

 Tire explosion is much powerful than disinflation that can cause tire, wheel rim, and
eventually transmission parts flying 500 meters away from the machine. Explosive
force and fragments of the explosion can lead to casualties and property damage.

 Recommend to fill the tire with nitrogen. If the tire is filled with air, it is recommended to
use nitrogen to adjust gas pressure, and nitrogen can mix with atmospheric gas. Tire
filled with nitrogen will decrease the possibility of explosion, for nitrogen is
incombustible, besides this, nitrogen can prevent the oxidation and aging of rubber
and corrosion of wheel rim parts.

 Equipments and staff are needed to avoid over-inflation. Leakage or rim damage is
due to the incorrect or improper use of inflatable equipment.

1.8.23 PRECAUTIONS OF TIRE STORAGE

Tires should be stored in warehouses, and unauthorized personnel are not allowed of
entering. If the tires are stored outdoors, there should be fence erected around the tires.

If the tire is put onto ground with its side, it will be squeezed, and its quality declines.

If the tire is falling down, it is better to run away, for the tires of engineering machinery are
extremely heavy, therefore, any attempts to stop its falling may lead to serious injury.

Erect the tires on level ground, fixed with wedge,

even if touched by unauthorized personal, they
cannot fall down.

55
 1.9 CATALOG AND REPLACEMENT CYCLE OF CRITICAL SAFETY

PARTS

To ensure the security of loader in operation, the user has to insist on regular maintenance.
In addition, in order to enhance security, the user has to replace parts regularly based on
the following table. The material of these parts will deteriorate as time goes by, or tend to
be worn and eroded easily. It is difficult to judge the condition of the parts only through
regular maintenance, as a result, no matter what conditions they are in, these parts should
be replaced regularly, to ensure their working performance.

If working time of the parts is less than replacement cycle, but finding abnormality in their
working, it is necessary to have a replacement or repair immediately.

If pipe clamp used to fix the tube has any damage, such as distortion or crack, it should be
changed with the tube.

When replacing tube, be sure to replace O-ring, gasket and parts like this at the same
time.

Please contact designated dealer of LONKING Holdings Limited to replace critical safety
parts.

REGULAR REPLACEMENT TABLE OF CRITICAL SAFETY PARTS

No. Critical parts needed regular Quant Replacement cycle

replacement ity

1 2 Each year or 2000 hours (subject to

Filter element of hydraulic oil tank
the earlier time)

2 Rubber hose from fuel tank to 1

Shuihanbao
3 Rubber hose from Shuihanbao to oil 1
injection pump
4 Oil return rubber hose from engine to 1
fuel tank
5 Rubber hose from pump to flow
1 Every two years or 4000 hours
amplifying valve
6 Flow amplifying valve confluence (subject to the earlier time)
1
rubber hose
7 Rubber hose from flow amplifying
1
valve to left steering cylinder
8 Rubber hose from flow amplifying
1
valve to right steering cylinder
9 Rubber house between steering
2
cylinders

56
10 Oil inlet rubber hose of steering gear 1

11 Upper rubber hose from steering gear

1
to flow amplifying valve
12 Lower rubber hose from steering gear
1
to flow amplifying valve
13 Oil inlet rubber hose of oil supply
1
valve
14 Rubber hose from pump to multi-way
1
valve
15 Rubber hose from multi-way valve to
2
tilt cylinder
16 Rubber hose from multi-way valve to
4
boom cylinder

57
 CHAPTER II OPERATION AND CONTROL

Right Cab

Cylinder Frame Hood

Rocker arm

Pull rod

Front
Rear

Balance weight

Lift arm Front Rear wheel

Bucket Cylinder Cylinder
wheel

Left

Schematic Diagram of Components of CDM860I.00II Loader

58
2.1 MAIN PERFORMANCE PARAMETERS AND SPECIFICATION

CDM860I.00II

STANDARD SPECIFICATIONS
ITEM SPECIFICATION

3
Bucket capacity (m ) 4.2-7.0

Rated payload (Kg) 7000

Lifting time(s) 5.8s

Total hydraulic cycle time (s) 10.8s

Forward I (km/h) 6.2
Backward I (km/h) 7.5
Forward II (km/h) 12.2
Maximum speeds Backward II (km/h) 12.7
(km/h) Forward III (km/h) 22.8
Backward III (km/h) 22.8

Forward IV (km/h) 36
Traction force (kN) 200±5
Maximum breakout force(kN) 240±5
Maximum Grade ability ( ° ) 30.0
Measured at centerline of
Performance

6560
Minimum turning outside tire (mm)
radius Measured at outer side of
7789
bucket (mm)
Loader length (with
bucket flat on ground) 9100±100
(mm)
Loader width (from wheel
3100±50
outside) (mm)
Bucket width (mm) 3200
Loader height (from cab
3460±30
top)(mm)
Dimensions(mm) Wheel base (mm) 3550±30
Wheel track (mm) 2350±10
Minimum ground
clearance (from 421±20
articulating point)
Max. dumping height
3314±50
(mm)
Unloading distance at
1408±50
max. lifting (mm)
Loader weight (Kg) 23700±300
Driver’ seat Above frame hinge

59
 ITEM SPECIFICATION

Type WP10G270E341

Rated power/rotational speed 199KW/2200r/min

Maximum torque/rotational speed 1100N·m/(1400~1600)r/min
Engine

Specific fuel consumption in rated

255
operating mode (bench test) (g/kw·h)
Fuel type ( according to ambient
0#/-10# light diesel oil
temperature)
Fan diameter (backward air exhaust)
800
(mm)
Type Single stage, single turbine, three elements
Hydraulic torque
Conversion ratio 2.355
converter
Cooling system Air cooled pressure circulation
Type Full automatic electric proportional gear shift
Number of speeds Four forward gears, Three backward gear
Transmission oil Gear pump
Gearbox
pump
Working pressure
1.6-1.8
(MPa)
Drive System

Main drive type Single stage reduction, spiral bevel gear

Hub reduction
Planetary reduction
type
Main drive and Speed reduction
26.6
wheel-side ratio
reducer Main drive
4.75
reduction ratio
Hub reduction
5.6
ratio
Type Four wheel drive
Drive axle and Tire 750/65R25 L-3TL
wheel Tire pressure
Front wheel, 0.45±0.02, Rear wheel,0.4±0.02
(MPa)
Type of braking Single line, dry-type braking
Brake system

Service brake Braking air

0.7-0.78MPa
pressure (Mpa)
Parking and
emergency Type of braking Pneumatic hydraulic fluid brake
brakes

60
 ITEM SPECIFICATION

Type Flow amplifying steering

Steering System

Number of steering cylinders - inner diameter × 2-100X324 mm

stroke (mm)
Steering pump Gear pump with constant displacement
System working pressure (MPa) 16
Steering angle (°) Left/ right 36
Number of boom cylinders - inner diameter × 2-180X864 mm

stroke (mm)
Number of bucket cylinders - inner diameter × 1-220X626 mm
Working mechanism

stroke(mm)
Distribution valve Hydraulic control pilot, two-link rod type
Model number D32
Displacement of working pump (ml/r) 112.5

System working pressure (MPa) 18

Single-rocking-arm, reverse six-link
Working device
mechanism

System voltage (V) 24

Electrical system

Battery capacity 2-N120

Lamp voltage (V) 24

Diesel engine starting 24V electric starting

Total capacity of fuel tank (L) 285L
Hydraulic oil filling amount (L) 280L
Oil capacity

Engine oil filling amount (L) 20L

Gearbox oil filling amount (L) 52L
Oil amount of front and rear drive axles (L) 46+46L

Operating medium Diesel engine

Warm air
Air conditioning

Heating power 5KW (10% error)

system

Operating medium R134a

Cool air
Refrigerating power 4.2KW (10% error)

System voltage (V) 24

Note:
1. Technical parameters involved in this instruction book are not inspection or test bases. Those
parameters may be changed without notice.
2. The foregoing oil filling standards are for reference only. Oil replenishment is performed depending on
actual liquid level of oil inspected.

61
2.3 PURPOSE

CDM860I.00II articulated and wheeled loader is a medium size loader featuring high
efficiency as well as diverse functions and mainly used for handling bulk materials in
mines, civil works, road constructions, harbors, and stock yards. The loader is capable of
carrying out lots of actions for examples loading, bulldozing, shoveling, traction, lifting,
delivering and so on.

The loader can be customized to include new functional devices, such as high dumping
bucket, extra-large coal bucket, side-dumping bucket, and wood-handling fork.

In the case of a standard bucket, the specific weight of bulk materials should be 1.5~1.8g/
2cm3; in the case of a high dumping bucket or extra-large coal bucket, the specific weight
of bulk materials should be equal to or less than 1.2g/cm3; in the case of a high dumping
bucket and extra-large coal bucket, the specific weight of bulk materials should be equal
to or less than 1.0g/cm3.

It is not recommended to use the loader long time for bulldozing or traction, otherwise the
temperatures of water, torque converter and transmission oil may rise sharply.

The loader is a general-purpose engineering machine. Do not use the loader in

environment with flammable material, explosive material, dense dust, or toxic gas.

63
 CHAPTER III OPERATION INSTRUCTIONS

3.1 STEERING WHEEL

The articulated loader uses fully hydraulic power steering. The steering wheel is arranged
inside the Cab and connected to the full-hydraulic redirector. Turning clockwise the
steering wheel turns the loader right; turning counterclockwise the steering wheel turns
the loader left.

The fully hydraulic power steering has the

following features:
1. The turning angle of steering wheel is not
equal to that of the loader. Continuously
turning the steering wheel can increase the
turning angle of loader to the expected value.
2. The faster the steering wheel is turned, the
faster the loader is turned.
3. The steering wheel cannot automatically
return to its original position, thus the turning
angle of loader remains unchanged. Therefore,
when the turning of loader is accomplished, it is
necessary to turn the steering wheel in the
opposite direction, to bring the loader to the
straight ahead direction.

3.2 NEGATIVE-POLE SWITCH OF BATTERY

The battery negative-pole switch is arranged at

the left side inside the rear hood.

The battery negative-pole switch differs from the

starter switch. Disconnecting the negative-pole
switch will turn off the electrical system of loader.
When the starter switch is turned off, some
electrical parts of loader may still be working
because the battery is still connected with
loader’s electrical system.

To turn off the battery negative-pole switch :

To disconnect the power supply to the electrical

system of loader, turn the battery negative-pole
switch handle counterclockwise to ―OFF‖ position.

Warning
Do not turn off the battery negative-pole switch while the engine is in operation,
otherwise the electrical system of loader may be damaged.

64
3.3 STARTER SWITCH
The starter switch (―electrical lock‖) is arranged
on the panel of control box in the right of Cab.
The starter switch can be turned clockwise to
three positions.

1. OFF-- When the starter switch key stays at this

position, the power supply to loader will be cut off.
The loader is off, i.e. automatic stop.

Warning

Only at this position can the starter switch key

be inserted or taken out!

2. ON--clockwise turn the starter switch key, the

first position is ―ON‖. Keep the key at this position,
the electrical system of loader is energized.

3. START--Insert and clockwise turn the starter

switch, the second position is ―START‖. With the
key at ―START‖ position, the motor is energized to
start the engine. Immediately release the key
after the engine has been started, the key will
automatically return to ―ON‖ position.

Warning

Before starting the engine, check that the negative-pole switch of the battery is
turned to “ON” position, and the gearshift handle is at the “Neutral” position.

Warning
If the engine cannot be started successfully, turn the starter switch to “OFF”

65
position, and then start the engine again, and do not just turn the starter switch to
“ON” position and then start the engine again. Failure to do so will cause damage
to the starter switch! Each time of starting shall not take more than 15 seconds;
interval between two times of starting shall be at least 30 seconds; do not
continuously start the engine for more than 3 times; if it is necessary to start the
engine for more than 3 times, wait until the motor cools down. Failure to do so will
shorten the service life of battery and cause damage to the motor.

3.4 SERVICE BRAKE PEDAL

The service brake pedal (foot brake) is arranged

on the left front floor of cab. The service brake
system of loader is a single-pedal, single-pipeline
system. To apply brake to front and rear axles,
tread the service brake pedal. In this case, the
brake lamp will light up.
To release service brake, take your foot off the
pedal.

66
3.5 ACCELERATOR PEDAL AND INSTRUMENT PANEL ADJUSTING

MECHANISM

The accelerator pedal is arranged on the right

front floor of Cab. Not depressing the accelerator
pedal, the engine will stay at the idle status.
Depressing the accelerator pedal will increase
the fuel supply to diesel engine thus the output
power of diesel engine.

The instrument desk adjusting mechanism is on

the right side of the instrument desk. Generally
speaking, the instrument desk tilts backward and
forms an included angle of 75°with the pedestal.
The adjusting range is 5° forward tilt and 20°
backward tilt on this basis.

3.6 ELECTRICALLY CONTROLLED SPEED-SHIFT HANDLE

The electrically controlled speed-shift handle is

arranged below the steering wheel.
Forward/ Reverse;
The electrically controlled speed-shift handle can
be turned to 4 forward gears (I, II, III and IV), 3
reverse gears (I, II and III) and 1 neutral gear.

3.7 PILOT JOYSTICK

Pilot joystick is mounted on the right side of seat
and used to control the working system. Reserved

67
The left and right movements of joystick are used
to control the moving direction of the bucket. The
front and rear movements of joystick are used to
control the moving direction of the lift arm. Both
joysticks are normally in a middle position. When
the engine is working, by pushing forwards the
pilot joystick, the lift arm will be lowered; by
pulling backwards the pilot joystick, the lift arm
will be raised; by pushing rightward the pilot
joystick, the bucket will dump; by pulling leftward
the pilot joystick, the lift arm will roll back. Slightly
moving forward or backward the two joysticks can
control the opening of main valve. The opening of
throttle valve of diesel engine can also be
controlled. The two kinds of controlling ensure the
exact movement position and speed of working
device.

The pilot joystick has the floating function:

By pushing the pilot joystick to the most front position, it will be attracted by the lift arm
floating magnet (the lift arm joystick will not return to neutral position even after the
operator takes his hand off it), and the lift arm will be brought to the floating status. To
terminate the lift arm floating status, pull back the lift arm joystick to the neutral position.
To have the bucket scrape materials, push the lift arm joystick to the lift arm floating
position, and the bucket will be raised or lowered according to road surface shape but not
contact thus protect the road surface.

3.8 LAMPS AND THEIR SWITCHES

The lamps of loader include front combination lamps (left, right), front working lamps (left,
right), rear working lamps (left, right), rear combination lamps (left, right), in-cab lamp, and
alarm lamp.

The front combination lamps include front headlamps, front small lamps, and front
steering lamps. The rear combination lamps include rear small lamps, rear steering lamps,
brake lamps, and warning lamps.

68
Front combination lamp

Front working lamp

Rear large lamp

Rear combination lamp

In-cab lamp

69
Warning lamp

Rocker switch assembly (below steering wheel)

1 2 3 4 5 6 7
1. Combination lamp switch: The combination lamp switch controls the ON and OFF state of
the combination lamp.
2. Front working lamp switch: The front working lamp controls the ON and OFF state of the
front working lamp.
3. Rear working lamp switch: The rear working lamp switch controls the ON and OFF state of
the rear working lamp.
4. Windshield wiper switch: The windshield wiper switch controls the ON and OFF state of the
windshield wiper.
5. Instrument lamp switch: The instrument lamp switch controls the ON and OFF state of the
instrument lamp.
6. HVAC switch: The HVAC switch controls the ON and OFF state of the HVAC line;
7. Double flash switch: Emergency fault alarm lamp controls the loader through switch. Both
left and right turn lamps are lit to remind passengers.
Each rocker switch has a switch indicator lamp. When the combination switch is closed, the
switch indicator lamp is lit up; when the combination switch is open, the switch indicator lamp
is not lit up.

Warning

Check if brake lamp, turn lamp or small lamps are damaged or defective before machine
operation. In case of any damage or defect, make necessary repair before machine
operation!!!

70
Rocker switch assembly (on right door decorative board)

2 3
1. Power selector switch: this switch controls whether the power from the gearbox at braking
needs to be cut off.
2. Rear Wiper switch: this switch is used to turn on or off the rear wiper.
3. Moving warning lamp switch: this switch is used to turn on or off the moving warning lamp.

Warning

Before traveling, please check it for damaged or failed brake lamp, steering lamp or
small lamp. Do not traveling the loader until all failures have been removed and all
damages repaired!!!

