Contents

Foreword ....................................................................................................................................... II
Safety Cautions ........................................................................................................................... III
Chapter I Safety.......................................................................................................................... 4
1 Contents of Safety Signs .................................................................................................. 4
2 Safety Rules ..................................................................................................................... 7
3 Safe Operation ................................................................................................................. 9
4 Safe Startup ................................................................................................................... 13
5 Safe Driving.................................................................................................................... 16
6 Safe Operation ............................................................................................................... 21
7 Safe Parking................................................................................................................... 25
8 Safety Inspection and Maintenance ............................................................................... 27
9 Safe Transport ............................................................................................................... 37
Chapter II Product Introduction .............................................................................................. 40
1 Appearance and Names of Parts ................................................................................... 40
2 Figure of Overall Dimension ........................................................................................... 41
3 Composition and Meaning of Product Model.................................................................. 42
4 Label .............................................................................................................................. 42
5 Applications .................................................................................................................... 43
6 Requirements for Working Environment......................................................................... 43
7 Characteristics ............................................................................................................... 43
8 Technical Performance and Parameters ........................................................................ 45
Chapter III Operation ............................................................................................................... 46
1 Be Familiar with the Machine ......................................................................................... 46
2 Running-in of New Loader.............................................................................................. 54
3 Operation of the Loader ................................................................................................. 55
Chapter IV Maintenance .......................................................................................................... 79
1 Maintenance Guideline .................................................................................................. 79
2 Maintenance Rules ........................................................................................................ 81
3 Maintenance Details ....................................................................................................... 86
Chapter Ⅴ System schematic ................................................................................................. 93

I
 Foreword
Welcome to use the wheel loader from ENSIGN. The company's products are manufactured in
accordance with《 GBT 35199-2017 Technical Conditions for Earth-moving Machinery Wheel Loaders》
and 《GBT 35198-2017 Test Methods for Earth-moving Machinery Wheel Loaders.》

This manual can guide you to correctly operate and maintain the machine. It shall be put in the cab,
and read by all related personnel whenever necessary. If the manual gets unreadable due to loss or
damage, please contact us or our dealer(s).

If you sell the machine, please transfer the manual to the new user(s).

Parameters, figures and contents related to this manual are applicable to the standard model. For
modified product, please consult us or refer to related information.

Please follow the manual of working tools for removal, replacement and use of them.

Besides, please carefully read technical documents on operation and maintenance of associated parts
(e.g. diesel engine).

We always make efforts to improve our products to be more advanced and reliable. We reserve the
right to such modifications, but do not promise to incorporate such modifications into delivered products.
We also reserve the right to modify data, machine and maintenance instructions. Changes of design
and instructions for operation and maintenance will be put into practice without prior notice. Please
consult us for the latest information about the machine or any doubt about this manual.

If deficiencies are found during the use of our products, please timely let us know your feedback
information for us to continuously improve product quality and better meet your demand.

Copy or reprint of this manual is prohibited without ENSIGN’s written approval.

Warning

 Incorrect operation, maintenance and repair are hazardous, which may cause injury or
death.

 Before operation or maintenance, the operator shall carefully read this manual. Do not
operate, maintain or repair the machine without reading and comprehending this
manual.

 Operation specifications and precautions specified in this manual are only applicable
to the specified applications of the machine. For the operation not specified but not
prohibited, make sure that the operation is harmless to yourself and anyone else.

 Under no circumstance is the operation or behavior prohibited in this manual allowed.

II
 Safety Cautions
Operators shall learn and obey current national and local safety regulations. If there is no such
regulation, safety instructions in this manual shall be applicable.

Most of the accidents are caused due to non-compliance with the regulations on machine operation
and maintenance. Please read, comprehend and follow all warnings and cautions in this manual and
on the machine before operation and maintenance to avoid accidents.

Safety measures are described in details in Chapter 1 “Safety”.

Since it is impossible to predict all potential hazards, the descriptions on safety in this manual and on
the machine may not cover all safety precautions. If a procedure or operation not recommended in this
manual is done, you must make sure everyone is safe and there is no damage to the machine. Please
consult us or our dealer(s) in case of failure to make sure the safety of some operations.

Precautionary measures for operation and maintenance in this manual are only applicable to the
specified applications of the machine. If the machine is used beyond the scope of service specified, we
will not shoulder any safety liability. Safety liability incurred by such operations shall be fully shouldered
by the user and the operator.

