Professional Documents
Culture Documents
SAFETY INFORMATION...................................................................................................................... 5
TECHNICAL SPECIFICATIONS....................................................................................................... 26
OPERATION......................................................................................................................................... 32
MAINTENANCE....................................................................................................................................49
PERIODIC MAINTENANCE.................................................................................................................... 50
MAINTENANCE SCHEDULE.................................................................................................................. 51
ENGINE................................................................................................................................................ 54
TRANSMISSION.................................................................................................................................... 59
AXLE.................................................................................................................................................... 61
HYDRAULIC SYSTEM........................................................................................................................... 61
TIRES................................................................................................................................................... 63
BUCKET LIMITATION DEVICE...............................................................................................................63
PARKING BRAKE..................................................................................................................................64
PIN AND DRIVESHAFT......................................................................................................................... 65
WELDING OPERATION.........................................................................................................................68
BATTERY..............................................................................................................................................68
FLUID SPECIFICATION......................................................................................................................... 70
ENGINE SYSTEM.................................................................................................................................. 72
TRANSMISSION.................................................................................................................................... 72
BRAKE SYSTEM................................................................................................................................... 73
WORK TOOL AND HYDRAULIC SYSTEM............................................................................................. 74
STEERING SYSTEM............................................................................................................................. 75
ELECTRIC SYSTEM.............................................................................................................................. 77
AIR CONDITIONING SYSTEM............................................................................................................... 77
2
Foreword
This manual includes guidelines on how to use this Wheel Loader safely and effectively.
This manual should be kept at hand and read periodically. If this manual is lost or becomes too
dirty to be legible, you should buy a new one from your dealer. If you sell the machine, make
sure this manual will be handed over to the new user.
This manual contains safety information, operation instructions, and lubrication and
maintenance precautions. The information, specifications, and illustrations in this manual are
based on information that was available at the time of publication. The specifications, torques,
pressures, measurements & adjustments, illustrations, and other items may change at any
time. These changes may affect the service that is given to the machine. Whenever a problem
arises regarding the machine or the contents of this manual, please consult the manufacturer
or dealers for the latest available information.
The safety section describes safety concerns that require your attention during operation,
maintenance or repair. Most accidents that involve product operation, maintenance and repair
are caused by failure to observe basic safety rules or protection measures. An accident can
often be avoided by recognizing potentially hazardous situations before an accident occurs. All
related personnel must be acquainted with potential risks of accidents. Those persons should
also have the necessary training, skills and tools to perform repair the failures. Improper
operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death. Do not operate or perform any lubrication, maintenance or repair on this
machine, until you have read and understood the operation, lubrication, and maintenance and
repair information. Safety precautions and warnings are provided in this manual and on the
product. If these hazard warnings are neglected, injury or death may occur.
The operation section describes basic operation technique, and guides the operator
through correct procedures of checking, starting, operating and stopping the machine.
Therefore the operator should keep this manual at hand for continuous reading and studying.
The maintenance section is a guide to machine daily maintenance, and classified on the
basis of maintenance intervals. This manual lists the maintenance interval on the basis of
service hour meter reading. Calendar intervals (days, weeks, months) can be used instead of
service hour meter intervals if they provide more convenient servicing schedules and
approximate the indicated service hour meter reading. EVERUN recommends that service
should always be performed at the interval that occurs first. Under extremely severe, dusty or
wet operating conditions, more frequent lubrication than is specified in the maintenance
intervals schedule might be necessary. Perform service on items at multiples of the original
requirement. For example, at every 500 service hours or 3 months, also service those items
listed under every 250 service or monthly, 50 service hours, or weekly, and every 10 service
hours or daily.
EVERUN cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are therefore not all inclusive. If a tool,
procedure, work method or operating technique not specifically recommended by EVERUN is
used; you should ensure that it is safe for yourself and others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
Each wheel loader has its own design operating capacity. Additional attachments or
modifications exceeding machine design capacity may adversely affect operation performance
of the loader, which include the operation stability as well as brakes and steering units. Please
contact your dealer for the latest information.
Components
Safety Information
Please read and become familiar with all of the safety information.
Failure to do so may result in serious injury or death.
This “Safety Information” section also contains precautions regarding
options and attachments.
Descriptions and Locations of Safety Messages
6
Safety Information
Safety Devices
Make sure that all protective guards and
all covers are secured in place on the machine.
Repair immediately if damaged.
Use safety devices properly, such as
control levers lockout device and seat belt.
Never remove any safety devices. Always
keep them in good operating condition.
Improper use of safety devices could result
in serious injury or death.
7
Safety Information
8
Safety Information
9
Safety Information
with your hand to avoid being burned. by falling objects, and its protection function
Do not remove the engine oil temperature may be weakened. In such a case, contact
sensor, water temperature sensor, converter your dealer for repair.
oil sensor and air conditioner water tube when Even if ROPS is installed, when operating
the machine is hot, to avoid being burned. the machine, the operator should wear the
seat belt, and use other the safety devices to
Crushing Prevention and provide proper protection.
Cutting Prevention
Precautions for Attachments
Keep your hands, arms and all body parts
clear of all moving parts such as, the area When installing and using an optional
between the work tools and cylinders or the attachment, read the instruction manual for the
area between the machine and work tools. The attachment and the information related to
clearance in the linkage area will change with attachments in this manual.
the movement of the work tools. This may lead Do not use attachments that are not
to serious accident or personal injury. If authorized by EVERUN or your EVERUN
entrance between the machine and moving distributor. Use of unauthorized attachments
parts is necessary, always stop the engine, could create a safety concern and adversely
and then lock the work tools. affect the proper operation and service life of
Support the machine properly before you the machine.
perform any work beneath the machine. Do not EVERUN is not responsible for any injuries,
depend on the hydraulic cylinders to hold up accidents, machine damages resulting from
the equipment. Equipment can fall if a control the use of unauthorized attachments.
is moved, or if a hydraulic line breaks.
Ventilation for Enclosed Areas
Unless otherwise stated, never make any
adjustment when the machine is operating or In an enclosed or poorly ventilated area, if
the engine is running. it is necessary to start the engine, handle fuel,
Stay clear of all rotating and moving parts. flush parts, or paint, immediately open the
Keep objects away from moving fan doors and windows to ensure that adequate
blades. The fan blade will throw or cut the tools ventilation is provided to prevent gas
or objects in between. poisoning.
If opening the doors and windows does not
provide adequate ventilation, fans should be
installed.
10
Safety Information
11
Safety Information
Check the coolant level, fuel level, and oil starting the engine will lead to delays in
level in the engine oil pan, clogging of the air discovery of abnormalities. And, this may lead
cleaner, and damage to the electric wiring. to serious injury or damage to the machine.
Adjust the operator’s seat to a position When checking the area one must ensure that
where it is easy to carry out operations, and there are no obstacles and do not allow people
check for wear or damage to the seat belt and to come near the operation area.
mounting equipment. Change the seat belt Check the functionality of the gauges,
after three years. work tools, and hydraulic system, brake
Check that the gauges work properly, and system, travel system and lubricating system.
check that the control levers are at the PARK Check for any abnormalities in the sound
position. of the machine, vibration, heat, or smell; also
Remove all dirt from the surface of the check that there is no leakage of air, oil or fuel.
window glass and lights to ensure good If any abnormalities are found, carry out
visibility. repairs immediately. If the machine is used
Adjust the side mirror to a position, which when it is not in proper condition, it may lead to
gives the best view from the operator’s seat, serious injury or damage to the machine.
and clean the surface of the mirror. And clean Before traveling or starting operations,
the surface of the mirror. If the mirror glass is check that safety bar is securely placed in the
damaged, replace with a new part. “unlocked” position.