3.9 INSTRUMENT ASSEMBLY AND HORN SWITCH

All monitoring instruments, warning system and steering indicating system of the loader
are integrated into the instrument assembly that is below the steering wheel. The
instrument system displays many items: engine water temperature, engine oil pressure,
engine speed, brake air pressure, fuel amount, transmission oil temperature, system
voltage, battery charging indicator, low brake pressure alarm, low transmission oil
pressure alarm arm, loader work hour meter, left and right direction signal indicators, cold
starter switch, hand brake indicators and high beam indicator.

71
3.10 INSTRUMENT ASSEMBLY
3.10
The electronic monitoring instrument provides the following physical quantity displa：
Analog display content ： Engine water temperature gauge, Fuel level, Working hour meter, Engine
speed, System voltage, Engine oil pressure, Transmission oil temperature.
Switch volume to display content
content： Left turning direction, Right turning direction, High beam, Width
lamp, Parking brake, Charging indication, Neutral indication, Return oil filtration alarm, Transmission oil
pressure alarm, Transmission torque converte oil filter alarm, etc。

3.10.1 Description of display interface

Description of display interface

3.10.2 Menu key prompt description

Back to the main interface Automatic brightness setting

Move the selection down/

Move to the right
reduce the value

Move the selection up/up Move to the left

Confirm/Move to the next level Yes

Exit/return to the previous

No
level

56
1. Press the "Video" button on the main interface
to enter the "Video" interface, which displays the
current picture of the camera in real time.The
three camera channels of M1\M2\M3 can be
switched by pressing F2, F3 and F4.You can exit
the video display interface by pressing F1 button
and return to the main interface.

2. Press the "Fault query" key to enter the "Fault

query" interface.

When the engine has no fault information, the

fault interface will be shown as "Engine fault (0)".
此 At this point, press the "OK" key F5 and there is
no response. Press F1 or F6 to return to the main
interface. When the instrument receives the
engine fault information, the fault interface is
shown as "Engine fault 1". Press "Ok" F5 to enter
the engine fault interface, and then press "OK" F5
again to enter the DM1 fault information interface.
The details are shown in the picture on the right:

57
3. Press the "Run Parameters" key to enter the
"Run Parameters" interface in the main interface.
The "Run Parameters" interface displays the
current operating condition information of the
machine in real time. Including hourmetre, oil
pressure, cooling water temperature, engine
speed, battery voltage, oil level, brake pressure,
transmission oil temperature and other numerical
real-time display. At the same time, including
charging, preheating, return oil filter, transmission
oil pressure, dual variable oil filter, high beam,
position light, left turn, right turn, neutral and
parking brake indicator and alarm information.

4. Press the "Maintenance Information" button to

enter the "Maintenance Information" interface.

Maintenance items can be Selected by pressing

"Select Move up" F2 and "Select Move Down" F3.
The meter is divided into different maintenance
items according to the hourly meter interval.
Press F2 or F3 to select different maintenance
items and press F5 to enter the specific display of
the maintenance items. For example, select
"Daily Maintenance Items every 10 hours or
Every day" and press "Confirm" F5 to enter the
daily Maintenance items every 10 hours or every
day interface. Under this interface, press F2 or F3
to switch maintenance information display.
As shown on the right:

58
5. Press the "Settings" key on the main interface
to enter the "Settings" interface. The "Settings
Menu" interface contains submenus: "Run
Parameters", "Brightness Settings", "time
Settings", "System Settings" and "History Fault
Query".

⑴In the "Settings" interface, select "Brightness

Settings" for confirmation and enter the
"Brightness Settings" interface. On the
"Brightness Settings" interface, modify the
brightness values by pressing up and down. The
range is 1 ~ 5, 1 is the darkest and 5 is the
brightest. Press the Auto button to activate the
Auto function, and the brightness is fixed in a
moderate range. At this time, the up and down
button will no longer work. Press the Auto button
again to cancel the Auto function, set the value to
resume, and the upper and lower buttons are
available.

59
（2）In the "Settings" interface, select "Time
Settings" for confirmation and enter the "Time
Settings" interface. In the "Time Setting"
interface, the up/down key is used to
increase/decrease the value, and the left/right key
is used to move and select. The selected time
number will be displayed in black on the green
background, while the unselected time number
will be displayed in green on the black
background.

At this point, click "Yes/No" to select whether the

week should be displayed in the "Clock/Alarm
Information Bar" on the main interface. The "Time
Setting" interface submits the time value of the
setting and whether it is displayed by the confirm
key, and returns the "menu". The "Time Setting"
interface exists for 1 minute at most, and if there
is no operation in 1 minute, the "menu" interface
will be returned.

In the "Settings" interface, select "System

Settings" for confirmation and enter the "System
Settings" interface. You need to enter the
password during entering.
①"Enter Password" interface. Up/down keys are
used to increase/decrease values, left/right keys
are used to move and select. Selected passwords
are displayed as Numbers, and unselected
passwords are displayed as *.The "Enter
password" interface exists for at most 1 minute. If
there is no operation in 1 minute, go back to the
"Menu" interface and press the "Ok" button to
submit the password. If the password is wrong,
return to the "Settings" interface.
The interface is shown on the right.

②In the "System Settings" interface, select

"Parameter Settings" for confirmation and enter
the "Parameter Settings" interface.

60
On the "Parameter Setting" interface, setting
items include: high alarm value of cooling water
temperature, low alarm value of fuel oil level, low
alarm value of system voltage and engine type.
You can switch Settings by up/down key. Select
Settings and press "+" or "-" to modify setting
values.Press F6 to confirm saving.

③In the "System Settings" interface, select "Video

Settings" for confirmation and enter the "Video
Settings" interface. The "Video Settings" screen
includes: restore default and image Settings.

In the "Video Settings" interface, select "Restore

Default" to confirm and enter the "Restore
Default" interface.
In the "Restore Default Parameters" interface,
press "Yes" to restore the instrument video image
to its default value; Press "No" to not perform the
action.
In the "Video Settings" interface, select "Image
Settings" for confirmation and enter the "Image
Settings" interface to set the parameters of video
brightness, color, contrast and chroma.

④In the "System Settings" interface, select "Fault

Record Clearing" for confirmation and enter the
"Fault Record clearing" interface.

The "Fault record clearing" interface selects

whether to clear the fault record by no/yes button,
submits the setting result by confirmation key, and
returns "System Settings" by return key.

61
3.10.1 WARM WATER VALVE
The engine coolant absorbs engine heat and
flows through the evaporator of air conditioning
system, and the evaporator then disperses the
heat, that’s how the air conditioning system
perform the heating function. Two manual warm
water valves are mounted to the water inlet and
outlet of evaporator, respectively.

When the air conditioning system is in operation, the two warm water valves should
remain open (counterclockwise turn their controls). To repair the air conditioning system,
close the two valves first (clockwise turn their controls). Failure to do so may result in
engine coolant loss. To renew engine coolant, open the warm water valves so as to also
renew the coolant of evaporator, as well as ensure the normal level of engine coolant.

Warning
If the ambient temperature falls below 0℃, the engine is not working, and the
engine coolant contains no anti-freezer, then empty the engine water tank and open
the two warm water valves, to drain the coolant in the evaporator. Otherwise the
radiator pipe may break due to extra-low temperature.

3.11 SEAT ADJUSTMENT

In light of the operator needs and work conditions, the operator seat is designed to be
adjustable in the following items: hardness (rigidity), front-rear direction, height direction
and backrest angle.

75
Forward and backward adjustments to seat
 A handle is provided in the lower front portion
of seat. Pulling up the handle can move the
seat horizontally. While moving the seat, you
will feel increased resistances at some
locations. These locations are used to hold
the seat, that is, if you release the handle at
one of these locations, the seat will be held
on that location. The seat can be moved
forwards by 75mm and backward by 30mm,
and can only be held on the said locations.
 The seat can be adjusted to three heights by
means of the two ―UP‖ keys that are provided
on the right of the seat.

Adjustment to backrest angle

A handle is provided in the lower left portion of

seat. Turning clockwise the handle can press the
backrest forward or backward to expected
position. Release the handle, the backrest will
remain at that position. The backrest can be
adjusted at most 12.5° forward and at most 15°
backward.

Height adjustment of seat headrest

Hold the seat headrest with both hands and pull
up or press down the headrest steadily and
forcefully to adjust the height of seat headrest.

Adjustment to seat flexibility (rigidity

adjustment)

A weight adjusting handle is provided in the lower

front portion of seat. This weight adjusting handle
is used to adjust the flexibility to meet operator
need. The weight adjusting handle can be turned
clockwise or counterclockwise. There is a weight
indicate or near the handle. By turning the weight
adjusting handle, the weight indicator will indicate
a different value, meaning the most suitable
weight of operator relative to the current seat

76
rigidity. The seat flexibility can be steplessly
adjusted from 50kg to 130kg, and the rigidity set
by the loader manufacturer is 70kg.

3.12 SAFETY BELT

The loader is provided with a safety belt. The operator should fasten the safety belt when
operating the loader, but he should first inspect the safety belt for worn or loose part. If
necessary, replace the safety belt.

Before using the safety belt, adjust its length to

ensure the good functioning and comfort of safety
belt. The length of safety belt can be adjusted by
moving the position of buckle in safety belt. The
anchorage of safety belt is arranged in the rear
right portion of seat. Insert the buckle into the
opening of anchorage. The anchorage will lock
the buckle.

Press the red button near the anchorage, the

buckle will spring out.

Before using the safety belt, inspect the

anchorage.

3.13 CAB DOOR LOCK

The keys to the right and left doors of Cab are the same. If the door is locked, the core of
lock cannot be pressed down with the thumb. To open the door, insert the key into the lock
core, clockwise turn the key for 180°and then take it out, press down the lock core and
pull out the door. To close the door, insert the key into the lock core, counterclockwise turn
the key for 180°and then take it out.

77
3.14 USE OF LOCATING LOCK
If the cab door opens 180°, the locating lock will be caught by the lock catch, which is
outside the cab. The control handle of locating lock is arranged in the middle of door.
Pressing down the handle will release the locating lock, to close the door.

Locating lock

Warning
Before operating the loader, the operator must close both the left and right doors,
to ensure safety.

3.15 ADJUSTMENT TO REAR-VIEW MIRROR

A rear-view mirror is installed on the left and right front of Cab top, respectively. Adjust the
rear-view mirrors to correct positions before operating the loader.

To adjust the position of rear-view mirror, loosen the bolt that fastens the rear-view mirror
support to the Cab, and then rotate the support. Loosen the connection bolt between
rear-view mirror and support, rotate rear-view mirror to the right position. Then tighten the
bolt.

3.16 TURNING LAMPS AND FULL-BEAM/LOW-BEAM HEADLIGHTS

The loader has the control switches for turning lamps and full-beam/low-beam headlights.
They are located below the right side of cab steering wheel.

78
Turning lamp and full-beam/low-beam headlight
switches
1. Turning lamp switch
This switch is used to turn on and off turning
lamps when the loader turns.
2. Full-beam/low-beam headlight switch
Rotating control handle is used to turn on and off
full-beam and low-beam headlights.

3.17 CHARGING DOCK

Reserved for charging of cigarette lighter and
mobile phone.
(Figure 1) 12V 100W
(Figure 2) 24V 120W

79
3.18 SUNSHADE
1. Pull the handle lever in the middle by hand to
unroll the sunshade cloth. Pull to an appropriate
position and release the lever, and the sunshade
will stop at that position; if the position is not
appropriate, continue to pull the lever to the
maximum position of travel. When the lever is
pulled near the maximum position of travel,
reduce the pull force for fear of damage to the
sunshade.
2. When the sunshade is at the lower maximum
position of travel, pull the curtain bell on the left to
cause the sunshade to move up. Release the bell
quickly at this time, and the sunshade will stop at
the corresponding position. Pull the bell again,
and the sunshade will continue to move up until
the sunshade cloth returns to its original position.

3.19 PLAYER
Basic operations:
① LCD screen
In the starting state, the screen displays the radio
frequency and current play message.
② Power switch/pause/radio station
selection button
In the standby state, press the button shortly to
start the player and press the button long to turn
off the player.
In the MP3 play state, press the button shortly to
pause the playing; press the button shortly again
to resume the playing.
In the radio receiving state, press the button
shortly to select from already saved radio stations
(in the present wave band, select radio stations
cyclically; press the AMS/BND button to switch to
the other wave band.)

80
③ Mode conversion/mute button (MOD/MUT)
In the starting state, press the button long to conduct mode conversion: radio – U disk – SD
card; press the button to mute, and press the button long again to unmute.
④ Volume up/forward selection/forward search button
Press the button long to turn up the volume; in the MP3 state press the button shortly to select
music pieces forward; in the radio receiving state, press the button shortly to search radio
stations towards high end semi-automatically.
⑤ Volume down/backward selection/backward search button
Press the button long to turn down the volume; in the MP3 state, press the button shortly to
select music pieces backward; in the radio receiving state, press the button shortly to search
radio stations towards low end semi-automatically.
⑥ Clock button (CLK)
Press the button to display the clock. In the clock state, press the button for 3 seconds to enter
clock setting and display clock flashing. At this time press the ―VOA+‖ button to gradually
increase hour setting, and press the ―VOA-‖ button to gradually decrease hour setting; press
the ―CLK‖ button shortly again to enter the minute setting. At this time press the ―VOA+‖ button
to gradually increase minute setting, and press the ―VOA-‖ button to gradually decrease minute
setting.
⑦ Wave band/automatic station saving button (AMS/BND)
In the radio receiving state, press the button shortly to conduct waveband conversion
(FM1-FM2-FM3), and press the button long to automatically search radio stations and store the
searched radio stations in order. After one round of automatic radio station search,
automatically play the programs of the first pre-stored radio station.
⑧ U-disk socket
Insert a U disk to automatically play music pieces in the corresponding format (MP3) and
meanwhile display the corresponding indicative icon.
⑨ SD/MMC card socket
Insert a SD/MMC card to automatically play music pieces in the corresponding format (MP3)
and meanwhile display the corresponding indicative icon.

81
1.LCD screen 2. Power switch/pause/radio 3. Mode conversion/mute
station selection button button
4. Volume up/forward 5. Volume down/backward 6. Clock button
selection/forward search selection/backward search
button button
7. Waveband/automatic 8. U-disk socket 9.SD/MMC card socket
station saving button
10. Decorative knob

82
 CHAPTER IV OPERATION

4.1 NOTICES ON OPERATION OF NEW LOADER

Even though each loader is properly inspected and adjusted before leaving the factory, it
is still necessary to abide by the following procedures during the running-in period,
otherwise the loader may get damaged or its performance may be reduced.

If the loader works under fully-loaded state before the expiration of the running-in period,
this will adversely affect the service life and safe operation, and finally cause fault.

NOTE:

1) Inspect whether the coolant, fuel, engine oil or hydraulic oil leaks every day.

2) Inspect the lubricating fluid every day and fill the lubricating fluid if necessary.

3) In the course of operation, pay attention to the instrument board and the indication of
various instruments from time to time.

4) Prevent the engine from getting overloaded.

5) Before the engine and other parts reach the operating temperature, remain the load
less than 80% of the rated load.

6) In the course of working, inspect whether the work attachment is normal.

7) Inspect whether any part is loosened or damaged owing to the transportation.

8) Inspect whether any wire or terminal is loosened, whether the instruments work
normally, and whether the electrolyte is sufficient.

9) After running the engine, it should be idle running 3-5min, and then working normally.

Lubricating fluid and filter element

1. Replace the engine oil and engine oil filter element 50 hours after the loader works for
the first time.

2. Replace the slewing reduction gear oil 250 hours after the loader works for the first
time.

3. Replace hydraulic oil filter element 250 hours after the loader works for the first time.

4. Replace the travelling reduction gear oil 250 hours after the loader works for the first
time.

NOTE: When replacing the lubricating oil or grease, please refer to the relevant
contents in Section “Inspection, Maintenance and Adjustment.”

83
4.2 RUNNING-IN OF NEW LOADER

For a new loader, the running-in will play an important role in prolonging the service life of
the loader, eliminating hidden faults and avoiding the occurrence of serious fault. The user
shall carry out operation and maintenance in accordance with the provisions relating to
running-in of new loader as specified in this Manual after purchasing the loader, and then
the loader may be used normally.

4.2.1 REQUIREMENTS ON RUNNING-IN OF NEW LOADER

1. The running-in period for a new loader is 100 hours

2. After the engine is started up, make it run at idle speed for 5 minutes

3. During the running-in period, the forward gears I, II, III and IV and reverse gears I, II
and III shall be arranged for running-in respectively. When starting up the loader, the
accelerator pedal shall be pushed down smoothly and slightly, the speed shall then be
increased gradually, and violent braking shall be avoided.