Under no circumstance shall the operations prohibited in this manual be performed.

The signs below are for identifying safety information in this manual.

Hazard -There will be hazardous consequence which will cause severe injury or death if

failed to avoid. This sign also indicates possibility of severe damage to the machine if failed to
avoid.

Warning -Consequences of potential hazard may cause severe injury or death if failed to

avoid. This sign also indicates possibility of severe damage to the machine if failed to avoid.

Caution -Mild or moderate injury may be caused if failed to avoid. This sign also indicates

possibility of damage to the machine or shortened service life of the machine if failed to avoid.

III
 Chapter I
Read through and implement all safety cautions,
otherwise, severe injury or death may be caused.
1 Contents of Safety Signs
1 Operation caution sign
On instrument desk
Cautions
 The driver must have a formal license, and
carry out operation and maintenance as
specified in the operation and maintenance
manual.
 Before startup, inspection and preparations
shall be done as specified.
 Before starting the loader or drive it
backwards, the driver shall observe the
surroundings to ensure there is no
pedestrian or obstacle, and honk the horn
to give a signal.
 Engine water temperature, oil temperature
and air pressure must be respectively
higher than 55℃, 45℃ and 0.45MPa,
otherwise, the engine shall not be under
high-speed or full-load running. Engine
water temperature shall not exceed 95℃,
and oil temperature shall not exceed 120℃.
Safety
Warning
2 Driving caution sign
At left rear of the cab
Cautions
 No one is allowed to get on or off during
running. Sitting on any part is not allowed
other than in the cab.
 The bucket or other attachments shall be
loaded as evenly as possible without
deflection to one side.
 Running at high speed after loading is
strictly prohibited.
 The loader must be decelerated for
turning. Sudden turn or brake is
prohibited.
 Do not drive at high speed on rainy or
snowy days and avoid turning on the
slope.
 Pay attention to instrument reading and do
not park close to fire source.
 Fully pull up the hand brake and chock the
wheel with triangular wood when parking
on a ramp.
 Avoid overhaul and maintenance during
running of the engine.
4
3 Start key reset sign 4 Lifting sign
Above start switch At lifting position of front/rear frame

Put the key to neutral

position after parking

5 Sign of no standing below booms 6 Sign of no standing at joint shaft

At both sides of booms At joint shaft of front and rear frames

7 Escape sign 8 Extinguisher sign

At right side in the cab At left rear side in the cab

Fire extinguisher

5
9 Sign of hydraulic oil tank 10 Sign of fuel oil tank
At one side of hydraulic oil tank At one side of fuel oil tank

11 Parking safety sign 12 Warning sign of safety distance

(Do not touch the machine until all parts At both sides of engine hood
are safely stopped.)
At both sides of engine hood

13 Air cylinder safety sign

At one side of air cylinder

6
2 Safety Rules
2.1 Safety regulations
 Only those specially trained and with
corresponding qualification are allowed to
operate and maintain this machine.
 Well know and follow all safety regulations,
cautions and instructions for operating and
maintaining the machine.

 Adjust operations according to physical

conditions and do not operate in case of poor
health. Do not operate the machine if you are
under the weather, or feel sleepy after taking
medicine or after you drink alcohol. It is
possible that you make incorrect judgment
and accident occurs under these
circumstances.

 Make sure that all persons understand the

hand signals used when working with other
operators or persons in charge of site traffic
guidance.

 Follow all safety related rules.

2.2 Safety devices

 Make sure all hoods and protective covers are at correct positions, and repair damaged parts.

 Correctly use safety devices such as parking brake lever, safety belt (if installed).

 Do not remove any safety device and keep it in good state.

 Incorrect use of safety device might cause severe injury or death.

7
2.3 Safety protection articles
 Personal protection articles shall be
determined according to specific working
conditions during machine operation or
maintenance, such as safety helmet made of
hard material, safety glasses, safety footwear, Certificate of Training
Completion
reflective vest, faceshield, earplug and thick
gloves.
 Do wear safety glasses, safety helmet made
of hard material and thick gloves when
throwing metal chips and tiny foreign
materials, especially when clearing away
foreign materials in air filter with compressed
air. Moreover, inspect and confirm there is no
person close to the working machine.
 Do not wear loose clothes or jewelry, nor have
long loose hair to avoid injury or death due to
be caught by operating lever or moving parts.