Check that the front lamps and working
lamps light up properly. If the results of the
Operation
inspection show any abnormality, carry out the Precautions When Starting Off
necessary repairs. Before starting off, check again that there
Be sure a fire extinguisher is present and is no one in the surrounding area and that
check the method of using it. there are no obstacles.
Do not operate the machine near any fire When starting off, sound the horn as an
or flame. alert.
When Starting Engine Operate the machine only when seated in
the operator’s seat.
Walk around your machine and check for
Always fasten the seat belt. (If equipped)
people and objects that might be in the way
Only the operator is allowed in the cab. Do
just before getting on.
not allow anyone ride on the machine body.
If a warning label, such as “DO NOT
If there is a backup alarm, please check
OPERATE”, has been attached to control lever,
that it works properly.
DO NOT start the engine.
When starting the engine, sound the horn Precautions When Traveling
as an alert. When traveling, never turn the key/start
Start and operate the machine only while switch to the off position. It is dangerous if the
sitting in the operator seat. engine stops when the machine is traveling
Only the operator is allowed in the cab. Do because the steering becomes heavy. If the
not allow anyone to ride on the machine body. engine stops, apply the brake immediately to
Start the engine in the cab; never start the stop the machine.
machine by creating a short circuit of the It is dangerous to look around when
electromotor, this may damage the electro operating. Always concentrate on the work.
circuit, and it is very dangerous. It is dangerous to drive too fast, to
If there is a backup alarm, please check start/stop suddenly, turn sharply, or zigzag.
that it works properly. If you find an abnormality in the machine
After Starting Engine Check-list during operation (noise, vibration, smell,
incorrect gauges, air leakage, oil leakage, etc.),
Failure to carry out the checks properly after
12
Safety Information
move the machine immediately to safe place bursting. If a tire bursts, it produces an
and look for the cause. extremely large destructive force, and this may
Set the work tools to travel position. (Lift cause a serious injury or accident.
30-40cm from level ground) If you are going to travel continuously,
please consult your EVERUN agent.
13
Safety Information
14
Safety Information
15
Safety Information
16
Safety Information
Do not turn the direction off the ramp. If Stop the engine before working with the
necessary, the machine should move away engine.
from the ramp, adjust the machine direction Avoid contacting with the metal that may
and then run up on the ramp. cause a short circuit between positive terminal
After the wheel loader is loaded on the (+) and negative terminal (-).
trailer, wedge the tire and tie and tighten the First connect the positive terminal (+)
machine with a cord. when assembling the battery. First disconnect
the negative (-) terminal (on the side of ground
Delivery
cable) when disassembling the battery.
When using the tow truck to deliver the First check which one is positive terminal
machine, the operator should obey by the (+) or negative terminal (-) when
regulation for the weight, width, length and the disassembling or assembling the battery. And
national and regional laws. tighten the nut.
When confirming the delivery route, the Wipe with the cloth when cleaning the top
operator should consider of the machine’s of the battery. Never use the gas, solvent, any
weight, height, width and length. other organic solvent or cleanser. Tighten the
When passing over bridges or structures cover of battery.
on private land, check first that the structure is If the battery electrolyte is frozen, do not
strong enough to support the mass of the charge the battery or start the engine with a
machine. When the tow truck is running on the different power source. There is danger that
road, the delivery must meet the requirement this will ignite the battery. When charging or
of the related regulations and obey by them. starting the engine with a different power
When delivering the machine, the machine source, melt the battery electrolyte and check
might be divided into several parts. So please for leakage of battery electrolyte before
contact the EVERUN dealer to conduct this starting.
work Disassemble the battery from the machine
Battery and Maintenance before charging.
17
Safety Information
touch to the machine when removing the everyone knows before starting the work.
boosting cable. If the machine engine cannot start or there
is a failure in the brake system, please contact
Battery Charging
the EVERUN dealer to repair the machine.
If the battery is not correctly charged, it may It is very dangerous to pull a machine on
have the possibility to explode. Therefore, an incline. The worker should select an area
charge the battery according to the correct with a small gradient. If this does not exist,
procedure and following rules. then select the area with the smallest possible
Charge it under proper ventilation and gradient.
remove the battery cover. This allows the If using the machine to tow another
hydrogen to diffuse and prevents explosion. machine that has failed, the steel wire line
The air from the battery might cause explosive. must be strong enough to support the failed
Do not have fire or spark near the battery machine’s weight.
and no smoking when charging.
Set the voltage of charger to agree with
one of charged battery. If there is something
wrong with voltage, the charger will overheat
and may catch fire, which might cause
explosive. There should not be any broken braided
Connect the positive charging clip (+) to wire, knots or reduced diameter on the steel
the battery the positive terminal (+) and tighten wire line.
the two terminals. Do not stride two feet to stand on the tow
If the charging rate of battery is less than wire or the steel wire line.
1/10, charge it highly. Set the discrete value When connecting the machine that needs
under the battery rated volume. If the charging towed, do not stand between the machine
current is too large, the electrolyte may leak or being towed and the towing machine.
evaporate, which could cause fire or explosion. To make sure the hook is in the correct
position, the hook of the towed machine should
be in line with the towing part of the machine,.
Maintenance Precautions
Before Maintenance
Attention: If maintenance that is not
instructed in this “Operation and Maintenance
Manual” is done, unexpected failure may arise.
Please contact the dealers appointed by
Towing Everun Machinery CO., Ltd for service.
18
Safety Information
maintenance. This is to prevent dirt from falling to touch the engine or the radiator.)
into the machine and to make sure that the 2. When the water fill cover can be
maintenance can be done safely. opened with a bare hand, unfasten the fill
If the machine is dirty in the course of cover to release the inner pressure.
overhaul and maintenance, it is difficult to If the top cover of the radiator needs to be
avoid dirt or mud going into eyes or slipping open, do not open it until the water
and getting injured. temperature cools down and the inner
A few tips for cleaning wheel loaders: pressure is released.
1. Wear anti-slip shoes to avoid slipping
Shut Down Engine Before Overhaul and
on wet surface. Maintenance
2. When cleaning wheel loaders with
high-pressure water, wear safety clothing. In the course of overhaul and maintenance,
This way, your eyes and skin can be park wheel loader on the flat ground where
protected from the impact of there is no danger of falling rocks or land slides.
high-pressure. If it is a low terrain, there should be no danger
3. Do not spray water directly onto the of flooding. Then shut down engine.
electrical components (e.g. sensors, wire After engine stops, move the work tool
connectors). If water get into electrical control lever to the “lifting”, “lowering” and
system, operation failure may arise. “rack back” positions a few times as to release
the remaining inner pressure in the hydraulic
Keep the Working Place Clean and Tidy systems. Lower the work tools to the ground.
Do not leave any service tools at the Pull up the brake lever to implement the
working place. Wipe up grease and lubricant
etc. to protect people from slipping. Clean and
tidy working place to ensure safe maintenance
If the working place is not tidy, danger
such as slipping and tripping may arise.
19
Safety Information
Fire Prevention
The gas diffused from fuel or battery might be
flammable. Follow the following attentions
when repairing or maintaining. Secure the tire with a wedge.
The storage of fuel, lubricant and other If the tire is supported only by equipment, it
combustible material should be far away from
20
Safety Information
will be dangerous for people to work under the When repairing the machine, do not take
machine, never work under poor quality unnecessary tools or parts. Maintenance when
support. the Engine is Running
To avoid getting hurt, do
Maintenance by Hanging the Frame
not do any maintenance
When the equipment or if the frame is when the engine is
hanging, use the lock bar to lock the front and running. If it is necessary
rear frame, put the handlebar in the middle and to do maintenance while
wedge the equipment and frame. Move the the engine is running,
control lever to the “Center” position. Use the abide by the following
blocks to stop the work tools and frame from rules:
moving. One operator should sit in the operation
Before hanging, wedge the wheel on one chair and also prepare to shut off the engine
side; put blocks under the machine when when necessary. All the workers should keep
finished. contact with each other.