4. During the running-in period, it is advised to work with bulk materials only, and the
traveling may not be carried out too violently. During the running-in period, the load on the
loader may not exceed 70% of the rated load.

5. Pay attention to the lubrication of the loader, and replace or add lubricating oil and
grease in accordance with the specified interval.

6. Pay attention to the temperature of gearbox, torque converter, front/rear axle, wheel
hub, parking brake, intermediate supporting shaft, hydraulic oil, engine coolant and
engine oil, and identify and eliminate the cause if overheating is found.

7. Inspect whether the bolts and nuts of all parts are properly tightened up.

4.2.2 OPERATIONS TO BE CARRIED OUT AFTER EIGHT HOURS OF

RUNNING-IN

1. Inspect the tightening of all bolts and nuts, especially diesel engine cylinder head bolts,
exhaust pipe bolts/nuts, front/rear axle fixing bolts, wheel rim nuts, transmission shaft
connecting bolts, diesel engine fixing bolts, gearbox fixing bolts and frame articulating
bolts.

2. Inspect the tension of generator belt and air belt.

3. Inspect the level of transmission oil, drive axle oil and engine oil.

4. Inspect the sealing property of hydraulic system and brake system.

5. Inspect the connection of each control handle and throttle lever.

6. Inspect the temperature and connection of each part of electrical systems, the power
supply to engine, the conditions and lightening devices and turn lamps.

84
NOTE: when inspecting the level of any oil or fluid, be sure to follow the relevant
operating procedure.

4.2.3 OPERATIONS TO BE CARRIED OUT AFTER EXPIRATION OF

RUNNING-PERIODS

1. Inspect the tightening of all bolts and nuts, especially diesel engine cylinder head bolts,
exhaust pipe bolts/nuts, front/rear axle fixing bolts, wheel rim nuts, transmission shaft
connecting bolts, diesel engine fixing bolts, gearbox fixing bolts and frame articulating
bolts.

2. Inspect the tension of generator belt and air compressor belt.

3. Inspect the sealing property of hydraulic system and brake system.

4. Replace the transmission oil and drive axle lubricating oil.

5. Replace the transmission oil filter, engine oil filter and diesel filter element.

6. Clean up the return filter element of the hydraulic oil reservoir.

NOTE: When replacing the transmission oil, drive axle lubricating oil and
transmission oil filter, be sure to follow relevant procedure as specified in chapter
"maintenance."

4.3 OPERATION OF LOADER

4.3.1 INSPECTION BEFORE STARTUP OF ENGINE

1. Inspect the level of engine coolant.

2. Inspect the level of engine oil.

3. Inspect the level of hydraulic oil in the hydraulic oil tank.

4. Inspect the sealing property of each oil pipe, water pipe and part.

5. Inspect the wiring of battery, and, if the connection between electrode and cable of the
battery is loosened, tighten it up in time.

6. Inspect whether the tire pressure is correct.

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Figure: Inspect the wiring of battery. Connect the
wiring according to the figure.

4.3.2 STARTUP OF ENGINE

1. Clear away the persons around the loader and the obstacles in the travelling direction
of the loader; inspect whether there is any person under the loader; except for the
driver who may sit in the cab for operating the loader, no other person may stand on
any portion of the loader.

2. Turn on the negative pole switch of the battery.

3. Go up and go down the stairs in accordance with the relevant safety provisions.

4. Adjust the rear view mirror, so as to obtain a good rear vision which is as closer to the
loader as possible.

5. Close the left and right doors of the cab.

6. Inspect whether the seatbelt is in good conditions, and then properly fasten the
seatbelt.

7. Inspect whether the gear-shift lever is at the neutral position; if not, please set the
gear-shift lever at the neutral position.

8. Inspect whether the pilot joystick is at the middle position; if not, please set it at the
middle position.

9. Inspect whether the fan switch and A/C switch of A/C system are at the off position; if
not, please set them at the off position.

10. Insert the key into the electric lock and then turn it clockwise by one step so as to turn
on the power supply, and then sound the horn so as to declare that the loader is about to
start up and no other person may approach the loader.

11. Inspect the level of fuel.

12. Slightly push down the accelerator pedal, and turn the key clockwise by one more
step so as to switch on the engine starting motor. Under normal conditions, the engine
can be started up within 10 seconds, and then please release the key immediately so
as to let the electric lock return to the original position.

NOTE: An attempt to start up the engine may not last for more than 15 seconds (the
starting motor may not work continuously for more than 15 seconds), and if the
engine cannot be started up, please immediately release the starter switch, wait at

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least 30 seconds and then attempts to start up the engine again. This is jointly
required by the features of starting motor and battery. If the loader cannot be
started up in three attempts, please carry out inspection, eliminate the fault, wait at
least three minutes, and then attempt to start up the engine again.

13. After the engine is started up, make it run at idle speed (700~800r/min) so as to warm
it up. Only after the temperature of the diesel engine cooling water reaches 55℃ and
the temperature of engine oil reaches 45℃ may the fully-loaded operation be carried
out.

14. When the engine is running at low speed, listen whether the engine works normally
and whether the gearbox makes any abnormal noise.

15. Inspect whether each instrument works normally and whether each lighting device,
indicating lamp, horn, wiper and brake lamp can work normally.

NOTE: Pay special attention to the engine oil pressure. The value indicated may not
be less than 0.07MPa (idle state). If the indicated value is less than this figure,
please stop the loader, inspect whether there is any fault with the diesel engine.
After the electric lock is turned on, the low brake pressure warning lamp will flash,
and the warning buzzer will sound; about half a minute after the engine is started
up, the low service brake pressure warning lamp shall go out. The warning buzzer
shall stop. If not, please inspect whether there is any fault with the brake system.

16. In cold season, please preheat the hydraulic oil. Push backwards the pilot joystick and
hold it there for 4-5 minutes, and at the same time push down the accelerator pedal,
so as to make the stopper of the bucket is pressed against the lift arm and make the
hydraulic oil overflow. In this way, the temperature of hydraulic oil will increase rapidly.

17. If there is no obstacle around the loader, please turn the steering wheel slowly, and
observe whether the loader turns.

4.3.3 TRAVELLING OF LOADER

1. Operate the pilot control valve handle so as to

move the bucket backwards to the limit state;
raise the lift arm to the transportation position,
namely the position whereby the lower
articulated point of the lift arm is 500-600mm
above the ground.

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2. Step down the service brake pedal, pull up
the parking brake button, slowly let go of the
service brake pedal, and observe whether the
loader moves.

WARNING: If the loader moves, immediately step down the service brake pedal, pull
up the parking brake button and apply the braking. Thereafter, inspect whether
there is any fault with the gear-shifting control system. If the loader is on a slope,
be sure to block up all wheels with chocks so as to prevent the loader from moving,
and then operate the loader.

3. Push the control handle so as to get the

forward gear 1 engaged or pull the
gear-shifting lever backwards so as to get the
reverse gear 1 engaged, and at the same
time push down the accelerator pedal
appropriately. In this way, the loader will travel
forwards or backwards.
4. Inspect the engagement of each gear. Drive
the loader to a flat and open ground, get each
gear engaged respectively, and inspect the
gear-shifting operation. If in the operation of
the previous phase, the inspection on
steering performance was not carried out
owing to the small place, please turn the
steering wheel now, and inspect whether the
loader can turn left or right.

NOTE: When carrying out gear-shifting operation, release the accelerator pedal
firstly and then operate the gear-shifting lever for realizing the gear shifting, so as
to protect the gear-shifting clutch.

5. Inspect the performance of service brake. On a flat and open ground, drive the loader
with forward gear 1 or forward gear 2 engaged, release the accelerator pedal, and at
the same time smoothly push down brake pedal. The loader shall slow down
obviously and then stop.

NOTE: If you cannot feel that the loader slows down obviously after the brake pedal
is stepped down, please immediately pull up the parking brake button and apply the
emergency braking. At the same time, by operating the pilot joystick, lower the lift
arm to the lowest position, tilt forwards the bucket, and insert the bucket teeth into
or push against the ground, so as to stop the loader and ensure the safety.

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6. In case there is a corner ahead, please
operate the loader in accordance with the
local laws and regulations relating to traffic.
When the loader is about to turn, pull or push
the turn lamp handle in the corresponding
direction. As indicated in the figure below,
push forwards the handle if the loader will turn
left, and pull backwards the handle if the
loader will turn right. Now the front/rear turn
lamps on one side of the loader and the
corresponding turn indicating lamp on the
instrument board will come on, so as to warn
the loaders and persons around the loader
that this loader is about to turn. Thereafter,
turn the steering wheel in the turning
direction, so as to make the loader to turn.

The loader is equipped with the articulated-type fully-hydraulic coaxial-flow-amplifying

powered steering gear, and the turning angle of the steering wheel is not equal to the
turning angle of the loader. When the steering wheel is turned continuously, the turning
angle of the loader will increase until the intended angle is obtained. The turning speed of
the loader will increase as the turning speed of the steering wheel increases.

After being turned, the steering wheel will not return to the original position automatically,
and the turning angle of the loader will remain unchanged. Therefore, after the turning of
the loader is completed, be sure to turn the steering wheel in opposite direction so as to
eliminate the relative angle between front and rear frames and make the loader run
straightly. After the turning operation is completed, pull the turn lamp switch to the middle
position, so as to turn off the turn lamps and turn indicating lamp.

For the purpose of carrying out the turning operation when the loader is travelling at high
speed, be sure to release the accelerator pedal firstly. If necessary, apply the service
brake to slow down the loader and then carry out the turning operation, so as to ensure
the safety.

WARNING: Do not carry out turning operation on a slope. The turning operation
may be completed only after the loader has been driven to the flat ground.

7. For the purpose of braking the loader, just release the accelerator pedal, and then
smoothly push down the brake pedal.

WARNING: When the loader is running at high speed, unless any emergency
circumstance occurs, be sure not to push down the brake pedal to the end violently,
otherwise the emergency braking may cause safety accident or damage the loader.

4.3.4 PARKING OF LOADER

 Drive the loader to a flat place which is free from the risk of falling stone, landslide or

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 flood.

 Apply the service brake to stop the loader.

 Pull the gear-shifting lever to the neutral position.

 Pull up the parking brake button and apply the parking braking.

 Operate the pilot joystick so as to lower the lift arm, place the bucket horizontal on the
ground and make the bucket press against the ground slightly.

 Make the engine run at idle speed for 5 minutes, so that all parts may cool down
evenly.

 Turn the electric lock’s key anticlockwise to OFF position to disconnect the control
circuit. Engine stops. Pull out the key.

 Set each switch at middle position or off position.

 Close the left and right doors, and then go down the stairs in accordance with the
relevant provisions.

 If the loader is to be parked for long time (for example, all the night), just open the side
door of the hood and pull the negative pole switch of battery to the off position, so as
to turn off the power supply.

 If no anti-freezing fluid is added in the coolant before the loader leaves the factory, just
open all water drain valves of the engine after parking the loader in winter, discharge
all coolant from the cooling system and the evaporator in A/C system, so as to prevent
any part from being frozen and damaged. If the anti-freezing fluid is added when the
loader leaves the factory, please operate as indicated in the nameplate on the rear
end of the loader.

 Lock up all equipment, pull out the key and take it with you.

NOTE: Be sure to park the loader on a flat ground. If it is necessary to park the
loader on a slope, be sure to block up the wheels with chocks, so as to prevent the
loader from moving.

If the loader is to be stored for long time, please operate in accordance with the
following requirements:

1. Before Storage

1) Clean up each part of the loader, dry the loader up and then store it in a dry
warehouse. If the loader can only be stored outdoors, be sure to park it on a concrete
ground where water may drain easily, and cover it with canvas.

2) Before storing the loader, fill the fuel tank with fuel, apply grease to each moving pin,
moving shaft and transmission shaft, and replace the hydraulic oil.

3) Pull the gear-shifting lever to the neutral position.

4) Pull up the parking brake button and apply the parking braking.

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5) Place the bucket on the ground horizontally, and pull the pilot joystick to the middle
position.

6) Set each switch at the middle position or off position, and then lock up all doors.

7) Apply a thin layer of grease onto the exposed portion of the hydraulic oil cylinder
piston rod.

8) Detach the battery from the loader and place it separately.

9) If the atmospheric temperature may reduce below 0℃, please add anti-freezing fluid
into the engine coolant, and make the anti-freezing fluid reach the engine and the
evaporator of A/C system. Alternatively, discharge all water in the cooling system, and
also discharge all water in the evaporator of A/C system.

10) Fix the front/rear frames with the frame fixing rods.

2. During Storage

1) Start up the engine once a month, run each system, and apply lubricating oil/grease to
all moving pins/shafts and the transmission shaft so as to get all moving parts well
lubricated. In addition, charge the battery.

2) Before starting up the loader, wipe away the grease on the hydraulic oil cylinder piston
rod.

3) Apply antirust agent to all portions which may get rusted.

NOTE: If the antirust agent is used indoors, be sure to open doors and windows, so
as to get the place well ventilated and discharge the toxic gas.

3. After Storage

When the loader is to be used after long-term storage, be sure to carry out the following
operations:

 Replace the lubricating oil of engine, gearbox and drive axle as well as the hydraulic
oil and anti-freezing fluid.

 Apply greases to all moving pins/shafts and the transmission shaft.

 Before starting up the engine, wipe away the grease from the hydraulic oil cylinder
piston rod.

4.4 WORKING OF LOADER

4.4.1 PREPARATION BEFORE WORKING

 Before the commencement of the working, use the loader to flatten the working place,
remove crowing portions, fill depressions, and remove the ground surface which is wet
and slippery. Clear away all large and sharp stones on the working place, so as to
prevent the tires from being scratched.

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 If using the loader to load materials onto or unload materials from a truck or hopper,
adjust the limit height of the caging device of the lift arm on the basis of the height of
the truck or hopper, so as to ensure that the bucket may safely enter into and exit from
the truck or hopper and to avoid the impact on truck or hopper imposed by materials
discharged from an excessively high position.

4.4.2 GENERAL TECHNIQUES

Common shovel-loading method

 The common shovel-loading method is suitable for the loading of bulk materials.

 Make the loader approach the materials at the speed under forward gear 2, align the
middle portion of the bucket with the material pile, hold the steering wheel with your left
hand, and operate the pilot joystick with your right hand so as to lower the lift arm to the
position which is 500mm above the ground.

 When the loader is about one meter away from the material pile, lower the lift arm
again and make the bucket contact with the ground, and then change the forward gear 2
to forward gear 1.

NOTE: When making the bucket contact with the ground, be sure not to make the
bucket apply a too large force onto the ground, otherwise the unnecessary
travelling resistance may occur. In addition, the front/rear frames of the loader shall
be placed straightly, and there must be no included angle between front and rear
frames.

 Push down the accelerator pedal so as to insert the bucket into the material pile with
full force; when the loader cannot move forward any more, push leftwards the pilot joystick
so as to turn the bucket backwards, and then pull the control handle to the middle position.
In this way, the loader may go ahead into the material pile. Repeat the operation
mentioned above until the bucket is filled with the material.

Combined shovel-loading method

 The combined shovel-loading method is suitable for loading relatively hard or sticky
materials. Before the bucket is inserted into the materials, all operations are the same as
those of common shovel-loading method. When the bucket cannot move forwards any
more after being inserted into the material pile, just pull backwards the joystick with your
right hand and then push it to the middle position, so as to lift up the bucket for once. In
this way, the bucket may go ahead for certain distance. Thereafter, push forwards the pilot
joystick and then push it to the middle position, so as to turn backwards the bucket for
once. In this way, the bucket may get further inserted into the material pile. Repeat the
operation ―insertion, lifting, inserting and turning‖ until the bucket is filled with materials.

Exiting from material pile

 After the bucket is filled with materials, just operate the pilot joystick so as to turn
backwards the bucket until the stopper on the bucket contacts with the lift arm, and then

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push the pilot joystick to the middle position. Now the maximum rollback angle is obtained.

 Raise the lift arm to a certain height, so as to ensure that the bucket may evade the
material pile when the loader is travelling backwards. Just hold the steering wheel with
your right hand, and pull backwards the gear-shifting lever to the reverse gear position
with your left hand, so as to make the loader travel backwards.

 After the loader exits from the material pile, just operate the pilot joystick so as to
lower the lift arm to the position whereby the lower linkage point of the lift arm is about
50cm above the ground.

Handling of materials

 Under any of the following circumstances, the self-handling may be carried out:

① The road is soft, the place is not flattened, and it is impossible to use freight vehicle.

② The handling distance is no more than 500 meters, and the use of freight vehicle is not
economical.