 Do not wear clothes with heavy oil dirt to avoid ignition.

 Compressed air may cause injury or death. Wear faceshields, protective clothes and safety
shoes when cleaning with compressed air. Maximum pressure of compressed air for cleaning
shall be lower than 0.3MPa.

 All protection appliances shall be inspected before use to verify they are of normal functions.

2.4 Unauthorized modification

 Any modification unauthorized by ENSIGN may cause hazards.

 Please consult ENSIGN or the designated dealer(s) before any modification of the machine.

 ENSIGN will not shoulder any liability for any damage due to unauthorized modification.

8
3 Safe Operation
3.1 Be familiar with the machine
 Learn about associated information, machine
structure, operation and maintenance, as well as
positions and functions of buttons, handles,
instruments and alarm devices of the machine.

 Learn about rules and regulations on operations,

and comprehend the guider’s hand signals.
 Immediately rub away the grease attached at or
nearby operating position to eliminate slipping
hazard.

 Accurately perform all inspections before and

after operations, for example, inspect whether
all safety protection devices are in safe state and
whether tyres are worn and air pressure of tyres
is normal. Ignorance of oil leakage, water
leakage, air leakage, deformation, looseness
and abnormal sound may cause faults or serious
accidents. Therefore, the machine must be
subject to regular inspection.

3.2 When leaving the seat, the driver shall

 Make sure that parking brake lever is reliably placed at locked position.

 Completely lower the working devices to the ground, lay the bucket flat, put the shift control
lever and the working devices lever at neutral position, shut down the engine, turn off the start
switch, and place stop dog under front and rear tyres as necessary.

9
  Do lock the machine, and well keep the key.

3.3 To get on and get off

 Inspect handrails or ladders before get on or
off, and wipe clean any oil stain, lubricant or
sludge to avoid slip. Besides, damaged parts
shall be repaired and loose bolts shall be
tightened.

 Do not jump on or off. Do not get on or off during movement of the machine.
 To get on or off, you shall face the machine,
hold the handrail and tread on the ladder to
keep three-point contact at least (two feet and
one hand or two hands and one foot) to
maintain your body stable.
 Do not grasp any operating lever when you get
on or off.
 Do not get on from the ladder behind the
machine or get off from the tyre beside the cab.
 Do not climb on or off with tools or other
objects in hands. Required tool shall be lifted
to the operation platform with ropes.
3.4 Fire prevention

Fuel oil and lubricating oil for the engine, hydraulic oil for the hydraulic system, hydraulic
transmission oil and gear oil for the transmission system, brake fluid for the braking system and
antifreeze for the dissipation system are all flammable. Therefore, smoke and fire close to the
machine are very hazardous. Especially for fuel oil, more attention shall be paid to fire prevention.
Thus, attention must be paid to the issues below.

10
  Keep fire source far away from the
flammable liquids mentioned above.
 Add the flammable liquids mentioned above
in ventilated places, with the engine off, and
prohibit smoking and approach to naked
flame during oil filling.
 Tighten covers of storage tanks of all the
flammable liquids mentioned above.

 Put the flammable liquids mentioned above in marked containers, put the containers at certain
place for storage by classification, and prevent anyone other than staffs from use of them.

 Do not carry out electric welding or flame cutting for the pipelines with flammable liquids. Clean
with nonflammable liquids before electric welding or flame cutting.

 Completely clear away flammables such as saw dust, leaf and paper on the engine and the
brake caliper, remove fuel oil, lubricating oil and other fragments on the machine and make
sure there’s no oilcloth or any other flammable.

 Take special care when the machine works if exhaust outlet of the muffler is close to flammable
places such as withered grass and paper.

 Pay attention to the environment nearby the machine when parking it, with special preference
to the places without flammables close to high-temperature parts like mufflers.

 Inspect fuel oil, lubricating oil and hydraulic oil against leakage. Immediately repair or replace
the damaged parts in case of leakage. Do not operate again before cleaning after repair.

 Keep the accumulator away from smoke and

fire, and maintain and use it in strict
accordance with product manual since
explosive gas may be produced nearby the
accumulator.

 Inspect dark places and do not use naked flame (match, lighter).