When the working in a place close to the
rotating parts, pay special attention to avoid
being rolled up.
Never allow any tools or any parts of
body to touch the fan vane or fan belt. This
is dangerous.
When washing the inside of the radiator,
prevent the equipment from turning. Also, pull
Work on Top of the Machine the brake lever to implement braking.
When working on the top of the machine, Do not touch any control levers. If you
make sure the footing is clear and follow the must touch them, first signal for other workers
rules to avoid falling. and warn them to go to a safety place.
1. Wipe up spilled lubricant oil or grease.
Using a Hammer
2. Work without tools around.
3. Watch your steps. When using a hammer, put on the safety
Never jump from the machine. When glasses, safety helmet and other protection.
climbing or down the machine, use the lift and Use copper stick as a mat between the
handrail and keep three points of contact (two hammer and the part, which is hit.
feet and one hand or two hands and one foot) When using the hammer to hit hard parts,
Using protective equipment if necessary. such as pins or bearings, fragments may fly
At the top of the engine, the hood may be into ones eyes and result in harmful danger.
slippery and dangerous. Do not stand on it. Welding Repair
The top of the tire may be slippery and
Welding repair should only be done in a
dangerous. Do not stand on it.
designated place and by qualified personnel.
When cleaning the glass in the front of the
The gas emitted by welding can cause fire and
cab, stand on the fender of front frame.
electricity danger. Never allow and unqualified
Do Not Drop Foreign Material in Machine operator to enter. When welding abide by the
When repairing the window or oil tank, be following the rules:
careful not drop foreign objects (such bolts, Break the battery connector to avoid
nuts, twine or tools). These things may cause explosion. Remove the painting in the welding
damage to the machine or cause other post and dangerous gas generated.
problems if dropped into the machine. When welding on the hydraulic system,
If there are some foreign objects dropped pipes, or any place close to them, they may
inside, remove them immediately produce combustible fumes and sparks. There
21
Safety Information
22
Safety Information
Put the waste oil in a container, do not them to the specified pressure. The stated tires
pour onto the ground and pressure are in the "Tires" section in the
directly Maintenance chapter.
While handling When inflating a tire, check that no one will
harmful material, such enter the working area. And use an air chuck,
as lubricant, fuel, and which has a clip and can be fixed to the air
coolant, melting agent, valve. While inflating the tire, check the
filter, storage battery inflation pressure occasionally so that it will not
and other materials, rise too high.
obey relevant laws. If the rim is not fitted normally, it may be
burst or
Repair and Check after Maintenance
deflate while
Unexpected problems may occur if the proper the tire is
checks and maintenance procedures are not being inflated.
performed. It may even damage the machine To ensure
or cause injuries, and so pay attention to the safety, place
following issue. a guard
Checking when the engine is off around the
1. Are all repair and maintenance parts tire and do
checked? not work in
2. Are repair and maintenance items front of the
correct? rim but work
3. Are there tools or parts dropped into on the tread
the machine? It is dangerous if they are side of the
wedged into the linkage systems of the tire.
control levers? Abnormal drop of inflation pressure and
4. Is the leaking water or oil repaired? abnormal fitting of the rim indicate trouble in
Are the bolts screws down? the tire of rim. In this case, be sure to ask a tire
Checking when engine running repair shop to carry out repairs.
Pay attention to safety and the following items: Do not regulate the inflation pressure after
1. Do the repair and maintenance parts working at high speeds or high loads.
work normally? Explosions of air-inflated tires have
2. Does the hydraulic system leak oil resulted from heat-induced gas combustion
when the engine running, speeding up or inside the tires. Explosions can be caused by
adding load? heat that is generated by welding, heating rim
components, external fire, or excessive use of
Tires
brakes.
Handling of Tire
If a tire or a rim is handled in a wrong way, the
tire may burst or may be damaged and the rim
may be broken and scattered, which can
cause serious injury or death. For the safety of
maintenance workers, comply with the flowing
proceedings. The energy of tire explode are stronger
Since maintenance, disassembly, repair than deflation. Explode can make tire rim and
and assembly of the tires and rims require parts of transmission fly out more than 500
special equipment and skills, be sure to ask a meter. It can arouse loss of property and
tire repair shop to carry out the work. personnel.
The specified tires must be used; inflate It is recommended to fill tire with N2. If the
23
Safety Information
tire has original air, it is suggested that such as deformation or cracking, replace the
nitrogen should be used to adjust the pressure. clamps at the same as the hoses.
The nitrogen can be mixed with air. The tires When replacing the hoses, always replace
inflated with nitrogen gas can prevent the tires the O-ring, gaskets, and other such parts.
from exploding because N2 is inflammable. Ask your EVERUN distributor to replace
The N2 can prevent from oxidation, aging of the parts critical to safety.
rubber and cauterization of rim parts.
Avoid excessive charging; this requires the
appropriate equipment and personnel for
instruction.
Storage of Tires
Tires should be stored in a depot. People
must not enter to the depot unless allowed. If
tires are stored outside, it should be have
barrier around tires, and hold up the sign of
“NO ENTRY”.
Stand the tires on the ground and fixated
them with a wedge so that they will not fall
down when any unauthorized person touches
them. If the tire is laid on the ground and one
side is in contact with the surface, it will be
staved and debased quality.
Stand aside if the tires are fall down.
Machines tires are very heavy and may cause
injuries while attempting to control them.
24
Safety Information
NO. Safety critical parts for periodic replacement Qty Replacement interval
1 Filter of hydraulic tank 1 Every half years or every 1000
hours (whichever comes first)
2 Fan belt 1
3 Fuel hose (fuel tank - fuel pre-filter) 1
4 Fuel hose (fuel pre-filter - transfer pump) 1
5 Fuel hose (transfer pump - fuel filter) 1
6 Fuel hose (fuel filter - high pressure pump) 1
7 Fuel hose (return fuel tube) 1
8 Seals of steering cylinder 2
9 Steering hose (pump - priority valve) 1
10 Steering hose (priority valve - steering unit) 1
11 Steering hose (steering unit - steering 6 Every 2 years or every 4000
cylinder) hours (whichever comes first)
12 Brake hose (air storage tank - air brake 1
valve)
13 Brake hose (air storage tank - manual brake 1
valve)
14 Brake hose (air brake valve - air boosting 2
pump)
15 Brake hose (air boosting pump - T connector 2
of F/R driving axle)
16 Brake hose (air controlled cut-off valve - 1
parking brake chamber)
17 Brake hose (air controlled cut-off valve - 1
speed shift valve)
18 Brake hose (manual brake valve - T 1
connector of air-controlled cut-off valve)
19 Brake hose (T connector of manually 1
controlled brake valve - barometer)
20 Air storage tank 1 Every 3 years or every 6000
hours (whichever comes first)
25
Technical Specifications
The content of this chapter has significant impact toward correct use,
maintenance and service of this machine.
26
Application
This wheel loader is a large type of construction equipment mainly used to load bulk
material. Primary operations include: digging, flattening, pushing material, loading, and
dragging.
This wheel loader is designed to work in ordinary construction applications, and is not fit to
be used in flammable, explosive, or poison gas environments; or in environments with large
amounts of airborne debris.
Forbidden operation
1. Overloading
2. Use as a lifting crane.
3. Overhead digging
Notes
The operation, maintenance and safe operation procedures written in the manual only
apply when the machine is used as prescribed. If users don’t follow these procedure as
described, EVERUN Machinery Company assumes no responsibility for accidents safety
responsibility caused by users’ incorrect operation which will be taken on by users themselves.