 In the course of handling, remain the lower linkage point of the lift arm at the
articulating position (about 50cm above the ground), and turn backwards the bucket to the
limit position (the stopper on the bucket contacts with the lift arm), so as to ensure that the
handling operation may be carried out safely and smoothly and no material will fall out.

 The speed of the loader in the course of handling operation depends on the handling
distance and road conditions. When passing any depression or crowing portion, just
release the accelerator pedal, and, if necessary, intermittently apply the service brake, so
as to slow down the loader, make the loader pass the obstacle slowly, reduce the impact
to the loader and prevent the materials from falling down.

WARNING: Do not lift up the bucket to a relatively high position for carrying out the
handling operation, otherwise the loader may overturn.

Unloading of materials

① Discharging of materials into truck or hopper

 When the loader which is loaded with materials is 15 meters away from the truck or
hopper, just release the accelerator pedal, and if necessary, intermittently apply the
service brake, so as to slow down the loader and make the loader approaches the truck or
hopper at a low speed. At the same time, pull the pilot joystick backwards to the limit
position until the control handle is caught up by electromagnet, and then release the
control handle (the handle will not return to the middle position automatically). The lift arm
will rise continuously until it reaches the limit height, and then the electromagnet will be
de-energized, the pilot joystick will automatically return to the middle position, and the lift
arm will not rise any more. In this course, the driver shall carefully drive the loader,
carefully observe the approach by the bucket to the truck or hopper, and may not make
the bucket collide with the truck or hopper.

 When the bucket is above the truck or hopper, just push down the brake pedal so as

93
to stop the loader, push rightwards the pilot joystick so as to tilt forwards the bucket, and
then discharge the materials into the truck or hopper. At this time, be sure to carefully
observe the movement of the bucket, and be sure not to make the bucket collide with the
truck or hopper. If the material is very sticky, just push and pull the control handle
repeatedly, so as to make the stopped of the bucket collide with the lift arm repeatedly, so
as to make the materials fall down from the bucket.

 If the length of the truck exceeds two times the width of the bucket, the unloading
operation shall be started with the materials on the front portion of the truck.

NOTE: Be sure not to make the stopper collide with the lift arm too violently or too
frequently, otherwise the loader may get damaged.

 After all materials are unloaded, just pull the pilot joystick backwards to the limit
position until the control handle is caught up by the electromagnet, and then release the
control handle (the handle will not return to the middle position automatically). The bucket
will turn backwards continuously until it is in the horizontal position, and then the
electromagnet will be de-energized and the pilot joystick will automatically return to the
retaining position. Thereafter, just pull backwards the gear-shifting handle to the reverse
gear position, and then release the brake pedal, so as to make the loader leaves the truck
or hopper.

 After the bucket fully leaves the truck or hopper, just lower the lift arm while the loader
the travelling, so as to get ready for the next working cycle.

② Discharging of materials at lower position

 When being handled between different places, sometimes the materials may be
discharged at lower position, which means that the materials are discharged with the
bucket located at a position close to ground. In this case, after the materials are
discharged, be sure to turn backwards the bucket until it is in the horizontal position and
then raise the lift arm, otherwise it is likely that the lift arm cannot be raised up owing to the
interference caused by the linkage of work attachment.

Push-transportation

 Place the bucket horizontally close to the ground, set the gear-shifting level at the
position of forward gear 1, and then push down the accelerator pedal, so as to make the
loader move forwards. If an obstacle is found in the course of working, just slightly raise
the lift arm and go ahead. When raising or lowering the lift arm, the pilot joystick shall be
operated between lowering position and lifting position and may not be fixed at lifting
position or lowering position, so as to ensure the smooth progress of the working.

Scraping

 Raise up the lift arm until it is about 1100mm above the ground, and tilt the bucket
forwards until its scraper contacts with the ground and the included angle between the
scraper and the ground is about 45°. In case the road is hard, just place the pilot joystick
at the floating position; in case the road is soft, just place the control handle at the middle

94
position. Pull the gear-shifting lever to the reverse gear position, and then push down
accelerator pedal, so as to make the loader travel backwards and use the bucket scraper
to scrape the ground.

Traction

 The loader may be towed by a 20-ton towing tractor for transportation. The method is
detailed as follows.

 Firmly connect the towing tractor to the towing pin of the loader.

 The towing tractor shall be equipped with the brake system with good performance.

 Place the bucket at the transportation position.

 All actions shall be slight and smooth when starting up or stopping the loader, and
brake shall be applied before going down along a slope.

NOTE: When applying the brake, be sure to brake the towing tractor firstly, and then
brake the loader.

4.4.3 WORK METHOD

 V-type work method

 Align the loader with the material pile, keep the included angle between the truck and
the travelling direction of the loader at 60°, and stop the loader about 12-15m away
from the material pile. After the bucket is filled with materials, make the loader travel
backwards until it is 12-15m away from the material pile. Therefore, turn the loader
and drive it towards the truck and at the same time lift up the bucket. After the
materials are discharged, return to the original position for the next shovel-loading
operation.

 Shuttling work method

 The shuttling work method is mainly used for the combined work of loader and truck
fleet. As indicated in the figure below, after the loader is loaded with materials, it will
travel backwards by 2-3 times the width of the truck. Thereafter, the truck will run
along one side of the loader and stop in front of the loader. The loader will go ahead
and raise up the lift arm. After the materials are discharged, the loader will travel
backwards to the original position. If the truck is not fully loaded, the truck will go
ahead by the width of the truck. After completing the next shovel-loading operation,
the loader will return to the original position, and then the truck which is not fully
loaded will travel backwards until it is in front of the loader, and now the loader will
discharge the materials onto the truck. Repeat this operation until the truck is fully
loaded, and then load the next truck. This working method requires the close
cooperation between the loader driver and the truck driver, and, if necessary, the use
of horn, light or gesture for communication.

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Figure: Shuttling Work Method

4.5 TRANSPORTATION OF LOADER

Before the transportation, be sure to survey the height, width and permissible load of the
transportation course. The total height, total width and total weight after the loader is
placed on the transportation vehicle may not exceed the specified value. If the height or
width exceeds the specified value, please consult with LONKING Holdings Limited or its
distributor for solution.

In order to prevent the safety accident caused by unexpected movement or sliding of the
loader in the course of transportation, be sure to clear away ice, snow and other slippery
materials on the dock or vehicle before the transportation.

NOTE: When transporting the loader, please comply with the national or local
regulations relating to height, width, length and weight.

Please carry out the transportation in accordance with the following procedure:

1. Before the transportation, be sure to block up the wheels of the towing tractor or truck
with chock (towing tractor in the figure).

Figure: Use Chock to Block up the Wheels of the

Towing Tractor

2. After the loader has driven onto the towing tractor or truck, no turning operation may
be carried out in the course of transportation. If it is necessary to carry out turning
operation, please carry out the operation only after the loader has returned to flat
ground.

3. After the loader is parked properly, use the bumper to fix the front/rear frames.

96
Figure: Installation of frame fixing rod

4. Horizontally place the bucket on the transportation vehicle, and then set the control
handle at the neutral position.

5. Pull the pilot joystick to the middle position.

6. Rotate the parking brake button to reset it.

7. Turn off the engine, set all switch at middle position or off position, and then pull out
the electric lock key.

8. Properly close and lock all doors, and then pull out the key.

9. Pull the negative pole switch of battery to the OFF position.

10. When using a truck or towing tractor to transport the loader, be sure to use chocks to
block up the wheels and use wire ropes to fix the loader, so as to prevent the loader from
moving in the course of transportation.

4.5.1 HOISTING OF LOADER

1. The hoisting operation shall be commanded and carried out by professionals who
have the hoisting-related knowledge.

2. Please calculate the maximum hoisting weight of crane and the loading capacity of
sling (the weight of loader is 21150±300 kg), so as to ensure the safety. In addition,
please ensure that the four hooks on the sling will be under even stress.

3. Before the hoisting operation, be sure to carry out the following preparation:

① Set the control handle at the neutral position.

② Place the lift arm and bucket at the lowest position, pull the pilot valve joystick to
the middle position.

③ Rotate the parking brake solenoid valve switch to reset it.

④Shut down the engine and pull the key out from the electric lock.

⑤Close and lock up all doors.

1. Pull the negative pole switch of battery to the off position.

2. Fix the front/rear frames with the frame fixing rod, so as to prevent the loader from

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 turning.

3. The sling shall be firmly fixed onto the lug on the loader which is marked with the
hoisting sign.

Figure: Hoisting Sign

WARNING: Incorrect hoisting operation may get the loader displaced and then
cause personal injury or property damage.

Towing of loader in trouble

Except in emergency circumstances, the loader cannot be towed. In case towing

operation is carried out, the distance must be short and necessary for moving the loader
to a place where inspection and repair can be carried out. In the course of the towing
operation, the speed may not exceed 2km/h; otherwise the gearbox may get damaged
owing to insufficient supply of oil. If long-distance movement is required, please use
special towing tractor.

WARNING: Incorrectly towing a loader may cause personal injury.

If the loader in trouble is towed on a bad road, it will further damaged.

If the brake system fails, the brake is out of use, and special attention shall be paid in the
course of towing operation.

Precautions for towing operation:

1. Unless the driver may control the direction and/or brake of the loader, no person may
stay on the loader which is being towed.

2. Before the towing operation, make sure that the towing rope or towing rod is in good
conditions and has the enough strength to tow the loader. The strength of the towing
rope or towing rod used shall be at least 1.5 times the gross weight of the loader to be
towed, so as to ensure that the loader can be pulled up from mud or along a slope.

3. The angle of the towing rope shall be minimized, and the included angle between the
towing rope and travelling direction may not exceed 30°.

4. Too quick movement of the loader may get the towing rope or towing rod broken.
Better effect may be obtained if the loader moves slowly and smoothly.

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5. In the course of towing operation, all persons shall keep away from the towing rope,
so as to avoid the personal injury caused by the broken towing rope.

6. Under normal conditions, the towing tractor shall be of the same size as the loader to
be towed. It shall be ensured that the towing tractor has enough braking ability, weight
and power to control two loaders.

7. When going down along a slope, in order to ensure that the loader towed can be
properly controlled and braked, a towing tractor or another loader of larger size shall
be connected to the rear end of the loader towed, so as to prevent it from being out of
control and overturning.

8. If the direction of the loader towed is controlled by the driver, the driver shall turn along
the direction of the towing rope.

NOTE: Before releasing the brake, be sure to block up the wheels of the loader with
chock, so as to prevent the loader from moving. If the loader is not properly
blocked up, it may slide. Take away those chocks before the towing operation will
commence.

1) To tow the loader with the engine running

1. If the power train and the steering system may work normally, the loader may be
towed for a short distance with the engine running, so as to draw the loader out from
muddy road or to the side of road.

2. If the service brake system and the parking brake system can work normally, just
press down the parking brake handle and push down the parking brake button before
the towing operation.

3. The driver of the loader towed shall turn the steering wheel correspondent to the
travelling direction.

2) To tow the loader with the engine switched off

If the engine fails, please tow the loader in accordance with the following method.

If the service brake system and parking brake system is properly sealed with no leakage,
the pressure oil in the energy accumulator may be used to release parking brake. In this
case, the pressure oil in the energy accumulator can only be used for 6~7 times. Please
use it cautiously. If the parking brake system leaks and the pressure oil in the energy
accumulator is not high enough to release the parking brake, please dismantle the
front/rear transmission shafts and get the loader towed.

1. Place the gear position of the gearbox in neutral position.

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Figure: Dismantlement of Front/Rear
Transmission Shafts

If it is suspected that the gearbox fails, just dismantle the front/rear transmission shafts
and then get the loader towed.

4.6 OPERATION IN COLD WEATHER

4.6.1 PRECAUTIONS FOR OPERATION AT LOW TEMPERATURE

If the ambient temperature is too low, it will be difficult to start up the engine and the
radiator may get frozen. Therefore, the following operations shall be carried out:

1. Only low-viscosity fuel, hydraulic oil and lubricating oil may be used, and anti-freezing
fluid must be added into engine coolant.

2. Precautions for use of anti-freezing fluid:

 Be sure not to use any anti-freezing fluid which contains methanol, ethanol or
propanol.

 Be sure not to use any anti-leakage agent, no matter it is used alone or together with
anti-freezing fluid.

 Be sure not to mix up anti-freezing fluids of different designation.

 When replacing the anti-freezing fluid, please refer to the nameplate on the rear end
of the loader for the concentration of anti-freezing fluid.

NOTE: The anti-freezing fluid shall be kept away from open flame, and no smoking
is permitted when filling the anti-freezing fluid.

3. Precautions for Use of Battery

1. When the ambient temperature lowers, the capacity of the battery will reduce. If the

100
 charging rate of the battery is too low, the electrolyte may get frozen. Therefore, if
possible, remain the charging rate at 100%, and preserve the temperature as possible,
so as to ensure that the engine can be started up easily in the next day.

2. In areas where the atmospheric temperature is extremely low, please use the battery
which can withstand the cold.

4.6.2 OPERATIONS TO BE CARRIED OUT AFTER COMPLETION OF

WORKS IN EACH DAY

In order to prevent the mud, water or snow on the loader from getting frozen and ensure
that the loader can be used in the next day, be sure to complete the following operations:

1. Thoroughly clear away the mud, water or snow on the loader, and prevent the
sealing performance from being damaged because mud, water or snow enters into sealed
portion and then gets frozen.

2. Park the loader on a dry and hard ground. If no such a ground is available, park the
loader on a wood plank. The use of wood plank may prevent the loader from being frozen
to the ground and ensure the normal use in the next day.

3. At low temperature, the capacity of the battery will reduce obviously as the storage
time lasts. Be sure to cover the battery, or move it to a warm place and install it onto the
loader for working in the next day.

4.6.3 AFTER COLD WEATHER HAS ENDED

After the weather becomes warm as the season changes, please carry out the following
works:

1. The semi-sticky fuel, hydraulic oil and lubricating oil shall be used for all parts.

2. If no permanent anti-freezing fluid is used, be sure to fully drain the water in the
cooling system, clean up the cooling system, and then fill the new coolant.

4.7 OPERATION UNDER SPECIAL CONDITIONS

4.7.1 OPERATION UNDER EXTREMELY COLD CONDITIONS

If the loader is working in extremely cold weather, protective measures shall be taken to
ensure the normal operation. The following detailed inspection can ensure the normal
operation of the loader at low temperature.

1. Inspect whether correct anti-freezing agent has been added into the cooling system.
Carefully inspect the cooling system, and record the leakage.

2. Keep the battery fully charged so as to prevent it from getting frozen. If water is filled
into the battery, be sure to make the engine run for at least one hour, so as to realize
the full mixing between water and electrolyte.

3. Maintain the engine at the best state, so as to ensure that it can be started up easily
under adverse weather conditions.

101
4. Select the engine oil of appropriate specification on the basis of the temperature.

5. It shall be ensured that the fuel tank is always filled with fuel. Before operating the
loader, discharge condensate from the fuel tank. Maintain and repair the fuel tank filter
element, discharge the wax-like condensate, and ensure that the cloud point of the
fuel used is lower than the lowest ambient temperature.

6. In accordance with the ―Table of Maintenance Interval‖ as given in this Manual and the
lubrication figure printed on the loader, fully lubricate the loader.

7. Start up the engine, and make it reach the normal operating temperature before the
commencement of any loaded work.

① When the engine is running at idle speed, if it is found that there is mud
or ice on any moving part, be sure to thaw such mud or ice with heat
before the loader is operated.

② Carefully operate the hydraulic part, until the normal operating

temperature is reached.

③ Inspect all control devices of the loader, and ensure that they work
normally.

8. Be sure to place a standby external air filter in the cab, so as to facilitate the
replacement of any part which is frozen or affects the breathing of engine.

9. Under cold weather, the start aid shall be sued. Please refer to the contents of ―Start
up of Engine‖ relating to start up under cold weather.

10. In order to prevent freezing situation, clear away all mud, snow and ice. If possible,
cover the loader with canvas, and prevent the edge of the canvas from being frozen to the
ground.

4.7.2 OPERATION UNDER EXTREMELY HOT WEATHER

The continuous operation at high temperature may get the loader overheated. If
necessary, monitor the temperature of engine and gearbox, and stop the loader so as to
cool them down.

1. Inspect and maintain the fan and radiator from time to time. Inspect the level of
coolant in the radiator. Inspect whether the dust, sand and insect which may block up
the cooling pipeline is accumulated on the radiation fin.

① At high temperature, the generation of scale in the cooling system may be

accelerated. The anti-freezing fluid shall be replaced each year, so as to remain its
function as a corrosion inhibitor.