 Get fire extinguishers ready, know how to use them, inspect and maintain as per operating
instructions.

 Do not operate the machine nearby naked flame.

 Prohibit short circuit.

3.5 Safety measures for operations under high temperature

 Engine coolant, engine oil and hydraulic oil are under high temperature and high pressure just
after stop of working. At this time, taking down the cover to drain oil or water or to replace the

11
 filter may cause serious scalding. Such operations shall be done according to specified
procedures after temperature drops.

 The engine shall be shut down before

radiator cover is taken down. After cooling of
the radiator, slowly loosen the cover to
release the high-pressure gas inside and
then take down the cover.

3.6 Driving on the road

 The machine is equipped with the working device which may block the vision ahead. Besides,
the weight of cargos concentrates on front wheels. Therefore, attentions shall be paid to the
front and rear stability when the machine drives on the road.

 Observe whether there’s dense fog, smoke

and dust or sandstorm that may obstruct the
vision.
 Get to know the work site in advance,
observe road conditions to verify whether
there are holes, obstacles, mud, ice or snow.

 Completely comprehend all operation requirements as well as the meanings of signal flags,
signals and signs.

3.7 Prevention of run-over injury or cut-off

 Do not enter or put hand, arm or any other
part of your body between movable parts, for
example, between working device and oil
cylinder, between body and working device,
joint shaft of front frame and rear frame. The
space at link mechanism increases or
decreases with the movement of working
device, so access into such space will
probably lead to severe accidents or injuries.
Do stop the engine and lock the front frame
and rear frame in case of need for access
between movable parts.

12
  Correctly support the equipment or
accessories in case of working below the
machine. Do not support by hydraulic
cylinder. Movement of the operation
mechanism or leakage of the hydraulic
pipeline may cause fall of accessories and
hazards.
 Do not make any adjustment during machine
running or engine start unless otherwise
specified.
 Keep off all rotating and moving parts.

 Keep fan blade of the engine free of foreign materials. Fan blade may throw out or cut off tools
or foreign materials that fall into or are pushed into it.

 Inspection or maintenance with the engine active is very hazardous and not allowable in
principle.

3.8 Cautions for working machines and tools

 Please read operating manuals related to working machines and tools and related information
in this manual when installing and using standby working machines and tools.

 Do not use working machines or tools unapproved by ENSIGN or its designated dealer(s). Use
of unapproved working machines or tools may cause safety problem which is adverse to
normal operation and service life of the machine.

 ENSIGN will not shoulder any liability for loss, accidents and damage of the machine due to
use of working machines and tools unapproved.

4 Safe Startup
4.1 Before machine startup

4.1.1 Safety at working site

 Carefully inspect for any abnormality of the surroundings that may cause hazards before
machine startup.

 Inspect terrain, soil property and ground conditions of the working site and determine the best
and safest working method. Roughly level and compact the ground before commencement of
working. Sprinkle water before commencement of working if there’s heavy dust and sand at
the site.

 Assign special person for traffic guidance, put up fences and paste the sign “No Admittance”
for working on the highway to guarantee safety of pedestrians and vehicles.

 For places with buried facilities such as water pipe, gas pipe and HV cable pipe, contact the
parts department to make clear burying positions and take care during construction to avoid
damage to these facilities and ensure safety during construction.

 Inspect ground conditions, water depth and water flow in advance in case of working in water
or swamp area or passing sand embankment. Make sure water depth does not exceed the
allowed value to prevent the bottom of drive axle housing from contacting water. After
completion of working, clean and inspect the position for filling lubricating oil. See “6.

13
 Requirements for Working Environment in Chapter 2” for fording depth.

 Do guarantee effective ventilation for working in closed place (e.g. indoors).

4.1.2 Inspection before engine start

 Carefully inspect the machine before working every day. Immediately reported any abnormality
found to the management. Do not start operation before abnormality elimination.

 Inspect whether there is accumulation of flammables such as saw dust, leaf and paper around
the engine and the accumulator, clear away it if any to prevent fire disaster.

 Inspect whether the machine has oil leakage, water leakage, bolt looseness, abnormal sound,
and damage or loss of parts, etc.

 Inspected whether there are oil dirt, lubricating grease, snow and other dirt on the floor,
rearview mirror, control lever, pedal and handrail in the cab. Immediately clean if any.