27
Technical Specifications
Engine
Model WP6G125E22
Rated Power (12 hours) 92 kW
Rated Speed 2200 rpm
Maximum Torque 500 Nm
Rated Fuel Consumption ≤240 g/kWh
Fuel 0#Fuel
Fan Diameter 600mm
Transmission
Torque Converter
Type single three-element part
Conversion Ratio 3.0±0.05
Cooling Method Oil-cooled, pressurized circulation
28
Technical Specifications
Transmission
Type power shift spur constant mesh
Gear Shift four forward gears, two reverse gears
Transmission pump pressure 1.3-1.5Mpa
Braking System
service brake
Type single circuit air-over-oil four-wheel caliper disc brake
Brake disc diameter Φ450mm
Electrical system
System voltage 24V
29
Technical Specifications
Battery 6-QW-80
Bulb voltage 24V
Diesel start 24V Electrical start
30
Technical Specifications
31
Operation
Please carefully read and understand the manual content before you use
the machine in order to correctly operate the machine. Correct operation
has great significance for users to remain safe, have high working
efficiency, and extend service life.
32
Operation
33
Operation
34
Operation
35
Operation
the oil temperature is more than 110℃, the lamps, and position lamps.
index would be at the red warning range.
Attention: When the converter oil
THROTTLE PEDAL
(Reference No. 14)
thermometer indicates that the
The accelerator pedal is located at the
temperature is high, please stop the
front-right side of the seat. The engine is at
machine at the safe place that is easy for
the idle speed when the pedal is in the
repair, and then check the transmission oil
neutral position. The fuel supply and the
level. DO NOT restart, work or drive the
power output of the diesel engine increase
machine before eliminating the troubles.
when the accelerator pedal is pressed
PREHEATING INDICATOR down.
(Reference No. 8)
It is in the dash panel, help to start engine.
Power cut-off selection
switch
HIGH BEAM INDICATOR (Reference No. 15)
(Reference No. 9) You can choose to cut off the power or
not when you push the brake pedal.
It shows high beam lamp is on.
Spraying Switch
Right turn Indicator Light (Reference No. 16)
(Reference No. 10) Water can be spayed to wash the glass.
When the vehicle turns right, the right light
will illuminate. Wiper Switch
(Reference No. 17)
Engine fault indicator light Used to control motion of wiper.
(Reference No. 11)
Service Brake Pedal
The engine has some fault, the light will be (Reference No. 18)
The service brake pedal is placed on the
on.
left forward side of operator’s seat. Step
Transmission Oil Pressure down on the service brake pedal and the
Gauge wheel side brakes of both the front and
(Reference No.12) rear axles will be engaged. At the same
The transmission oil pressure gauge time, turn on the brake light switch so that
indicates the oil pressure of the gearbox. the brake light shines. Loosen the service
The normal working pressure should be at brake pedal and then free service brake.
the range of 1.3MPa to 1.5MPa. When braking system has failed
Attention: When the transmission oil immediately repair it to insure that the
pressure gauge indicates that the oil machine has sufficient brake ability.
pressure is low, please stop the machine at
a safe place that is easy for repair, and
HAZARD WARNING LIGHT
then check the gearbox and the oil level in SWITCH
the transmission, please add oil if there is (Reference No. 19)
not enough in the gearbox. DO NOT restart, When encountered with emergency
work or drive the machine before situation, open this light.
eliminating the troubles.
COMBINED SWITCHES
COMBINED SCREEN
LEVER
(Reference No.13) (Reference No. 20)
The switch can control front lamps, high The screen shows the speed of the engine,
and low beam, turning lamps and rear working hours, voltage, coolant
36
Operation
37
Operation
USB PORT
(serial number 31)
USB port can be used for charging, etc.
CIGAR LIGHTER
(serial number 32)
Push it and keep just for 2-3 seconds,
then pull it out.
38
Operation
39
Operation
Breaking-in a New Wheel fixing nuts of diesel engine, gear box, bolts
at front and rear axle articulation. If needed
Loader tighten them.
Proper Break-in is very important to 2. Check whether the tightness of fan belt,
prolong the life of the machine, to eliminate engine belt and AC compressor belt is
potential malfunctions, and to avoid fatal proper.
accidents. After purchasing the machine, 3. Check oil levels of the transmission,
the users need to operate and maintain the drive axle, and the diesel engine.
machine according to the rules of proper 4. Check the sealing condition of the
break-in described in this manual, and then hydraulic and brake systems.
the machine can be operated normally. 5. Check the connecting condition of
every control lever and throttle parts.
Break-in Rules: 6. Check the temperatures and
1. The machine must be broken in before connecting condition of every electric
100 hours of use. system, states of electric supply from
2. Start the engine and let it run at speed generator, lamps, lightening and steering
for 5 min. signals.
3. During break-in, forward gears I, II, III, Attention: When checking the oil level,
IV, reverse gears I, II should be used comply with certain operation rules.
conservatively.
4. Start the machine in idle speed, and
After the Break-in
speed it up gradually to the higher speed. 1. Check the tightening conditions of
Sudden start, speeding up, sharp steering bolts and nuts, especially the bolts of
and brake should be avoided except in diesel engine cylinder head, exhaust pipe
emergency condition. and front, rear axles, nuts for rims,
5. It will be better to load light things connecting bolts of driving shafts and fixing
during break-in and to avoid abrupt nuts of diesel engine, gear box, bolts at
operations. During break-in, the load front and rear axle articulation.
should be less than the 70% of the rated 2. Check whether or not the tightness of
load and the speed should be less than the fan belt, engine belt and AC compressor
70% of the rated speed. belt is proper.
6. Pay attention to the lubricating state of 3. Check the sealing condition of the
loader, replace or add the lubricant or hydraulic and brake systems.
grease at set intervals. 4. Replace the hydraulic oil in gearbox,
7. Check frequently the temperatures of lubrication in drive axle.
gearbox, torque converter, front and rear 5. Replace the filter for gearbox, engine
axles, hubs, brakes, and middle supporting oil, and replace the filter elements for fuel
axles and hydraulic oil, engine coolant, tank.
engine oil. Check out and fix the faults if 6. Clean the return filter elements in
there is overheating. hydraulic tank.
8. Check whether the bolts and nuts in Attention: When replacing the
each connecting part are loose. transmission oil for, lubricant for drive axle
and hydraulic oil for diesel engine, comply
After the first 8 running with the specified operation rules.
40
Operation
3. Check the hydraulic oil level. You should release the start switch
4. Check the sealing condition in the immediately if the machine cannot start.
water pipe, oil pipe and other parts. Wait more than 30 seconds to start again.
5. Check that there are no loose battery This is resulted from the characteristics of
terminals, and tighten if necessary. the starter and the battery, if the engine
6. Check that the tire pressure is normal. does not start after three consecutive times,
check out the reason. After removing the
Starting Engine trouble, wait at least three minutes to start
1. Check that there are no people or the engine.
obstacles in the surrounding area, and 13. After starting the machine, it should
there are no servicemen under the loader. remain in idle speed (750 20r/min) to
Except for operator in the cab, do not allow warm the machine, after the engine cooling
any person to stand anywhere on the water temperature up to 55°C, the engine
machine or sit in the cab. oil temperature up to 45°C, allow the
2. Turn on the battery switch. machine work in capacity load.
3. Follow the safety instructions when 14. Listen attentively whether or not the
stepping on and off the machine. engine works normally in the low speed,
4. Adjust the side mirror to a position, and whether or not the gearbox brings the
which gives the best view from the abnormal sound.
operator’s seat, and approaches to the 15. Inspect whether or not all gauges are
loader as near as possible. normal and whether or not each lighting
5. Close the doors of cab. attachment, indicating lamp, horn, wiper,
6. Inspect the safety belt and tightly and brake light can work normally.
secure it. Attention: Especially pay attention to the
7. Confirm the machine is in the neutral indicated value of the engine oil pressure,
gear position; if not, please move the lever it should not be lower than 0.1MPa (in idle
to the neutral gear position. speed condition). If it is lower than this
8. Check whether the control lever is on value, you should stop and inspect
the middle position. If not, please pull it to whether or not there are troubles with the
the middle position. engine.