② If necessary, clean up the cooling system on a regular basis, so as to ensure that

the pipeline is clean and clear. Don’t use the water which is excessively alkaline,
otherwise the scale and rust may appear more easily.

2. Inspect the level of electrolyte every day. Maintain the electrolyte at an appropriate
level, so as to prevent the battery from getting damaged. At high temperature, please

102
 use weaker electrolyte. Dilute the electrolyte of which the specific gravity is 1.280 until
the specific gravity is lowered to 1.200-1.240, and fully charge the battery. Whenever
the specific gravity reduces to 1.160, be sure to re-charge the battery. If being placed
at high temperature for long time, the battery may automatically discharge its
electricity at a relatively high rate. If the loader will be parked for several days, please
detach the battery and place it in a cool place.

NOTE: Don’t place acid battery near a lot of tires, for the acidic gas may harm
rubber.

3. Maintain and repair the fuel system in accordance with the Section ―Engine Fuel
System‖ in this Manual. Before filling the fuel, inspect the level of fuel in the fuel tank.
Both high and low temperature can cause the concentration of materials in the fuel
tank.

4. Carry out lubrication in accordance with the ―Table of Periodic Maintenance‖ or the
lubrication sign on the loader.

5. Don’t park the loader under sunshine for long time. Park the loader under the covering
material, so as to prevent sunshine, dirt and dust.

① If no appropriate covering material is available, please cover the loader with

canvas. Be sure to prevent dust from entering into engine, gearbox or hydraulic
system.

② Under the high temperature and high humidity, all parts of the loader may get
corroded, and they may get corroded easily in rainy days. Rust and pocket may
appear on metal surface, and spots may appear on the surface of other parts.

③ Apply the anti-corrosion lubricating oil onto the unpainted or exposed surfaces.
Use insulating compound to protect wires and terminates. On the damaged
surfaces, use paint or appropriate antirust agent to prevent rust or corrosion.

4.7.3 PERATION IN DUSTY OR SANDY AREA

1. In most areas, the loader may generate dust in the course of work. However, when the
loader is used in a place where there is a lot of dust and sand, protective measures
shall be taken.

2. Keep the cooling system and cooling areas clean, clean them up with compressed air,
and take this measure as frequently as possible.

WARNING: When using the compressed air, please wear the safety goggles

1. When maintaining or repairing the fuel system, be careful so as to prevent dust and
sand from getting into the fuel pipeline.

2. Maintain the air filter from time to time, inspect the air control indicator every day, and
keep the dust cover and dust valve clean. Try best to prevent dust and sand from
entering into any part of engine.

3. Lubricate the loader in accordance with the lubrication sign and lubrication interval

103
 table on the loader. Before carry out the lubrication, clean up all lubrication nipples,
because the sand in the lubricating oil may cause the wear and accelerated wear of
parts.

4. Keep the loader as clean as possible. Park the loader under canopy or cover it with
tarpaulin, so as to protect the loader against the corrosion caused by wind and sand.

4.7.4 PERATION IN RAINY AND HUMID ENVIRONMENT

The precautions for operation in rainy environment are similar with those for operation
under high temperature conditions.

Apply lubricating oil onto all exposed surfaces, especially damaged and unpainted
surfaces. Apply lubricating oil onto the location where the paint is damaged as soon as
possible, so as to prevent corrosion.

4.7.5 PERATION IN SALT WATER

Salt water and sea water is highly corrosive. When operating the loader in salt water,
please pay special attention to the following matters:

1. After the loader is stained with salt water, immediately wash it with fresh water and
then dry it up.

2. Apply anti-corrosion lubricating oil onto all surfaces which contact with salt water,
especially those surfaces where the paint is damaged.

3. Repair the damaged paint in time.

4. Lubricate the loader in accordance with the lubrication sign and lubrication interval
table on the loader. As for the loader working in salt water, the lubrication interval shall
be shortened appropriately.

4.7.6 OPERATION AT HIGH ALTITUDE

Under normal conditions, the precautions for operation at high altitude are the same as
those for operation at low temperature. Before operating the loader at high altitude, be
sure to adjust the mixing ratio of fuel and air in accordance with the relevant engine
manual.

Measure the operating temperature of the engine, and inspect whether the engine is
overheated. The cover of radiator shall be properly sealed, so as to prevent the pressure
of the coolant from being released.

104
 CHAPTER V MAINTENANCE AND REPAIR

5.1 PREPARATION BEFORE MAINTENANCE

Follow with the "Maintenance and Security Matters" mentioned in the previous
chapter

5.2 REGULAR MAINTENANCE

Instructions:

1. Before any operation or maintenance, make sure the instruction manual of the machine
concerning safety, warning and descriptive information has been read and understood
completely.
2. The user is responsible for proper maintenance of the machine, including adjusting
mechanism, adding lubricants and other operating fluids, replacing filters and replacing
parts due to normal wear or aging. Failure to maintain the entire machine according to
correct intervals and specified procedures may lead to a drop in performance to the
machine as well as accelerated wear on its parts and components.
Note:
1) Before any continuous maintenance cycle, it is necessary to complete all previous
maintenance work firstly. In completing any item of maintenance work, it is necessary to
ensure that any other items that are supposed to be performed according to cycles shorter
than its cycle are done simultaneously with that item of work. For example, if a collection of
items of work supposed to be performed once every 500 hours or every three months needs
to be done, some other items must be performed simultaneously, including any item
supposed to be performed once every 250 hours or every month, once every 100 hours or
half a month, once every 50 hours or every week, or once every 10 hours or every day.
2) It is imperative that all maintenance cycles be determined by work time. However, calendar
time-based cycles could replace work time-based ones if calendar time-based maintenance
plans turn out to be more convenient and the numbers included in calendar time-based plans
are approximate to those in the corresponding work time-based plans. Carry out maintenance
work, no matter what time is adopted, work time or calendar time, whichever comes first;

3) It is necessary to shorten time specified in the maintenance cycles table and carry out
maintenance more frequently under the extremely harsh, dusty, wet, or other unfavorable
working conditions.

I. Routine maintenance items to be performed once every 10 hours or once a day

1. Check the engine coolant and make sure that the engine has been filled to the full; If the
machine equipped with attached tank, check the coolant level whether in the normal
range or not, add coolant as necessary.
2. Check the engine oil level of engine and the liquid level of injection pump governor, and
ensure the level stays within the normal operating range, add it as necessary.
3. Check the hydraulic oil level in the hydraulic tank to ensure that the level stays within the
normal operating range, add it as necessary.
4. Check the oil level of the transmission to ensure that the level stays within the normal

105
 operating range, add it as necessary.
5. Check the fuel whether it is enough or not, add it if necessary.
6. Check the air filter of engine whether it is clean or not, replace it if necessary.
7. Drain all air reservoirs for pneumatic brake machines; but not for hydraulic brake
machines;
8. Add lubricating grease to all articulated points, pin shaft sleeves and other positions
according to the lubrication schematic diagram of the machine;
9. Check and make sure air pressure of tires is normal and no abnormal wear exists; check
all hydraulic components and hydraulic pipes whether spilled oil or existing abnormal
wear.
10. Check and make sure all systems could not spill oil, water and air. Visually inspect and
make sure engine fan and driving belt no loosening or damage.
11. Check the fixed bolts and nuts on the engine, transmission, drive axle, and rims to ensure
that no loosening; inspect the bucket teeth and the knife plate, and replace them as
necessary;
12. Check and ensure the start-up performance of the diesel engine, the color of its exhaust,
and the sound of the engine are normal; after observing the machine while it operates for
ten minutes, inspect whether any alarm of abnormal sound or overheating exist or not.
13. Check and make sure the following parts of the machine work normally: dashboard,
lights, seat belt, reversing alarm system, generator, brake system and steering system.
At the same time, ensure that all switches, quick couplers, operating levers, pedals,
operating handles, buttons and others elements of the machines can be operated
normally.

II. Maintenance items to be performed once every 50 hours or every week

1. Drain the strainer (oil-water separator) of the engine fuel system;

2. Check and add the brake-fluid of the machine. (Note: A brake-fluid of the same model as
the original fluid must be used. Otherwise, the original fluid must be completely emptied
through a port near the brake caliper and add a new brake-fluid);
3. Check the oil level of the final reducer at each end of the drive axle, and the oil level of
the main drive in the center of the axle housing; add oil as necessary (Note: Oil of the
same model as the original oil must be used; Otherwise, the service life of the oil will be
affected.)
4. Start the machine, and after finishing one to two operating cycles, lower the arm to the
ground and then stop the engine, inspect the oil levels in the hydraulic oil tank and the
transmission and replenish the tanks as necessary (Note: Oil of the same model as the
original oil must be used; otherwise, the service life of the oil will be affected);
5. Check the gap between any brake pad and the matching brake disk and make
replacements as necessary; Tighten the fixed bolts and nuts on all transmission shafts to
ensure that no loose bolt or nut exists;

6. Carry out the following operations if these 50-hour maintenance items are performed on
the machine for the first time, or skip it: replace the engine oil, engine oil filter and diesel
oil filter elements.

III. Maintenance items to be performed once every 100 hours or every half a month

106
1. Remove foreign matters from all air-cooled radiator surface of the machine to ensure that
the cooling system can operate normally;
2. Carry out the following operations if these 100-hour items are performed on the machine
for the first time, or skip it: replace the transmission oil, the oil filters of the transmission
and torque converter and the outer oil filter of transmission and torque converter; (the
filter is optional, not for all machines) open the bottom cover of the transmission; clean
the filter net and the magnet carefully and then put them back in place.

IV. Maintenance items to be performed once every 250 hours or every month

1. Check the air intake system of the engine. Visually check the service indicator of the air
filter. Clean or replace the filter element of the air filter if the yellow piston of the
indicator rises into the red region;
2. Replace the engine oil, the engine oil filter, the fuel oil filter and the oil-water separator
filter element.(the filter is optional, not for all machines)
3. Adjust the tension of the driving pulley of the engine and the air conditioning compressor
belt and the generator belt, check the damaged condition and replace it if necessary.
Tighten all bolts fixed the battery and clean its top;
4. Check the implement, weld seam of the front and rear parts of the frame and fixed bolts
whether they have cracks or loosening.
5. Carry out the following operations if these 250-hour items are performed on the machine
for the first time, or skip it: collect and filter the working hydraulic oil, replace the oil intake
filter element, replace the return oil filter element for the working hydraulic oil, clean the
inside of the hydraulic oil tank, return the filtered hydraulic oil to the hydraulic oil tank, and
replenish the hydraulic oil tank as necessary to ensure an appropriate oil level in the tank;
(Note: When replacing the hydraulic oil filter element, the original hydraulic oil must be
filtered or replaced).

V. Maintenance items to be performed once every 500 hours or every three months

1. Tighten the bolts for connecting the front/rear axle and the frames, and the plate bolts for
articulating the front and rear parts of the frame. Check the structure, hood and cab of the
machine whether they are damaged, repair them as necessary.
2. Check and eliminate the water and impurities in the diesel tank, clean the oil filter and
respirator; check and adjust the engine air valve.
3. Check the brake pads and disks and replace them if any brake pad is less than 2/3 thick
and any damaging brake disk;
4. Collect and filter the working hydraulic oil, replace the oil intake filter element of the
hydraulic oil tank, clean the hydraulic oil tank, return the filtered hydraulic oil to the
hydraulic oil tank, and replenish the hydraulic oil tank as necessary to ensure an
appropriate oil level in the tank; (Note: When replacing the hydraulic oil filter element, the
original hydraulic oil must be filtered or replaced)
5. Replace the oil in the transmission, the oil filters of the transmission and torque converter
and the outer oil filter of transmission and torque converter (the filter is optional, not for all
machines); open the bottom cover of the transmission, clean the filter net and the magnet
carefully, and then put them back in place;
6. Replace the oil for the final reducer at both ends of the drive axle, as well as the oil for the
main drive in the center of the axle housing; replace all the drive axle gear oil once each
year even if the total number of work hours is less than 500.

107
VI. Maintenance items to be performed once every 1000 hours or every half a year

1. Replace the hydraulic oil, the return oil filter element of hydraulic oil, and the oil suction
filter element of hydraulic oil, and clean the hydraulic oil tank;
2. Clean the diesel tank and replace the oil suction filter element of diesel tank and the inner
filter element of the engine.
3. Check ROPS (it is optional, replace it based on the model);
4. Replace the dryer of the brake system; (it is optional, replace it based on the model)

VII. Maintenance items to be performed once every 2000 hours or every year

1. Replace the coolant of the engine.

2. Check the differentials of the front and rear axles and wheel hub reducer and repair them
if necessary.

VIII. Maintenance items to be performed once every 4000 hours or every two years

1. Check the performance of the engine and replace the hose of fuel system of the engine.
2. Check the airtightness of the distribution valve and working cylinder and repair or replace
them if necessary.
3. Check the working condition of torque converter and transmission, repair them if
necessary.
IX. Maintenance item to be performed once every 6000 hours or every three years.

Check the high pressure oil pipes and sealing elements of hydraulic system and replace them
if necessary.

X. Maintenance item to be performed once every 10000 hours or every five years.

Check the transmission and drive axles, dismantle and repair them if necessary.
Note:
① The steering bearings of the front and rear parts of the frame need to be checked after
working 5000 hours and replace it if any abnormal sound exists.
② The seat belt needs to be replaced once three years after the date of manufacture or
6000 hours after the date of operating (whichever comes first);

108
 Attachment 1 Machine No.:
Registration Table for Phase-by-phase Checking and Maintenance of the Loader
(No.1)

Brief defect
Work time 50h 100h 250h 500h 1000h 2000h 4000h 6000h 10000h Check date Checked by
description

50h ●
100h ● ●
150h ●
200h ● ●
250h ● ●
300h ● ●
350h ●
400h ● ●
450h ●
500h ● ● ● ●
550h ●
600h ● ●
650h ●
700h ● ●
750h ● ●
800h ● ●
850h ●
900h ● ●
950h ●
1000h ● ● ● ● ●
1050h ●
1100h ● ●
1150h ●
1200h ● ●
1250h ● ●
1300h ● ●
1350h ●
1400h ● ●
1450h ●
1500h ● ● ● ●
1550h ●
1600h ● ●
1650h ●
1700h ● ●
1750h ● ●
1800h ● ●
1850h ●
1900h ● ●
1950h ●
2000h ● ● ● ● ● ●
2050h ●
2100h ● ●
2150h ●
2200h ● ●

109
 Attachment 1 Machine No.:
Registration Table for Phase-by-phase Checking and Maintenance of the Loader
(No.2)

Brief defect
Work time 50h 100h 250h 500h 1000h 2000h 4000h 6000h 10000h Check date Checked by
description

2250h ● ●
2300h ● ●
2350h ●
2400h ● ●
2450h ●
2500h ● ● ● ●
2550h ●
2600h ● ●
2650h ●
2700h ● ●
2750h ● ●
2800h ● ●
2850h ●
2900h ● ●
2950h ●
3000h ● ● ● ● ●
3050h ●
3100h ● ●
3150h ●
3200h ● ●
3250h ● ●
3300h ● ●
3350h ●
3400h ● ●
3450h ●
3500h ● ● ● ●
3550h ●
3600h ● ●
3650h ●
3700h ● ●
3750h ● ●
3800h ● ●
3850h ●
3900h ● ●
3950h ●
4000h ● ● ● ● ● ● ●
4050h ●
4100h ● ●
4150h ●

110
 Attachment 1 Machine No.:
Registration Table for Phase-by-phase Checking and Maintenance of the Loader
(No.3)

50 100 500 1000 4000 6000 10000 Check Checked Brief defect
Work time 250h 2000h
h h h h h h h date by description

4200h ● ●
4250h ● ●
4300h ● ●
4350h ●
4400h ● ●
4450h ●
4500h ● ● ● ●
4550h ●
4600h ● ●
4650h ●
4700h ● ●
4750h ●
4800h ● ●
4850h ●
4900h ● ●
4950h ●
5000h ● ● ● ● ●
5050h ●
5100h ● ●
5150h ●
5200h ● ●
5250h ● ●
5300h ● ●
5350h ●
5400h ● ●
5450h ●
5500h ● ● ● ●
5550h ●
5600h ● ●
5650h ●
5700h ● ●
5750h ● ●
5800h ● ●
5850h ●
5900h ● ●
5950h ●
6000h ● ● ● ● ● ● ●
6050h ●
6100h ● ●

111
 Attachment 1 Machine No.:
Registration Table for Phase-by-phase Checking and Maintenance of the Loader
(No.4)

Brief defect
Work time 50h 100h 250h 500h 1000h 2000h 4000h 6000h 10000h Check date Checked by
description

6150h ●

6200h ● ●

6250h ● ●

6300h ● ●

6350h ●

6400h ● ●

6450h ●

6500h ● ● ● ●

6550h ●

6600h ● ●

6650h ●

6700h ● ●

6750h ● ●

6800h ● ●

6850h ●

6900h ● ●

6950h ●

7000h ● ● ● ● ●

7050h ●

7100h ● ●

7150h ●

7200h ● ●

7250h ● ●

7300h ● ●

7350h ●

7400h ● ●

7450h ●

7500h ● ● ● ●

7550h ●

7600h ● ●

7650h ●

7700h ● ●

7750h ● ●

7800h ● ●

7850h ●

7900h ● ●

7950h ●

8000h ● ● ● ● ● ●

8050h ●

112
 Attachment 1 Machine No.:
Registration Table for Phase-by-phase Checking and Maintenance of the Loader
(No.5)
50 100 500 1000 4000 6000 10000 Check Checked Brief defect
Work time 250h 2000h
h h h h h h h date by description
8100h ● ●
8150h ●
8200h ● ●
8250h ● ●
8300h ● ●
8350h ●
8400h ● ●
8450h ●
8500h ● ● ● ●
8550h ●
8600h ● ●
8650h ●
8700h ● ●
8750h ● ●
8800h ● ●
8850h ●
8900h ● ●
8950h ●
9000h ● ● ● ● ●
9050h ●
9100h ● ●
9150h ●
9200h ● ●
9250h ● ●
9300h ● ●
9350h ●
9400h ● ●
9450h ●
9500h ● ● ● ●
9550h ●
9600h ● ●
9650h ●
9700h ● ●
9750h ● ●
9800h ● ●
9850h ●
9900h ● ●
9950h ●
10000h ● ● ● ● ● ● ●

113
5.3 LUBRICATION CHART

Grease the lubricant at various sliding bearing or rolling bearing sections, such as:

1. Driving shaft with cross head.

2. All pin sets at both ends of the tanks.

3. Hinge pin sets of front and rear frame; sub-frame swing the pin sets.

4. Each pin sets of the working device

Inject grease into the above mentioned sections with pressure. Please note that inject
grease in time depending on the working status.