9. Check whether the fan switch of 16. During winter, you should preheat the
air-conditioning system is in " natural fan" hydraulic oil. Pull the bucket control level
and the changeover switch on "OFF", if not, back and maintain for 4 - 5 minutes, at the
please turn it to the correct position. same time step on the accelerator pedal.
10. Insert the key and turn it once This will cause the plate of bucket to stop
clockwise to power up the entire vehicle. against the lift arm and cause hydraulic oil
Sound the horn, which means that the overflow. This will make the oil
machine will start and other personnel temperature rise more quickly.
cannot approach this machine. 17. Inspect whether the service brake, and
11. Check the fuel level in tank. the parking brake systems work normally.
12. Press accelerator pedal slightly, and 18. If there are no obstacles around the
continue to revolve the key clockwise to machine, you should slowly rotate the
the next position to turn on the engine and steering, observe whether there are
start the motor. In the normal condition it movements in right or left orientation.
can start in 10 seconds. When the machine
is starting, you should release your hand
Before Traveling
and let the starting electric lock return. 1. Operate the pilot valve control level,
Attention: Do not hold the key pull bucket control level back to rack-back
continuously for more than 15 seconds. position, and lift the lift arm to the carrying
41
Operation
position, namely the distance between the teeth or bucket cutting edge insert or sit on
bottom of bucket and ground is about the ground, forcing the machine to stop to
30-40cm. ensure security.
6. Inspect the union situation of every
gearshift. Drive the machine to an open
and flat area; integrate every gear
separately to inspect the situation of shift
gears.
42
Operation
machine is operated at high speed, sudden and put it in a dry garage. If it only can be
complete braking is not permitted except in put in open air, it should be put on concrete
urgent situations. This may result in an road and covered with a canvas.
accident or damage to the machine. Fill the fuel tank and lubricate the
moving pins, acting axles, and change the
Parking and Storage hydraulic oil.
Select Location Put the gearshift control lever to the
neutral position.
1. Park the machine in flat place, without
Place the hand brake lever in the
falling stones, loose dirt of flooding.
‘break’ position.
2. Stop the machine with the brake.
Put the bucket down to the ground, put
3. Put the gearshift control lever to the
the pilot valve control lever to the neutral
neutral position.
position.
4. Put the hand brake lever to ‘park’
Put every switch to neutral or ‘OFF’
position.
position and lock every door.
5. To operate pilot valve control lever, put
Apply a thin film of grease to hydraulic
the lift arm down to the ground and lower
cylinder exposure part.
the bucket.
Take out the battery from the machine.
6. To cool down every part evenly, keep
If the temperature is lower than 0ºC,
the engine running for 5min after parked.
add antifreeze to the engine, make sure
7. Turn the power key to ‘OFF’ position,
that the antifreeze can reach the engine
turnoff the engine, switch off the machine
parts and evaporate air conditioner. Or
power, pull out the key.
drain the water in the cooling system so
8. Put every switch to neutral or ‘OFF’
the water in the air condition will also
position.
evaporate.
9. Lock the doors, and then step down
Fix the front and rear with blocks or
using the ladders.
structure fixtures.
10. If the machine will be stopped for a
long time (overnight, for an example), open During Storage
the right charged battery cover and put the Once a month start the machine, run
power switch to ‘OFF’. every system, lubricate every moving pin,
11. In winter, if there is no antifreeze in the moving axle, and charge the batteries.
machine, open each water valve in the Before starting the machine, clean up
engine, drain all the antifreeze in the the grease on the rod of the hydraulic
cooling system and evaporate the air cylinders. Apply a thin film of grease again
conditioning system to prevent frozen parts after the operation.
of the machine. Apply a thin film of rust preventive oil to
12. Lock everything and take the keys with every rusty part.
you.
Attention: If applying the rust preventive
Attention: Keep the machine on the plane
oil indoors, open the door and window to
ground. Use chock near the tire to stop the
machine if the machine is located on a vent the poisoned air.
slope. After Storage
When ending the long-term storage, do the
If the machine will be stopped for a long
following work:
time, it should be located complying with
Change the lubrication in the engine,
the rules as follows:
gearbox, driving axle and the hydraulic oil
Before Long-Term Storage and antifreeze.
Clean all parts of the machine dry it Lubricate all the moving pins and
43
Operation
44
Operation
45
Operation
Scraping Work
Lift the arm, and turn the bucket forward
until the cutting edge is touching ground,
the angle between cutting edge and
ground should remain about 40 degrees,
Right Angle Loading
for a hard road, lift control lever, it should
be put into the floating position, and it WL is faced to material mass, after
should be put the middle position for soft shoveling material, drive along linear
material road, gearshift lever should be direction. And drive the dump truck
turned backward shift, step on accelerator between WL and material mass. This
pedal, to make machine backward, scrape method needs little time and shortens the
ground by cutting edge. work cycle time effectively.
46
Operation
47
Operation
48
Maintenance
49
Periodic Maintenance
The service hour meter determines the maintenance intervals or calendar intervals (daily,
weekly, monthly, etc.). Maintenance procedures are stated in this manual. EVERUN
requested maintenance should be done either by the service hour meter or the time interval,
whichever occurs first. Under extremely severe, dusty or wet operating conditions, more
frequent lubrication than is specified in the maintenance intervals schedule might be
necessary.
Other than daily maintenance schedules, four periodic maintenance points should be
considered: PM250: every 250 service hours, PM500: every 500 service hours, PM1000:
every 1000 service hours, and PM2000: every 2000 service hours
During maintenance, daily maintenance and initial maintenance of related components should
be strictly performed. Then, perform respective periodic maintenance according to specific
service hour.
50
Maintenance
Maintenance Schedule
51
Maintenance
52
Maintenance
53
Maintenance
Antifreeze Fluid
The main function of antifreeze fluid is to
decrease the condensation and increase
the boiling point of the coolant. The
antifreeze fluid is also needed when
operating the machine under the normal
temperature, because it can increase the
Fasten the radiator filler cap.
boiling point of the coolant, the additive
If filling coolant is needed every day,
included in the antifreeze fluid can also
reduce the framework corrosion and please check engine-cooling system for
cracks. leaks. If there is a leakage, follow through
with the necessary repair, then fill
The antifreeze fluid EVERUN recommends antifreeze fluid to corresponding level.
are listed as follows: Fill the Coolant
Prior to filling the coolant of a new engine,
Changcheng
or an engine with a clean cooling system,
Lowest ambient Antifreeze Fluid
choose the anti-freeze fluid density of the
Temperature (C) Model
coolant basing on the lowest local
-50 YF-3
temperature (10°C below the lowest local
-45 YF-2A
temperature is even better), calculate the
-40 YF-2B
anti-freeze fluid quantity by volume of the
-35 YF-2
total engine cooling system, the total
-25 YF-1
cooling system volume of this machine is
When replacing antifreeze fluid, use 30 liters.
premium antifreeze liquid and fill according Attention: Make sure not to use water as
to its use guide. Attention: Antifreeze fluid a coolant, this will caused corrosion
is highly flammable, do not use near an damage. If water is used as coolant, the
open flame. warranty to the cooling system is void.
Checking the Coolant Level Attention: Do not fill coolant then the
engine is at a high temperature, this could
The water radiator is located on the rear of
cause engine body damage. Wait until the
the machine.
engine temperature is below 50 C, and
Wait until the temperature of the
then continue.
engine coolant drops to below 50°C, then
Fill the Coolant as Follows:
remove the water radiator filler cap slowly
1. Turn on the power negative switch;
in order to relieve pressure. Any contact
Maintenance
insert the key into the ignition and turn water inlet pipe to the ON position (when in
clockwise to 1 gear position, turn on the the ON position, valve handle and the pipe
machine power; toggle the transfer switch are in the same direction).
of the air-conditioning system to the warm 3. Start engine, run the engine for 5
position. minutes at idle speed, then stop engine.
2. Manually turn the engine water inlet Turn the start switch to the first gear
pipe valve to the ON position (when in the position again, turn on the machine power;
ON position, valve handle and the pipe are toggle the transfer switch of the
in the same direction). air-conditioning system to the warm
3. Open the radiator filler cap, fill the position, make sure the electromagnetism
coolant slowly, until the coolant level is at water valve in open position.
the high level mark of the radiator tank, 4. Wait until the temperature of the
and maintain the level for ten minutes. engine coolant drops to below 50°C, then
Attention: When filling the coolant, the air remove the radiator filler cap slowly in
must be vented from the lines of the engine order to relieve pressure.
cooling system. 5. Open the drain valve under the
4. Keep the radiator filler cap open, start radiator and the drain valve of engine
engine, run engine for 5 minutes at low idle lubricating oil cooler, drain the coolant to a
speed, then another 5 minutes at high idle container.
speed, and enable the coolant temperature 6. After draining the coolant, close the
to go above 85 °C. drain valve under the radiator and drain
5. Check the coolant level again. If valve of engine lubricating oil cooler.
necessary, continue to fill coolant to the 7. Check all water pipes and the clamps
high water level mark of the surge tank. of the cooling system for damages, make
6. Check the sealing of the water radiator replacement if necessary. Check the
filler cap and change the filler cap if it is radiator for leaks, damage and dirt, clean
damaged. and repair if necessary.
Attention: If the coolant leakage is caused 8. Fill the engine cooling system with
by the user, for any subsequent losses cleaning fluid, which is mixed by the water
resulting from decreases in anti-freeze fluid and the sodium carbonate, the proportion
density, EVERUN will not take any of mixture is in every 23 liters of water add
responsibility. 0.5 liters sodium carbonate. The fluid level
should be at the engine normal fluid level,
Clean Cooling System and remain stable after ten minutes.
Every 2,000 service hours or two years Attention: When filling the cleaning fluid,
(whichever occurs first), completely the air must be vented from the lines of the
replace the coolant and clean cooling engine cooling system. During the entire
system. Before this, if the coolant becomes cooling system cleaning process, the
contaminated, the engine overheats or engine is running with the radiator filler cap
there are some bubbles in the radiator, open.
clean the cooling system. Use the following 9. Keep the radiator filler cap open, start
steps to clean cooling system: engine, when coolant temperature
1. Turn the power to the negative switch; increases to more than 80 C, run the
insert the key into start switch and turn engine for another 5 minutes.
clockwise to 1 gear position, turn on the 10. Stop the engine and drain cleaning
machine power; toggle the transfer switch fluid.
of the air-conditioning system to the warm 11. Fill the engine cooling system with
position. clean water to the normal level, and keep
2. Turn the manual valve of the engine for ten minutes. Keep the water radiator
55
Maintenance
filler cap open, start engine, when coolant If the diesel engine generates black smoke
temperature increases to more than 80 C, or power decreases, the air filter may be
run the engine for another 5 minutes. plugged and need maintenance.
12. Stop the engine, drain out the water. If
the water being drained is still dirty, the From the indicator set in the air filter case,
cooling system must be cleaned until the you can see if the elements need replacing
water is clean. or cleaning.
Warning: The engine coolant is poisonous,
do not drink, please handle it according to Use the following procedure:
the local relevant laws and regulations.
56
Maintenance
57
Maintenance
58
Maintenance
oil into a container and replace oil filter. surface just contact mounting base, fasten
Fasten the plug; fill the clean engine oil again the oil filter to the specified position
until the oil level reaches the "H" scale on with a belt wrench.
the dipstick. Run the engine at idle speed, Attention: Tightening too much can
check the oil filter and drain plug for leaks. damage the thread or the sealing of the oil
Stop the engine, wait for about 10 minutes, filter.
and let the oil fully drain into the engine oil
pan. Check the engine oil level once more, Transmission
if the oil is insufficient, fill oil to the oil
Transmission Oil
dipstick "H" scale. Attention: Within 15
seconds after engine starts, the engine oil Check Oil Level
pressure gauge should have the reading. If Transmission filling port is located inside
there is no reading, stop the engine the rear frame left side plate. Examine
immediately in order to avoid damaging transmission oil level routinely according to
engine, check engine oil level for correct the regulations in order to guarantee the oil
position. quantity. Use the oil dipstick on filler cap of
transmission to check the oil level (oil level
Replace the Engine Oil Filter
should be on the middle of oil dipstick
1. Clean the peripheral region and the scale of transmission when the machine is
filter-mounting base. running.)
Use following steps to check
transmission oil level:
1. Check the cold oil level before starting
cold machines. The purpose for that is to
have the enough oil when the machine
starts. It is more important when the WL is
parked for a long time.
2. The level should be on the upper
position of the oil dipstick before starting
2. Remove the oil filter with the belt the engine. If the level is on the lower
wrench. position of the oil dipstick, add the enough
3. Clean the contact surface of the oil in order to start the machine.
mounting base gasket with the clean cloth. 3. Park the machine on the flat field. The
If the used O-ring sticks on the mounting transmission control knob should be in the
base, remove it. neutral position. Engage the parking brake.
Mount the lock pin of frame to prevent the
machine from moving and rotating. Run
the engine at idle speed.
4. Start and run the engine for 5 minutes.
The transmission oil level should be near
the middle position of oil the dipstick. If the
oil level is higher, drain some oil by loosing
the drain plug on the bottom of
transmission. If the oil level is lower, add
transmission oil.
Attention: High or low transmission oil
4. Install a new O-ring. level may damage transmission. Keep the
5. Install the oil filter on the mounting transmission oil level in the correct position.
base, tighten the oil filter by hand till gasket Attention: Pay attention to the cleanliness
59
Maintenance
when checking transmission oil level and should be near the middle position of oil
replacing the transmission oil. Avoid dirt dipstick. If oil level is higher, drain some oil
from entering into the transmission so it by loosing the drain plug on the bottom of
doesn’t damage it. transmission. If the oil level is lower, add
transmission oil.
Replacing Transmission Oil
10. Turn the filler cap clockwise to fasten.
On one side, the transmission oil is
used as a service fluid for the hydraulic Replace Transmission
torque converter of the transmission Suction Screen
hydraulic system. On the other side, it is
1. Drain the oil according to the
used for cooling and lubricating the torque
transmission oil replacement method.
converter and transmission components.
2. Loosen the suction pan bolts and
So the transmission oil type should match
remove the suction pan. Take out the
the requirement. Replace the transmission
suction screen.
oil according to the specified oil change
3. Install the new suction screen and
intervals. Otherwise, the service life of
tighten the suction pan bolts.
transmission will be shortened.