114
 5.4THE CHINESE AND FOREIGN OIL TYPE LIST FOR WHEEL LOADER

International standard serial number and

NO. Oil Name Chinese standard serial number and type
type
Ordinary CD 15W/40 Ordinary CF-4 15W/40
Engine Oil
LOW temperatureCD 5W/40 or CD OW/40 LOW temperatureCF-4 5W/30
1
Oil for Engine Ordinary 0# Ordinary 0#
Diesel Oil
LOW temperature-35# or -50# LOW temperature-35# or -50#
Ordinary CH-4/SJ 15W/40 Ordinary VCH-4/SJ 15W/40
Oil for DF Engine Oil LOW temperature LOW temperature
2 Cummins CH-4/SJ 5W/40 or CH-4/SJ OW/40 CH-4/SJ 5W/40 or CH-4/SJ OW/40
Engine Ordinary 0# Ordinary 0#
Diesel Oil
LOW temperature-35# or -50# LOW temperature-35# or -50#
PTF-2
1.GM company'sTrack-coach PTF-2
2.Allison company's C-3,C-4,C-5
Ordinary(LOW temperature)
3.Catepillercompany's TO-3,TO-4
8D N46D Ordinary)8# N46、
4.Mobil company's ATF220
5.BP company's Hydraulic TFCZ
6.Shell company's Rotella 10W
3
JARNC-4 which was developed by Xi'an PTF-3
Petroleum University Jiarun Industry and 1.John-Deer company's
Hydrodynamic Transmission PTF-2 have the same quality J-20B,J-14B,JDT-303
Oils 6#(n32)= PTF-2 2.Ford company's
8#(n46)= PTF-1 M2C41A,MIC86A,MIC134A
N68#(Anti-wear hydrodynamic transmission 3.Massay-Ferguson company's
oils)= PTF-3 M-1135,M-1127A
OrdinaryAPI GL-5 SAE90
OrdinaryLS-90
(RecommendMobilGX90)
4 Gear Oil
Low temperature Low temperatureAPI GL-5 SAE80W-90
LS-80W-90 (Recommend MobilGX80W-90)

OrdinaryL-HM46# OrdinaryMobilDTE 15M

5 Hydraulic Oil
Low temperatureL-HV46# or L-HS46# Low temperatureMobilDTE FM46
Ordinary 2# Lithium saponify Ordinary2# Lithium saponify
6 Lubricating Grease Centralized lubricating Centralized lubricating
1# Extreme pressure lithium saponify MobilEP1
7 Brake Fluid XILIAN 719# MobilDOT3
8 Air Conditioning Refrigerants R134a R134a

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 5.5 OIL INFORMATION
In the large scale of -30 to 50 Celsius, grade, provision and addition in each small
range for the recommended engine oil, transmission oil, hydraulic oil, drive axle oil, pin
shaft lubrication grease, diesel oil, specified quantities and filling quantities (with
international grade and metric unit).

Capa
Environment temperature
city
Type
-30 -20 -10 0 10 20 30 40 50 Filling
quanti
API CF-4 and higher ty

SAE 10W-30
Engine oil
SAE 15W-40 20 L

SAE 5W-40
Hydraulic
transmissio SAE 10W 50 L
n oil

Hydraulic L-HM46
270 L
oil
L-HV46

Drive axle SAE 85W-90 62 L

gear oil

SAE 85W-90
Lubrication
NO.2 2KG
grease

0# ——

Diesel oil
——
-10#

116
5.6 UNIVERSAL TORQUE TABLE

Unless otherwise stated, the screw used in the machines should be tightened according to
the following table.

Universal torque table of metric thread

Tightening torque (N.M)
Specifications
8.8 class 10.9 class
M6 9~12 13~16
M8 22~30 30~36
M10 45~59 65~78
M12 78~104 110~130
M14 124~165 180~210
M16 193~257 280~330
M18 264~354 380~450
M20 376~502 540~650
M22 512~683 740~880
M24 651~868 940~1120
M27 952~1269 1400~1650
M30 1293~1723 1700~2000
M33 1759~2345 2743~3298
M36 2259~3012 2800~3350
M39 2932~3898 4111~5481

Torque table of the thread inserts smeared with sealants

Pipe Thread Size Code Tightening torque (N.M)
3/8 15±2
3/4 24±4
1/2 23±3
1 45±4

5.7 MAINTENANCE OF THE ENGINE COOLANT

The engine cooling system has great influence on the performance, reliability and
durability of the overall engine. Therefore to properly maintain the engine cooling system
is extremely important, the engine overheat and over-cold, piston and piston ring and
cylinder liner are locked deadly, thermal fatigue crack occurs on the cylinder head,
lubricants quickly degenerate, spot eroded, air eroded and others faults are common
failures in the cooling system, they will not only cause the overall deterioration of power,

117
economical efficiency, reliability and durability of the engine, but also cause serious
damage to the engine.

5.7.1 COOLANT COMPOSITION

The coolant of the engine is composed and with water, antifreeze liquid and additives in
certain proportion.

LONKING recommends using the mixture of 50% ethylene glycol or propylene

glycol-based antifreeze and 50% soft water as the coolant of the engine in most weather
conditions.

① Water used in the coolant

The water used in the coolant must be soft water (distilled water is preferable), and
prohibit to use the untreated water as the coolant of the engine. Hard water or the water
containing with calcium and manganese ions with a high rate is apt to produce
water-insoluble compounds and prone to generate furring in the water jacket of t the
engine, causes blocking waterways, heat transfer hindered, and results in engine
overheating; while the water containing higher rate of sulfate or chloride-containing will be
corrosive.

② Anti-freeze fluid

Antifreeze has the double features of antifreeze and anti-boiling, has anti-corrosion and
other functions as well. Therefore, when the engine is working at a relatively low
temperature, the antifreeze should be used in order to prevent the water freezing in the
cooling system of the engine, to avoid the engine overheating due to the termination of
cooling water circulating, or to keep the body, cylinder cover and heat radiator from
expanding and cracks as the water freezes with the expanded v size. Along with the mass
ratio increasing in the antifreeze coolant, the boiling point of coolant increases, the
freezing point lowers. The antifreeze concentration should not exceed 68.1% (the freezing
point is of -68℃), otherwise the performance will be worsened: the freezing point of
coolant will rise instead, and it is easy to form a gel. The normal concentration range is of
40% to 60%, 50% of the concentration of antifreeze cooling fluid is recommended, at the
moment, the freezing point of the coolant is of -35.5℃, while the boiling point at
atmospheric pressure is of under 103℃, the boiling point in the cooling system is of about
110℃ .
Warning

As antifreeze is flammable, do not close to the naked fire.

③ Additives

Usually the additives contain anti-rust agent, foam suppressing agent, coloring agents etc.
The anti-rust agent can delay or prevent the engine water jacket wall and the radiator from
rusting or corrosion. The air in the coolant will produce a lot of bubbles under the stirring of
the blades of the water pump, these bubbles will hinder the cooling water jacket wall from
heat radiating. The foam suppressing agent can effectively inhibit the generation of the

118
bubble. Coloring agent normally makes the coolant presenting blue-green or yellow for
identification. In the process of engine operation, the additive will gradually deplete.
Therefore, it is quite necessary to replace the cooling liquid periodically.

Therefore, the normal maintenance of the engine coolant not only functions as good
anti-rust, anti-corrosion, furring generation to a variety of metals within the cooling system,
but also effectively reduces the cavitations erosion (cavitations erosion is a kind of
damage phenomenon of the fluid engineering, and the outer wall of diesel engine cylinder
liner will also produce metal falling off resulting from cavitations corrosion, and will
gradually form a honeycomb-like with different diameter sizes, and is damaged finally).

Warning

1. When the temperature is below 0℃, it is necessary to inspect the coolant

concentration regularly.

2. As for the region where the engine is operating above 0℃ year around, the
water via anti-rust, and anti-furring treatment can be used as coolant, and it is
forbidden to use untreated water as the engine coolant.

5.7.2 ADDING COOLANT

1.The new machine or the engine after cleaning

the cooling system requests to add coolant, or in
case of adding coolant due to weather conditions, Inlet water
pipe of heat
Pressure
the freezing point of the coolant to be chosen radiator
cover
Upper water chamber of
should be at least 5 ℃ lower than the local heat radiator
E Expansion
minimum temperature. space is of at least
Bypass of 6%
small cycling D reserving water
(inside the is of at least 11%
The total volume of engine cooling system is of engine)

about 48L, while the water inlet room of the heat Water
returning
radiator in the cooling system should contain 6% pipe or
water
refilling
of the total volume as expansion volume and at pipe

least 11% of the total volume of reserving water. Outlet water

pipe of heat
See right figure: radiator

In fact, the volume of antifreeze of the cooling

system requires is about 45L or so (to be
confirmed that the coolant in the previous cooling
system, including heating section of the
air-conditioning system has been exhausted).

1. Manually switch on the negative pole switch

Warm
of battery, and insert the key into a starter water
switch and rotate in clockwise direction to valve

switch to shift one to turn on the whole vehicle

power, switch on the heating function of the

119
 air-conditioning system.

2. Switch on with counter-clockwise rotation the

water valve of the two heaters of the inlet and
outlet water pipe of the evaporator from the
engine to air conditioner system.

Warm water valve for controlling the water inlet of

the air-conditioning system, see right figure:

3. Open the pressure cap on the top of heat

radiator, and slowly fill the coolant, and the
filling rate should be maintained at 19L/min,
and to ensure a fill rate of over 90% of the
total volume at one time.

4. After the coolant level is stable, start the

engine with the pressure cover open, run 25
minutes in total at low, high and idle speed,
ensure coolant temperature reaches 82 ℃
and above, to remove the air accumulated in
the cooling system when filling in at the first
time.

5. Inspect the coolant level of the heat radiator,

add coolant to the appropriate position (6%
expansion space need to be reserved).

Tighten the pressure cap of the heat radiator.

5.7.3 INSPECT COOLANT LEVEL REGULARLY

Heat radiator is located at the tail of the machine.

Water inlet of heat radiator, see right figure:

1. Slowly uncap the pressure cap at the upper section of the heat radiator, and gradually
release the pressure.

Warning
Under thermo-mechanical state, do not immediately open the heat radiator
pressure cap, to avoid the high-temperature coolant or steam damaging the skin,
gradually open or wait until the coolant temperature drops down to about 50℃ and
then open it.

2. Maintain the coolant in the right position (6% the expansion space need to reserved),

120
 add coolant, if necessary.

Warning
Adding coolant when the engine is at high temperature will cause coolant boiling
and damages to the engine. Fatherly fill coolant till the coolant temperature is
below 50℃.

3. Tighten the heat radiator pressure cap.

5.7.4 CLEANING OF COOLING SYSTEM

The machine takes 4800 hours running or two years (whichever occurs first) as a cycle,
and it requests to replace coolant and clean up the cooling system.

Prior to that, if the coolant is contaminated, and the engine is overheating, corrosion or
bubble occurred in the cooling system, it is necessary to clean the cooling system in
advance and replace coolant.

 Manually switch on the negative pole switch of the battery, insert the key in starter
switch and turn with clockwise rotation to switch on the power of the whole vehicle,
and turn on the warm function of the conditioning air-system.

 Turn on the water valve of the two heater of the inlet and outlet water pipe of the
evaporator from the engine to the air-conditioning system with counter-clockwise
rotation.

 Start the engine, turn off after 5 minutes idle operation, then switch on again, slowly
turn off the pressure cap of the heat radiator to release pressure till the coolant
temperature is below 50℃.

 Open the outlet valve at the bottom of the heat radiator, drain out the engine coolant.

Warning

As the engine coolant is toxic, do not drink or casually discard.

5. After drain out the engine coolant, turn off the

outlet valve at the bottom of heat radiator, see

right figure:

6. Re-fill soft water into the engine and add proper amount of special cleaning agent with
the same filling method as that of the coolant.

7. Repeat the above steps 4, 5, and 6 till the cleaning liquid is discharged without too
much dirt.

8. Fill the coolant with the method specified for adding coolant.

121
5.7.5 ENGINE AIR FILTER MAINTENANCE
When the Engine is working, it demands clean and fresh air from filter, and proper
maintenance may protect the cylinder liner, piston, piston rings, valves and other parts of
from wearing and reduce the wearing. Air Filter also has the role of reducing the intake
noise.

Warning

1. Air filter must be replaced when the core is broken.

2. In case of maintenance, do not pollute the internal side of the filter.
3. Do not drive the car without air filter core or air filter.

5.7.6 MAINTENANCE AND REPLACEMENT OF AIR FILTER ELEMENT

Set pressure drop alarm indicator connector at

the outlet of the air filter, the yellow piston of the
air filter indicator moves to the red area when the
engine is running in high idle speed. The air filter
needs maintenance.
Air filter alarm indicator is shown in the right
figure.

1. Shut down the engine, and remove the air

filter cover.

2. Unscrew the filter cover in arrow direction.

122
3. Remove coarse filter.

4. Remove fine filter.

5.Blow away the dust on the filter paper ofcoarse

filter with compressed air free of oil mist, water
(pressure less than 300KPa). (After coarse filter
is cleaned five times, it is needed to replace air
fine filter and cleaned fine filter shall not be used
again.)

6. Inspect with flash light after clean the coarse filter, if any small hole or tiny article is

123
found over the main filter core, and any damages over gasket or seal, replace with a new
coarse filter.

7.Install the clean coarse filter into the air filter shell to ensure the even contact of the
sealing part at the end of the coarse filter.

8.Clean-up and install the cover of air filter, tighten the cover with hand and fasten the end
cover.

9.Press the indicator to reset the indicator.

If the engine starts, the yellow piston of air filter indicator moves to the red area, or the
engine produces black smoke, with power dropping down; it requires replacing with a new
coarse filter. Inspect the air filter maintenance indicating lamp or at any time, clean the
coarse filter regularly (when the indicating lamp lights up) and replace (every 1000 hours),
if the working environment and areas are very harsh, then may shorten the cleaning and
replacement cycle accordingly.

5.7.7 CLEAN DUST COLLECTION CUP OF THE AIR FILTER

Dust collection cup is for collecting the dust and water inside the air filter, press the dust
cup regularly, and drain out the water and dust.

Warning

1. When the air filter core is broken, it must be replaced.

2. Conduct the maintenance on air filter periodically according to the requirement
of the air filter maintenance instructions.
3. In case of maintenance, do not pollute the internal side of the filter.
4. Do not start the engine with air filter or air filter core disassembled.

124
5.8 USE OF FUEL SYSTEM AND RELATED MAINTENANCE

5.8.1 FUEL TANK

The fuel tank is located on the left side of the cab.

The fuel tank is shown in the right figure:

5.8.2 CLEANING OF FUEL TANK

Removal of moisture and impurities from fuel:
1. If conditions permit, diesel shall be allowed to settle for 24 hours before being filled into
fuel tank.
2. Before oil filling, unscrew the drain plug on the bottom of fuel tank once every week to
remove moisture and impurities at the bottom of fuel tank.
3. After end of daily work, fill up the fuel tank with diesel to remove moisture from fuel tank.
4. After each filling up of fuel tank, keep still for 5~10 minutes so that moisture and
impurities in diesel will settle at the bottom of fuel tank.
5. After end of daily work, unscrew the drain plug at the bottom of diesel pre-filter, primary
diesel filter and secondary diesel filter to remove moisture and impurities.
Repeat the above steps till the drained oil is clean.

5.8.3 FUEL OIL LEVEL INSPECTION

1. Drive the loader to the even site, turn off the engine.

2. Turn the key clockwise and switch to shift one, and power on the whole car.

3. Inspect the amount of instruments on stage fuel table instructions.

4. Inspect the elongated oil level of the fuel tank.

5. If the fuel level is below the center of the min. limit of the level line of the oil (about
20L), you need to add fuel. And observe it at any time to ensure that the fuel level will
not lower than the center line of the oil min. Level.

125
5.8.4 APPLICATION AND REPLACEMENT OF FUEL FILTERS
Engine fuel filter can filter out impurities and particles in the fuel in order to reduce the
wear of the precision coupling of the fuel pump and injector. After fuel is filtered, the dirt
will be kept at the outer surface of filter. As the filter element is made of diesel filter paper,
therefore, it requires regular maintenance and replacement. The replacement cycle is
every 500 hours running of the engine.

Fuel filters should be replaced according to the following steps:

1. Firstly clean the fuel filter (coarse filter and fine filter), and clean the install seat.

2. Dismount the fuel filter from the install seat with a belt wrench.

3. Remove the seat gasket on the screw connector of the install seat. Clean the sealing
surface of install seat with the non-fiber cloth.

4. Install a new gasket to the threaded connector of the install seat of the fuel filter;
smear a layer of engine oil over the sealing surface of the engine; fill the oil filter with full
clean diesel.

5. Screw the oil filter on the install seat by hand, after the gasket contacts with the install
seat, tighten it with from semi-circle to 3 / 4 circle. In order to prevent the damage of filter,
do not over-tighten the oil filter with mechanical method.

5.8.5 APPLICATION AND REPLACEMENT OF FUEL PRE-FILTERS

The function of the pre-filter is basically same as that of the filter. The only difference is
that the accuracy of the pre-filter is slightly lower as 10цm (filter accuracy is of 7цm), and
the pre-filter has a water cup to discharge the water and impurities in the fuel system.
Pre-filter replacement cycle is same as that of the filter.
Fuel pre-filter is to be replaced according to the following steps:
1. Clean the area nearby the install seat of the fuel pre-filter.
2. Dismount the fuel pre-filter from the install seat, and clean the seal surface of the
install seat of with non-fiber cloth.
3. Dismount the transparent drainage cup from the lower part of the fuel pre-filter.
4. Clean up the water drain cup, and replace new seal ring, and then install it into a new
fuel filter core of the fuel pre-filter.
5. Fill the fuel into the pre-filter, replace new seals, and smear a layer of engine oil over
the engine, and then install it to the install seat.

126
5.8.6 MAINTENANCE OF ENGINE OIL
Inspect the oil level of engine oil

1. Park the loader to even field, turn off engine and rotate the parking brake button to
reset.

2. After engine turns off, 10 minutes later, so that the oil in the engine crankcase to flow
back into the engine oil pan.

3. Open the hood, the engine oil level and refueling port are all at the right side of the in
the engine.

4. Unscrew and pull out the oil level meter, clean the oil level meter with a clean cloth,
re-insert it into the engine oil level port till the end, then pull out to inspect the oil level
again, the oil level should be located between the "L" scale and " H " of the scale.

5. If the oil level is below the "L" scale, please add oil; if the oil level is above the "H" scale,
please loosen the release screw piston at the bottom of the oil pan to release some oil.

Warning

Too much engine oil and too little engine will all apt to damage the engine.

5.8.7 REPLACEMENT OF ENGINE OIL

1. When getting up to the required oil change cycle, it requests to replace the engine oil.
Park the machine on the flat playground, and start the engine till the water temperature
reaches to 60℃, the engine turns off. Rotate the parking brake button to reset. Remove
the oil outlet screw piston at the bottom of the engine, drain out the oil with a container to
receive the oil, and replace the oil filter.

2. Screw on the oil outlet screw piston, and then fill in the clean engine oil from the inlet
port to the oil level of "H" of the clean-foot scale. Run the engine under the idle speed to
inspect whether there are any leakage occurred on the oil filter and oil outlet piston.

3. Turn Engine off, about 10 minutes later, allow the engine oil fully to flow back into the
oil pan, and re-check the oil level, if the oil is in shortage, please refill the oil until the oil
falls between ―L" and "H" level of the foot scale.

Warning
Change the oil filter when change the engine oil.

127
5.8.8 REPLACEMENT OF ENGINE OIL FILTER
1. Clean the area near to the install seat of the filter of the engine.

2. Remove the oil filter with the belt wrench.

3. Clean the contact surface of the seal gasket of the install seat with a clean cloth. If
the old O-ring is glued to the install seat, replace it.

4. Install a new O-ring, fill the new oil filter full with clean oil, and seals the contact
surface with a layer of clean engine oil.

5. Install the oil filter to the install seat; tighten it to the surface of the oil filter gasket with
install seat. Tighten the oil filter according to the regulated requirement with belt
wrench.

6. Inspect oil level; if the oil is insufficient please add more.

Warning

To tighten the oil filter excessive tight may damage the seals and cause leakage.

5.9 INSPECT ELECTRICAL SYSTEM

The electrical system of the machine is mainly consists of batteries, energy conversion
devices (generator, starter) and power consuming devices (instruments, devices, etc.).

5.9.1 INSPECT BATTERY

Battery is shown as the right figure:

1. Inspect in cold weather

In cold weather, if the battery's electrolyte has been frozen, neither recharge the battery,
nor use the other power supply to start the engine, this would cause the batteries on fire;
melt the battery electrolyte prior to starting, and inspect whether there is any leakage.

2. Inspect the battery shell

Do not add more power if the battery case cracks or leaking battery acid, identify the
reason then replace the battery.

128
3. Inspect the liquid level of battery

The installed battery is of maintenance-free type, without the necessity to add the battery
electrolyte (distilled water) to the battery cell. When the charging indicator turns gray, it
shows that the electrolyte is insufficient, probably due to leakage or the failure of charging
system. Must find out the fault and replace the battery.

4. Inspect the charging state

Inspect the charging status by reviewing the indicating inside the device.

1) Green: Normal.

2) Black: Charging is not sufficient.

3) Pale: No longer available and cannot charge.

5. Inspect the battery terminals

1) The battery has the terminals broken cannot be recharged, investigate the reason
before replace the battery;

2) When there are any oxide surfaces over the terminals, please remove the oxide
surfaces and clean the terminals before charging.

5.9.2INSPECT ELECTRICAL DEVICES

1. Inspect in cold weather

In cold weather, remove the water, snow or mud covered on the wire, cable plug
connectors, switches, or sensors, as well as those parts, to avoid parts failures;

2. Inspect lighting equipment, etc.

1) First inspect the lights, horn, wiper and other electrical components to find out whether
they are fault-free or not;

2) If there is any error, then inspect the corresponding fuse to find out whether there is
any error according to the schematic, if there is any error, replace it;

3) If the relevant fuse has no error, then inspect the electric cable of each electric parts
with the entire vehicle charged with electricity, to inspect whether there is 24V voltage,
if no voltage, then inspect the power cable between electrical parts and the fuse is
broken or not;

4) If the voltage is measured, please replace the relevant electric parts.

3. Inspection of Instrument and equipment

1) After the machine is powered on, inspect whether instrument indications are normal;

2) In case of any failure, first inspect whether the sensors are damaged or not; in case of
no damage, inspect the corresponding temperatures in the following table to confirm
whether the resistances meet the requirements in the table below.

Tempera Comparison of the temperature sensor parameters

129
ture (℃)
Resistance (Ω)
40 218±30
80 56±3
100 30.5±0.5
120 17.75±0.4
Pressure sensor parameters comparison
1.0MPa hydraulic and pneumatic
2.5MPa air pressure sensor
sensors
S/N
Pressure Resistan Permissible Pressure Resistan Permissible
(MPa) ce (Ω) error (Ω) (MPa) ce (Ω) error (Ω)
1 0.0 10.2 ±5 0.0 10.2 ±5
2 0.1 30 ±5 0.25 30 ±5
3 0.2 48 ±5 0.5 48 ±5
4 0.3 65 ±5 0.75 65 ±5
5 0.4 82 ±5 1.0 82 ±5
6 0.5 99 ±5 1.25 99 ±5
7 0.6 116 ±5 1.5 116 ±5
8 0.7 134 ±5 1.75 134 ±5
9 0.8 151 ±5 2.0 151 ±5
10 0.9 168 ±5 2.25 168 ±5
11 1.0 184 ±5 2.5 184 ±5
General Parameters of Fuel Sensor
Empty 1 / 8 oil 1/4Oil 1/2 Oil 3/4 Oil 7/8 Oil Full oil
Oil Level
oil level level Level Level Level Level level
Resistan
10±5 33±5 58±5 95±5 132±5 157±5 180±10
ce

3) If the sensor is fault-free, then inspect the cable from each sensor to the front of the
instrument, to inspect whether it is normal without damage or not.

4) If there is no damage, then loose, short circuit and, connect a small resistor in series,
then the indicator will display the max. value, the indicating hand does not point to a
mark, if it cannot normally indicate, and then replace the meter.

130
5.9.3 SOLDERING

When perform soldering on the whole machine,

follow the following regulations to avoid damage
to machinery and security incidents.

1. Before soldering, shut down the engine,

unplug the key switch, turn off the negative
pole switch of battery;

2. Before soldering, must remove the wiring

harness connectors of the dashboard to
avoid damage to instrument;

3. While welding, must keep away from the wire

bund of the machine and take measures to
avoid flash and the damage caused by flying
sparks;

4. Continuously use the voltage more than

200V;

5. Keep the length of the cable between

soldering region and grounding is of within
1m;

6. Avoid to arrange the seals and bearings in the

area between the soldering region and the
grounding cable;

7. Do not weld the pipe with fuel, engine oil and

hydraulic oil;

8. Do not weld containers sealed or with poor

ventilation.

5.10 TRANSMISSION OIL MAINTENANCE

5.10.1 INSPECT OIL LEVEL OF GEARBOX

Refueling port of the gearbox is at the left side of

the frame articulated section; please inspect the
oil level of the gearbox regularly according to the
regulated cycle.

Gearbox may be damaged if its oil level is too

high or too low. Please keep transmission oil level
in the correct position.

Fill from the refueling port of the gearbox.

131
Judging criteria:

When the engine stopped, oil is drained out from

the screw piston at the upper oil level;

When the engine runs, the minimum oil level does

not lower than the screw piston at the bottom oil
level.

In course of inspecting oil level of gearbox,

replacing transmission oil and replacing the fine
filter of the gearbox. We must pay great attention
to the cleanliness, prevent the dirt from entering
the transmission system and avoid damage to the
gearbox.

5.10.2 TRANSMISSION OIL REPLACEMENT

It is required to replace transmission oil within the regulated oil change cycle. And the
replacement procedures are as follows:

1. Park the machine on the flat ground, and set the speed shifting handle in neutral gear
shift, rotate the button of the parking brake to reset, and put on a fixed frame rod, to
prevent the car from moving and rotating.

2. Start the engine and run it at idle speed, when the engine oil temperature reaches its
operating temperature (about 80℃ ~ 90℃), the engine turns off.

3. Drain out the oil by unscrewing the oil outlet screw piston at the bottom of the gear
box.

As the oil is still at a higher temperature, therefore it requires wearing protective

equipment, and careful operation, so as to avoid personal injury.

4. When replacing transmission oil, it is necessary to replace the fine filter of the gearbox
as well.

5. Remove the transmission oil pan. Clean the filter screen with compressed air or diesel
fuel.

6. Install transmission oil pan, drain plug and corresponding sealing elements.

7. Refuel the clean transmission oil from the oil filling pipe of the gearbox, and inspect
the oil level of gearbox according to the above method, and fill to the regulated oil
level.

8. Before replacing transmission oil, cover the parking brake well to prevent the friction
plate of parking brake from oil and reduce the brake performance.

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5.11 MAINTENANCE OF DRIVE AXLE OIL

5.11.1 INSPECT OIL LEVEL OF DRIVE AXLE

Inspect the oil level of the drive axle according to the regulated cycle.

Too high or too low oil level of drive axle will result in damages to drive axle, and keep the
oil level of the drive axle in the correct position.

Drive axle fueling and oil level judging criteria:

Fill oil from the filling port of the left and right wheels, and take the oil overflowing out with
the middle oil piston of the axle off as the oil fully filled.
Inspection procedures:

1. Drive the machine to a flat and open ground, slowly move the machine with low oil
charging, keep the oil level mark of the front drive axle wheel-side to be located at the
level position.

2. As the oil level meter lines of front and rear drive axle cannot simultaneously locate in
a horizontal position, so the oil level of front and rear drive axle should be inspected
twice.

3. Rotate the parking brake handle for braking. Place the speed changing handle in
neutral gear position, and put on a fixed pole frame to prevent the car moving and
rotating.

4. The engine stops.

5. Remove the oil outlet screw piston, the oil level inside the drive axle should be located
at the lower edge of the oil outlet port. If the oil level is below the lower edge of the oil
outlet port, it requests to add clean drive axle oil. Observe 10 minutes after fueling to
confirm the oil level is stable or not.

6. Screw on the oil outlet piston.

7. Inspect the oil level of the rear driving according to the above operation procedures.

5.11.2 REPLACEMENT OF THE DRIVE AXLE OIL

It requires replacing drive axle oil within regulated cycle.

The replacement procedures are as follows:

1. Drive the machine to park at a flat ground; slowly move the car with low oil supplying,
to keep the oil outlet screw piston at the end side of the wheel rim of the front drive axle to
be located at the lowest position.

2. As the oil outlet screw pistons at the end side of the wheel rim of the front drive axle
cannot be located at the lowest position at the same time, therefore, the front and rear
drive axles should replace oil twice.

3. Rotate the button of the parking brake to reset it. The handle of the speed changing
should be placed at neutral position, put on frame fixing bar to avoid car moving and

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rotating.

4. Run the engine for 10 minutes under idle speed, and the engine turns off.

5. Screw off the oil outlet screw piston at the end surface of the wheel rim of the front
drive axle, and the oil outlet screw piston at the middle part of the axle, drain out the oil
and receive the oil with container.

6. Refuel according to the above-mentioned ―drive axle refueling and oil level judgment
criteria‖.

7. Screw on the oil outlet screw piston.

8. Repeat the procedure to inspect the oil level of the rear drive axle

9. Since the oil may at relatively high temperature, it is necessary to wear protection
tools and facilities, and handle with care to avoid injuries.

5.12 INSPECTION AND REPLACEMENT OF TIRE

Warning
If the tire or wheel rim is handled mistakenly, tire may burst or broken and wheel rim
may be damaged and spread, which may result in serious injury or death.

Maintenance, dismount, repair and installation of tire and wheel rim need special
equipment and know- how, so you must bring it to tire repair shop to repair, or by specially
trained personnel to carry out and comply with all relevant safety requirements.

Recommend to use dry nitrogen (N2) to full the tires. If the original tires are filled with air, it
is recommended to use nitrogen gas to adjust its air pressure, nitrogen can be mixed with
atmospheric gases. Tires filled with nitrogen can reduce the possibility of explosion.

When tire pressure is inspected and adjusted, it should be carried out after the tire is fully
cooled.

Pressure of Nitrogen inflated tire is the same as that of the air-inflated tire.

5.13 MAINTENANCE FOR LONG TIME PARKING

If the machine will be stored for a long time exceeding one month, the following steps
should be followed with:

1. The machine should be stored in dry room. If the car has to be parked in the open air,
it should be stopped on the concrete ground for easy drainage of water, and cover it
with canvas.