4. Fill the oil according to the
Use following steps to replace
transmission oil replacement method.
transmission oil:
Attention: Pay attention to cover the
1. Start the engine and leave it running
parking brake before replacing the
for a few hours to allow the dirt, metal and
transmission oil. This will prevent the
sediment to float in the fluid.
parking brake friction discs from getting
2. Park the machine on a flat surface.
saturated with oil, which will reduce the
When the transmission control knob is in
braking performance.
the neutral position, engage the parking
brake. Mount the lock pin on frame to Replace the Transmission
prevent the machine moving and rotating. Filter Element
3. Stop the engine, unscrew the drain
plug located at the bottom of transmission, 1. Clean the peripheral region and the
and drain the oil into a container. transmission filter-mounting base.
4. Unscrew the drain plug under the 2. Remove the transmission filter housing
torque converter; drain the oil into a with the belt wrench, and remove the
container. Warning: The transmission oil element.
temperature is still high. So wear protective
equipment and operate carefully to avoid
personal injury.
5. Use a magnet to clean the iron chips
attached the drain plug and the iron chips
in the transmission.
6. Install the drain plug of transmission,
and drain plug and seals under the oil
cooler of torque converter.
3. Clean the contact surface of the
7. Install the drain plug and seals under
mounting base gasket with the clean cloth,
the torque converter.
8. Unscrew the filler cap of transmission. and install a new element.
Fill the clean transmission oil through filling 4. Install the transmission filter housing.
hose. The transmission oil level should be
at the highest level.
9. Start and run the engine for 5 minutes.
Observe that the transmission oil level
60
Maintenance
61
Maintenance
Check Hydraulic Oil Level tank under the filling port. Use diesel to
The hydraulic tank is located on the left wash the bottom of hydraulic oil tank and
side of cab. There is a level gauge to its four sides and dry it with a clean cloth.
indicate the hydraulic oil level on the front 8. Mount the drain plug of hydraulic tank,
part of hydraulic tank. When checking the return filter, cover, filling screen, tank
hydraulic oil level, park the machine on a cleaning flange port and the inlet pipe.
flat surface, place the bucket on the ground, 9. Fill the clean hydraulic oil from the
and make sure the front frame and rear filling port of hydraulic tank to allow the oil
frame are straight without an angle. At this level reach the upper scale of hydraulic
time, the hydraulic oil level should reach level gauge. Screw on the filler cap.
2/3 of the level gauge. 10. Remove the lock pin of frame and start
the engine. Operate the working valve
Replace the Hydraulic Oil control lever. Raise and lower the boom,
Replace the hydraulic oil every 2000 dump and rack back the bucket, and steer
service hours or every year. The method is left and right at the largest possible angle
as follows: twice or three times to make the hydraulic
1. Clean the dirt in the bucket. Park the oil fill the cylinder and lines. Then, run the
machine on a flat surface and put the engine for 5 minutes at the idle speed to
transmission control lever in the neutral vent the air from the system.
position. Engage parking brake and mount 11. Stop the engine and open the filler
the lock pin of frame. Start the engine and cover of hydraulic tank. Add the clean
run it for 10 minutes at idle speed. hydraulic oil to 2/3 scale of hydraulic tank
Repeatedly raise the boom, lower the level gauge.
boom, dump and rack back bucket etc. Replace Heavily Polluted Hydraulic Oil
2. Finally, raise the boom to the highest
position and pull the bucket to the furthest If the operating condition is bad or the
back position. Stop the engine. hydraulic oil is seriously polluted, such as
3. Push the bucket control knob of being black, or foamy. Please immediately
working valve forward. Dump the bucket replace the hydraulic oil.
under the gravity effect and drain the fluid 1. Clean the dirt from the bucket. Park
of tilt cylinder. When the bucket is tilted at the machine on a flat field and put the
the required position, push the boom transmission control lever in the neutral
control lever of working valve forward. position. Pull the parking brake lever and
Lower the boom under gravity effect and mount the lock pin of the frame. Start the
drain the oil of boom cylinder. engine and run it for 10 minutes at the idle
4. Clean the drain port under the speed. Repeatedly raise and lower the
hydraulic tank. Unscrew the drain plug; boom, dump and rack back the bucket etc.
drain the hydraulic oil into a container. At 2. Finally, raise the boom to the highest
the same time, unscrew the filler cap and position and backward the bucket to the
quicken the drain process. largest position. Stop the engine.
5. Remove the inlet pipe of hydraulic oil 3. Push forward the bucket control knob.
tank and drain the hydraulic oil left in the oil Dump the bucket under the gravity effect
tank. and drain the fluid of the tilt cylinder. When
6. Remove the hydraulic return filter the bucket is tilted at the required position,
element from the hydraulic tank and push the boom control lever forward.
replace it with a new filter element. Open Lower the boom under gravity effect and
the filler cap and take off the filling screen drain the oil of boom cylinder.
to wash it. 4. Clean the drain port under the
7. Remove the cleaning flange disc of the hydraulic tank. Unscrew the drain plug;
drain the hydraulic oil into a container. At
62
Maintenance
the same time, unscrew the filler cap and related safety regulations. It is
quicken the drain process. recommended to fill tire with N2. If the tire
5. Remove one end of all pipes to drain has original air, it is suggested that
the remained fluid of steering cylinder, nitrogen is used to adjust the pressure.
hydraulic oil cooler and pipes. The nitrogen can be mixed with air.
6. After draining the oil, mount the drain Inflating tires with nitrogen gas can prevent
port plug under the hydraulic tank and all the tires from exploding because of N2’s
pipes removed. inflammability. The nitrogen is helpful to
7. Open the filler cap of hydraulic tank preventing oxidation, rubber aging and rim
and fill the clean hydraulic fluid to the lower parts corrosion. Check and adjust the tire
mark of level gauge. inflation pressure after the tire cools down.
8. Replace the oil again according to the The tire pressure is the same for both
‘Replace the Hydraulic Oil’ section nitrogen and air filled tires. EVERUN
mentioned above. And replace the return suggests choosing the tire inflation
filter element. Clean filling screen and pressure according to application:
hydraulic tank. Tire Spec.:20.5-25
Tire Inflation Pressure (MPa)
Front Wheel: 0.343
Replace the Return Filter Rear Wheel: 0.294
Element of Hydraulic Tank Attention: If the machine travels for a long
1. Raise the boom and at the same time distance and at high speed, park the
put the bucket in the rack back position. machine for 30 minutes every 45 km in
Use the support against the boom to order for the tire to cool down.
prevent the work tool falling. Position the
work tool control lever in the neutral
Bucket Limitation Device
position. Apply parking brake and stop the The machine has a bucket automatic
engine. leveling function. Operate the bucket
2. Unscrew the mounting bolts of filter automatic leveling function reasonably to
cover on the side of tank and remove the increase the production effectively.
cover. The cover might come off because
of the spring. When taking off the bolts, the Adjust the Bucket’s
cover should be pressed down. Automatic Leveling Device
3. Take off the spring, then remove filter 1. Park the machine on a flat surface. Put
element.
the transmission control knob in the neutral
4. Mount the new filter element, spring
position. Operate the control knob of
and cover.
5. When installing the cover bolts, press working valve to make the bucket level to
the cover and tighten the bolts evenly. the ground. Pull the parking brake lever
6. Check the oil level and add the oil if and stop the engine. Install the lock pin to
necessary. the frame.
7. Check the filter cover for leaks. 2. Loosen the arrow bolt. Move the arrow
63
Maintenance
Parking Brake
The parking brake should be often
checked to guarantee parking safety and
the braking performance of emergency
braking. Step 2: Take out the fixed pin of friction
1. Adjust the tire pressure to the disc.
regulated value. The bucket is leveled at
about 300mm away from ground. And
confirm that the service break works well.
2. Start the engine and allow the machine
to face a slope of 18% (angle is
10°12′) .The road should be flat and dry. Step 3: Lightly take off the friction disc.
3. Step on the service brake pedal and
stop the machine. Put the transmission
control knob in the neutral position and
then stop the engine.