2. Before store the car for a long time, please completely clean each part of the car, do
not leave any dirt or mud on the surface and air it dry.

3. Put the bucket down level on the ground, set the gear shifting joystick at neutral
position. Rotate the button of the parking brake to reset it, push the negative switch to
the off position, and lock the door of the cab.

4. Fill diesel full into fuel tank, fill lubricating grease over the pins and shafts, and smear

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 a layer of engine oil over the exposure part of the piston rod of the hydraulic cylinder.

5. Dismount the battery and store it separately.

6. If the temperature drops down to below 0℃, add anti-freeze fluid into the engine
cooling system, and to fill the anti-freeze fluid to reach to the engine body and the
evaporator of the air conditioner system.

7. Drain out the water in the cooling system, please note to drain out the water in the
evaporator of the air condition system.

8. Start the car once a month, to run each system, and fill lubricating grease over all
moving pins and shafts, to ensure all moving parts to be lubricated. Before star the
engine, remove the engine oil over the piston rod.

5.14 MAINTENANCE UNDER SPECIAL CONDITIONS

Maintenance for the operation in mud, water or rain

Inspect the connections around the car to confirm whether there are loose joints, machine damage or
leakage.

After operation is completed, clean the mud, rocks, gravel, etc. left on the machine; inspect the
welding seam to confirm whether there are cracks and whether there is loose; carry out daily
lubrication and maintenance.

If the car is working in acid rain or corrosive media, please flush to clean the affected parts with clean
water rinse.

The maintenance under heavy dust or very hot environments

Clean the air filter more frequently.

Flush the surface of the heat radiator to remove the embedded dust and dirt.

More frequent replacement of fuel filter.

If necessary, inspect and clean up the starter motors and generators.

The maintenance for the operation in rocky environment,

Inspect the wheel and tire assembly to confirm whether there is any damages or excessive wear and
tear.

Inspect joints and fasteners to confirm they are loose or damaged.

More frequently inspect the bucket or breaker to confirm whether they are damaged or excessively
worn.

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If necessary, install the anti-litter fence at the top and front of the windshield of the cab.

The maintenance of the operation under special cold area

Use the fuel which is compatible with the ambient temperature

Use the antifreeze which is compatible with the ambient temperature.

Confirm the battery's ambient temperature, as for the especial coldness, remove it at night, and store
it in a warm place.

Remove the slurry on the body timely, in order to prevent damaging the equipment due to freezing.

5.15 MAINTENANCE OF HYDRAULIC OIL

5.15.1 INSPECT THE OIL LEVEL OF THE HYDRAULIC OIL

Hydraulic oil tank is behind the cab. The round oil

mark indicating the level of the hydraulic oil is on
the left side of the hydraulic oil tank.

When inspecting the oil level of the hydraulic oil,

park the car on a flat ground, put the bucket on
level ground, at this time, the hydraulic oil level
should reach the middle position of upper oil
mark.

5.15.2 REGULAR REPLACEMENT OF HYDRAULIC OIL

Every 2000 working hours or every year the hydraulic oil should be replaced. If the oil
deterioration occurs due to poor working conditions, or hydraulic oil is contaminated, such
as the color changes to black, oil foaming, please replace the hydraulic oil.

Warning
During the oil changing process, the machine need to be operated at a variety of
actions, please note to perform in accordance with the relevant safety regulations.
During the oil change process, we should pay great attention to cleanliness of the
oil, do not let dirt coming into the hydraulic system.

1. Clean up the impurities and debris in the bucket, and park the car at the flat and open
spaces, install a fixed frame rod, rotate the parking brake button to reset it, speed

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 changing handle is placed in the neutral position. Start the engine and run it at idle
speed for 10 minutes, during the previous process, repeat several times to lift the lift
arm, lower down lift arm, forward dumping the bucket and backward dumping the
bucket, and other activities.

2. Finally, raise the lift arm to the highest position, and backward the bucket to maximum
position, the engine turns off.

3. Firstly push the pilot joystick to the right, so that the bucket is tilted forwards under its
own weight to pour out the oil in the bucket cylinder; after the bucket turns to right
place, push the joystick forward and the lift arm lowers under its own weight to pour
out the oil in the lift arm cylinder

4. Push the pilot joystick to the middle position.

5. Clean up the oil outlet cover at the bottom of the hydraulic oil tank, screw off the oil
outlet screw piston and receive the oil with container. At the same time, screw offs
the air filter to speed up the process of draining oil.

6. Remove top cap of the oil return filter of the hydraulic oil tank, replace the oil return
filter core. Dismount the top cap of the oil filter of the hydraulic oil, and replace the filter
core.

7. Block the sucking back port of the hydraulic oil tank with a clean cloth, flash to clean
the inside wall of the hydraulic tank with diesel from the top cover installation port of
the sucking back filter of the oil tank, and drain out the oil from the oil outlet pipe.
Finally, clean the bottom of the oil tank and four sides of the wall with a clean dry cloth,
take out the cloth blocking at the oil sucking port.

8. Install the oil outlet screw piston for hydraulic oil drainage, return oil filter, oil suction
filter and top cap.

9. Fill clean hydraulic oil for the refueling port of the hydraulic oil tank, so that the
hydraulic oil level reaches the middle position of upper oil mark of the hydraulic oil,
screw on the refueling cap.

10. Remove the frame fixing rod, start the engine, operate the pilot joystick for lifting the
lift arm 2-3 times, tilting the bucket backwards and forwards and turning the bucket to
the left and right to the maximum angle, fill the oil cylinder with hydraulic oil. Then let
the engine run at idle speed for 5 minutes to exhaust air from the system.

11. Engine turns off, open the hydraulic tank filler cap, and add clean hydraulic oil to the
middle position of the upper oil mark of the hydraulic oil tank.

Warning
If the hydraulic oil has been seriously polluted, in addition to drain out the hydraulic
oil from the hydraulic tank, heat radiator of hydraulic oil, lift arm cylinder, bucket
cylinder with the above mentioned method, open the end with a pipe, to drain out
hydraulic oil in the cylinder and inner cavity of various pipes. Then fill the clean
hydraulic oil to the middle position of upper oil mark.

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5.16 BUCKET MAINTENANCE

5.16.1 REPLACE BUCKET O-RING

Warning
As metal objects may fly out, it is better to wear safety helmets, gloves and eye
protection cover when replace the pin.

Inspect the O-ring on the bucket, if it is worn or

damaged, please replace it.
Figure 1

Release the pin platen bolts of the bucket (1,

Figure 2), and then remove the bucket pin (2),
take out the lift arm (3).

Remove the old O-ring, install the new O-ring (4,

Figure 3), and confirm that the O-ring on the lift
arm (3) groove has been cleaned.
Figure 2

Figure 3

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Find out the lift arm pin hole and bucket pin hole,
to install the bucket pin (2, Figure 4).

Lock the Pin Plate bolts of Bucket (1, Figure 2).

Figure 4

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 CHAPTER VI COMMON FAULTS AND
TROUBLE-SHOOTING

Fault Cause Action

Switch for gearing again, or re-adjust the
Shift is not geared on.
variable speed handle of the system
Oil level of the gearbox is too
Fuel to the regulated oil level.
low.
Handle rod of the speed
Diesel engine Find out the reason not returning to right position
changing valve cannot return
cannot start to run. and remove.
to original position.
Speed changing oil pump is
Replace oil pump or oil seals
damaged or oil seal is leaking.
Oil Pump is in poor sucking
Inspect whether the Oil sucking Pipe fails or not.
conditions.
Low pressure of the oil outlet
port of the torque converter is Inspect oil level of the gearbox, clean the oil filter
low, and the torque converter of the oil pan and oil filter of the outlet.
voltage fails.
Lack of driving Engine speed is insufficient. Inspect engine speed.
force Inspect the speed changing oil pressure and the
Clutch slips
oil seal of the piston.
When the oil temperature of the torque
Oil temperature of the torque
converter is higher than 120℃, stop the car for
converter is too high
cooling down.
Pressure release Valve groupFind out the reasons and perform maintenance
fails.
Pressure for
Oil filter is blocked Clean the oil filter
changing speed is
Pump Failure Replace oil Pump
too low
Oil seal of the clutch is leaking oilChange oil Seal
seriously.
Oil flying out from the end of theReplace the oil seal of the shaft side of steering
Oil level of the steering pump pumps.
gearbox is Oil flying out from the end of
Replace the oil seal of the shaft ends of the
increased the shaft of the working pump
steering pump.
of the hydraulic system
Oil level of the Gearbox is too
Fuel to the requested oil level
high or too low
Clutch slips Inspect the oil pressure of the clutch
Clean oil filter screen and oil filter of the oil pan
Filter is blocked
of the gearbox.
Speed changing Pump is in Inspect speed changing pump to confirm the oil
bad oil suction condition hose is offset or blocked
Speed changing pump wears, Inspect the speed changing pump to confirm
fuel supply is insufficient. that there is any leakage or not, and remove it.
Oil temperature of
torque converter is Oil cooler partially is blocked Inspect and clean oil cooler of the gearbox.
too high. Inspect oil used for double change (add volume
and fuel quality) to confirm it meets the
requirements or not
Inspect the oil returning pressure of the torque
converter is not too high or not, hydraulic
Oil deteriorates
resistance is too high may lead to a rapid
increase of the oil temperature in the oil return
system.
Inspect the oil temperature meter, oil
temperature sensor is accurate or not.
Loose steering wheel nut Make adjustment as required
The idle stroke of
Worn or damaged connection
the steering wheel
between steering column and Disassemble and repair
is over-sized.
steering gear

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 Fault Cause Action
Loss flow of steering pump is inadequate. Inspect or replace the steering pump
Steering torque is Pressure change of the safety pressure
Adjust its pressure (pressure)
insufficient valve
Steering pump leaks seriously inside. Repair or replace
Oil seal of the cylinder is worn or
Change oil seal
damaged
Distribution valve is excessively worn, Dismount and repair, to make the
the fitting gap between valve rod and clearance reach to the required value
Lift arm raising valve body exceeds the specified value. or replace the distribution valve
force or bucket Find out the leaking point and remove
Pipeline system leaks oil.
tilting force is it.
inadequate The working pump/steering pump
Replace working pump//steering pump
seriously leaks inside.
Safety valve is adjusted improperly; the Adjust the system pressure to the
system pressure is too low. specified value
Oil tube and oil filter is blocked Clean oil filter and change oil

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Fault Possible cause Fault phenomenon Elimination method
Identify other causes
Refrigerant leak in the system No pressure indication Refill with refrigerant

Electrical devices
(compressor/evaporating
Normal pressure indication Replace defective devices
fan/condensate fan) work properly
or not
Refrigeration function of air-conditioning system does not work

Replace the belt or adjust it

Loose or broken
to a value within prescribed
Compressor belt
limit
does not Normal pressure indication
No pull-in of
work
clutch/ circuit
problem
Loose plug
The controlled electrical device does not work
connector
Blown fuse The electric device does not work
Failure of
temperature Compressor does not work
controlled switch
Repair or replace defective
Damaged
Compressor does not work parts
pressure switch
Circuit fault
Damaged relay The controlled electrical device does not work
Damaged
refrigeration Devices other than evaporating fan do not work
switch
Damaged air
No electrical device works
volume switch
Other circuit
The controlled electrical device does not work
damage
Low pressure (negative pressure), frosted outlet
Plugged expansion valve
of expansion valve
Low pressure is on the low side and beyond the Clean the air-conditioning
normal range, or is negative pressure system and replace drying
Plugged drying bottle Noticeable temperature difference between bottle or expansion valve
pipes on both sides of drying bottle, frost
formation on drying bottle
Damaged or not well connected
Low air speed at air outlet Repair the air outlet
air outlet
Heater valve for heat exchanger is Close water valve or make
Heat means the valve is not closed
not closed or leaks water replacement
Check leaking positions,
Both high pressure and low pressure are on the
Inadequate refrigerant add the right amount of
high side
refrigerant
Both high pressure and low pressure are on the
Let out the right amount of
Surplus refrigerant high side, and there is no air bubble in level
refrigerant
glass
Non-condensable gas within the Both high pressure and low pressure are on the
system high side
Filth blockage of air inlet of
Too much earth and thick dirt on surface/objects
evaporator/filth blockage within Clear away the filth
Inadequate refrigeration

clogging air inlet

core body
Check the circuit and
Zero current or no fan operation with damaged
Failure of condensate fan motor, make repair or
fan blades
replacement
Filth blockage on condenser
Too much earth and thick filth on surface Flush with water
surface
Condenser inlet air temperature is
Keep air inlet able to take
too high, or the dissipation of
Air inlet is above 40℃/air inlet is clogged in enough air and natural
discharged hot air is not
wind
satisfactory
Loose belt Harsh noise Adjust the belt
Replace expansion valve,
Low pressure indicates negative pressure/frost
Clogged expansion valve vacuumize again and add
forms on evaporator
refrigerant
Replace expansion valve,
No temperature difference between inlet and
Damaged expansion valve vacuumize again and add
outlet of expansion valve
refrigerant
Replace drying bottle,
Low pressure is on the low side and beyond the
Clogged drying bottle vacuumize again and add
normal range, or is negative pressure
refrigerant
Noticeable temperature difference between
pipes on both sides of drying bottle

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 Fault feature Cause Elimination method

Reverse polarity connection of power Connect to power source

Power lamp of MP3 player source

is not lit up Disconnected protective tube or open Check and connect power line correctly, replace

power line protective tube

No power voltage Connect the power line properly

Open loudspeaker circuit Connect the loudspeaker circuit properly

Mute MP3 player
SD/MMC card, U disk have no Check the content of SD/MMC card, U disk

corresponding format

Internal resistance of power source is Change power source

Light (unclear) sound of
too big
MP3 player
Poor contact of aerial plug Adjust aerial plug

Single track of MP3 player Open circuit of one loudspeaker line Connect the loudspeaker line properly

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 VII. MAINTENANCE AND SERVICING OF
AIR-CONDITIONING SYSTEM

No. Item Content

Whether air blower operates with abnormal noise

1 Evaporator Whether air inlet & outlet are smooth

Whether water drainage is smooth

Whether fastening bolts loosen

Compress Whether the tightness of the belt is appropriate

2
or Whether the clutch pulls in properly

Whether dust and filth is too much

Whether the surface of core body is affected by filth blockage and
3 Condenser needs periodical cleaning
Whether electronic fan works properly

Whether connections loosen or leak(oil stain at leaks)

4 Pipeline
Whether flexible hose is damaged

5 Switch Whether gears work properly without loosening

Electric
6 Whether any electric connector loosens or is damaged
connector
Temperatu
Whether the device works properly and whether indicator lamp is
7 re
lit up properly
controller
8 System Whether all parts work properly without abnormal noise

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 CHAPTER VIII ENVIRONMENTAL PROTECTION
REQUIREMENT
When performing maintenance, the parts replaced should not be arbitrarily discarded, and
should be recycled.

When performing maintenance, do not put coolant, oil (fuel, engine oil, hydraulic oil,
transmission oil, gear oil, grease, etc.), electrolyte or other objects may cause
environmental pollution, directly on the ground, use the special containers to collect them
and dispose them in accordance with relevant regulations.

The treatment of the pollutants should be complied with local laws and regulations.

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APPENDIX: REFERENCE TABLE OF PROPORTION OF
COMMON MATERIALS
No. Material name Specific Categories Reference to the value of Kg/m3 Notes
Stick thin dry soil 1250
Caking dry soil 1520
Powder dry soil 1550
1 Ordinary soil
Wet soil 1725
Mud-like soil 1730
Tight soil 1840
Wet soil 1750
2 Clay
Dry soil 1485
Loose dry sand 1440
3 Sand Wet sand 1680
Water-Wet Sand 1850
Broken sand stone 1500
4 Sandstone
Solid sandstone 2300
Dry gravel 1485-1650
Wet gravel 2015
Gravel pit 1900
5 Gravel Dry clay mixed 1185
Wet clay mixed 1650
Dry sand mixed 1730
Wet Sand Mixed 2000
6 Bauxite 1425
7 Gravel 1600
8 Slag Dry 650
Smokeless Coal 1190
Bituminous coal 950
9 Coal
Dry peat 415
Wet peat 1125
75% of the geotechnical 1955
Weathered
10 50% of the geotechnical 1725
rock
25% of the geotechnical 1585
Crushing Block 1600
11 Gypsum Break bulk 1810
A solid block 2780
Fragmentation 1550
12 Limestone
A solid block 2600
13 Slag 1760-2100
Chunky 1650
14 Granite
Overall 2800
15 Hematite 2460
16 Magnetite 2780

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