4. Pull the parking lever button, loose the
service brake pedal slowly and check if the
machine moves or not.
Step 4: Replace it with a new friction disc.
Service brake performance
Ensure the machine’s parking brake
system operate normally before checking
the service brake performance in order to
apply the parking brake to stop the
machine in an emergency condition. The
machine travels at 20km/h at the flat, Step 5: Punch the fixed pin lightly.
straight and dry concrete road. Step on the
service brake pedal to brake fully. After the
machine stops, push the transmission
control knob to the neutral position. Pull the
lever of parking brake and then loosen the
service brake pedal. Check the machine
braking distance, which should not be Step 6: Tighten the retaining screw of pin.
more than 9 m when the machine travels at
32km/h. Break the machine quickly and
ensure that the machine does not run off
track.
64
Maintenance
Step 2: Pull out the friction disc slowly after Machine Lubrication Service
taking out the pin.
and Maintenance
In order to decrease the additional
lubrication necessary, to decrease the
failure rate, to improve the service and
maintenance of the machine, to increase
the machine life and reliability, and
especially to correctly complete
maintenance lubrication process, please
complete maintenance strictly according to
Step 4: Punch the pin lightly and tighten the following procedure:
the retaining screw of pin.
Reference points for
lubrication addition:
65
Maintenance
At the junction of the soft (hard) tubes After the Articulated Boom assembly Pin
and the lubrication nozzel, add lubrication
using the handle until the oil begins to seep
out.
For daily lubrication maintenance, refer
to the following pictures
Swing Stand and Rear Frame Joint
66
Maintenance
67
Maintenance
68
Maintenance
external oxidized cover before recharging. room temperature. Reduce the charging
current to a half and continue to charge.
When Charging
1. Wear the safety glasses.
2. Keep vent when charging and charge
at the normal temperature.
3. No smoking and avoid fire when
charging.
4. After charging, first connect the
positive wire when connecting the wire.
After charging, first disconnect the
negative wire.
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Maintenance
Fluid Specification
Use the following regulated specification and varieties to ensure the machine normally
operate when adding and replacing the different kinds of oil.
Component
Ambient Temp. Specification Remark
Used
Engine -40℃ API CH-4 , CG-4 , Recommended oil:
CF-4/SJ,SAE5W-40 Please contact local
-15℃~50℃ API CH-4, CG-4,
agency or EVERUN
CF-4/SJ,SAE15W-40
-20℃~40℃ API CG-4 , CF-4 , dealer. Use
CF/SJ,SAE10W-30 EVERUN appointed
-15℃~50℃ API CF-4 , CF/SG , oil.
SAE15W-40
Transmission -5℃~40℃ PTF
For more details, please consult local
dealers of oil.
Axle -40℃ SAE75W-90 , API
GL-5
-20℃~40℃ SAE85W-90, API
GL-5 or SAE80W-90,
API GL-5
Hydraulic -5℃~40℃ ISOVG46, L-HM46
System -26℃~40℃ ISOVG46, L-HV46
-40℃ SAE5W-40
Booster SAEJ703 DOT4 or
DOT3 Break Fluid
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Failure Causes and Repair
Engine system
Refer to the XC6110 engine manual for specific troubleshooting details.
Transmission
Transmission oil pressure is too low in every gear
Problem Solution
1. Transmission oil level is too low 1. Fill transmission oil level to the proper
level
2. Oil leakage in main pipe lines 2. Check and repair
3. Transmission oil suction filter screen is 3. Clean or replace the filter screen
blocked
4. Transmission oil pump is damaged 4. Repair or replace the pump
5. Improper pressure valve adjustment 5. Readjust the valve setting
Brake System
Insufficient service brake force
1. Brake system oil leakage 1. Replace the sealing parts
2. Air present in the brake system hydraulic 2. Bleed the air out of the brake system
brake lines hydraulic brake lines
3. Insufficient pressure in the air lines 3. Check the sealing performance in the air
compressor, storage tank, and lines
4. Worn booster cup 4. Change the cup
5. Oil on friction disc 5. Investigate root cause and determine
corrective action
6. High abrasion of the friction disc 6. Replace with a new friction disc
73
Failure Causes and Repair
74
Failure Causes and Repair
Failure in resetting
1. Deformation of the multi-way valve reset 1. Replace
spring
2. Dirt between multi-way valve rods 2. Clean the parts
Steering System
Heavy Steering
Normal steering when the steering is slow, heavy steering when the steering is fast
1. Insufficient oil supply from the pump 1. Repair and replace oil pump
2. Inflexible operation of the priority valve 2. Identify potential solutions and/or replace
spool the priority valve
3. Priority valve control pressure is too low 3. Adjust the control pressure
4. Air present in the oil lines between the 4. Turn the steering wheel until the tires are
priority valve and steering gear at its maximum steering position, then
continue to turn the steering wheel, forcing
the safety valve open, thereby venting the air
out of the steering system
75
Failure Causes and Repair
Foam in the oil, abnormal sound coming from the oil, oil cylinders sometimes move and
stop while the steering wheel is being turned
1. Air in the system 1. Check oil level and add oil to the required
level. Check whether there is air leakage in
the suction oil and resolve venting the air out
of the system
Heavy steering when the throttle is low, normal steering when the throttle is high
1. Low pump volume efficiency 1. Replace oil pump
2. Large clearance between the priority 2. Replace the priority valve
valve spool and body
No tactile operator feedback
Operation of the steering wheel is still light when the tires are at there limited steering
position
1. Pressure setting of the bidirectional 1. Re-adjust the bidirectional cushion valve
cushion valve on the oil port of the steering starting pressure, which should not less than
gear is lower than that of the steering safety 1.25 times of the steering safety valve set
valve pressure
2. Severe wear and excessive clearance 2. Replace the worn parts or the steering
between the valve body, sleeve, and spool, or gear
between the stator and rotor pair of steering
gear
Steering failure
Steering wheel cannot return to the neutral position. The pressure drop increases in the
neutral position
1. Spring plates are broken 1. Replace the broken spring plates
76
Failure Causes and Repair
Electric System
Generator does not generate electricity, or the voltage is low
1. Drive belt is slipping 1. Adjust the belt
2. Connector contains oily dirt or is worn 2. Clean the oily dirt off using a clean cloth
moistened with gasoline or grind it using fine
abrasive paper
3. Bad contact between electric brush and 3. Check and repair
connector
4. Excitation coil is open circuit 4. Inspect the outer magnetic field and
check the excitation loop with a light bulb
5. Residual magnetism disappears 5. Magnetically charge or replace with a
new generator
Generator is overheating
1. High voltage regulator voltage 1. Adjust regulator voltage
2. Worn bearings or less lubrication 2. Replace bearings or add lubrication oil
3. Short circuit in connector or armature coil 3. Disassemble, repair or replace
77
Failure Causes and Repair
4. Compressor does not work. When the 4. Repair or replace with the compressor
engine speed varies, only slight changes are valve plate
observed between low and high-pressure
readings
5. Cooling system lines are broken, or 5. Repair cooling system lines, inspect
refrigerant is leaking, Low and high pressure system for leakage, evacuate lines, and fill
readings are zero with Freon
6. Dryer of the receiver or expansion valve is 6. Disassemble, repair or replace
blocked
78
Failure Causes and Repair
Increasing noise
1. Drive belt is loose or worn 1. Tighten belt or replace with a new belt
2. Compressor is loose on its mounting 2. Tighten bracket mounting screws
bracket
3. Blower motor is loose or worn 3. Repair or replace the motor
4. Slip of the electromagnetic clutch is 4. Disassemble, repair or replace
resulting in noise
5. Inner parts of the compressor are worn 5. Repair or replace the compressor
79