 Inspect whether coolant level, fuel oil level and oil level in the engine sump are normal (see
“3.6 Supply of oils in Chapter 3”) and inspect whether the air filter is blocked.

 Adjust operator seat to a position suitable for operation (see 1.2.8 Adjustment of the seat in
Chapter 3). Inspect whether safety belt and the fixture (if installed) are damage. Safety belt
must be replaced after 3-year service.

 Inspect whether each instrument works normally and inspect the stop position of control lever.

 Clear away the dirt on windows and all lights of the cab to guarantee good visibility.

 Adjust rearview mirror to proper position to ensure good vision for the operator. If the glass of
rearview mirror has been damaged, it shall be timely replaced with a new one.

 Do not place or leave any part or tool around operator seat. Due to vibration during driving and
working, these parts and tools may fall off and cause damage to the control lever or the switch,
or move the control lever and start the working device, which will lead to accidents.

 Inspect whether all lighting lamps and signal lamps there are normal and carry out repairs in
case of any abnormality.

 Inspect whether lock levers of front and rear frames have been unlocked.

 Clear away the grease on handrails and pedals, as well as the sludge and fine sands on shoes
to avoid slip during getting on and impact to operations.

 Inspect whether tyres are worn or damaged, and whether assembling bolts and nuts are loose.
Pay special attention to whether rim nuts are loose. Timely repair or replace damaged parts in
case any abnormality.

14
4.1.3 During engine start
 Before getting on the machine, make an
inspection tour for the machine and inspect
whether there are persons or obstacles
above, below or nearby the machine. Pay
attention to whether there are persons in
working area. If there is anyone, alert him/her
to leave.

 Do not start the engine if there is warning

label “No Operation” on the control lever.
 Sit on the seat and buckle up safety belt (if
installed).
 Be familiar with alarm device, instrument and
operation operation mechanism on the No
instrument panel Operation

 Confirm the parking brake lever is in braking mode and all operation mechanisms are placed
at neutral position.

 Honk to warn.

 Start the engine (see 3.2.2 Start of engine in Chapter 3 for specific operation).

 The engine shall be started only from the cab. Forbid to start by means of short circuit of
starting motor. Start of the system via bypass may damage circuit system of the machine, and
such operation is very hazardous.

4.1.4 Inspection after engine start

Carry out inspections below after starting the engine and before operating the machine to ensure
no potential safety hazard.

 Carry out inspection in a broad place without obstacles, and keep everyone off the machine.

 Inspect whether the engine has abnormal sound or vibration during running. Existence of such
abnormality indicates possible fault of the machine. In this case, the operator shall immediately
report to the management and do not start operation before abnormality is eliminated.

 Detect engine speed control under conditions of neutral gear.

 Observe instruments, apparatuses and warning lamps and ensure they can work normally
within specified range.

 Operate gear operation mechanism to ensure accurate positions of front gear, neutral gear
and rear gear and flexible operation of all control levers.

 Inspect whether parking brake valve and fuel pedal operating valve are normal according to
the operating manual. Test whether left steering and right steering are flexible at low speed.

 Make sure the parking brake lever is in released state before driving.

15
5 Safe Driving
5.1 Alarm
 The operator needs to open hazard
warning signal to give hazard warning to
other road users on the road and off the
road in case of machine failure to work or
work at low speed.

5.2 Attention to self safety and that of others

 Develop good habit of operation for
everyone’s safety.
 Honk before starting the machine and start
the machine after confirming safety.
 Especially make sure there is no person or
obstacle all around.
 Inspect braking effect on dry, flat and solid
pavement.
 Do not put any arm or foot on the working
device or stretch out of the machine.
 Adjust the height of the working device to
keep lower hinge pin of boom 400~500mm
(16~20in) above the ground. Drive the
machine on flat ground.

 Be concentrated during operation. Pay

special attention to the heading direction
and persons around. Honk for warning in
case of hazards.
 Reliably fix the door of the cab for driving
and do not drive with the door open.

16
  Driving with person pick-up is very
hazardous. Anyone other than the operator
is not allowed to stay in the cab. No one is
allowed to sit on the body of the machine.
 Prohibit using the bucket as working
platform or person carrier.

 Follow traffic rules on general roads.

Choose proper speed when passing by the
crossings to avoid causing traffic jams.
 Drive the machine along the side of the
road, give way to other automobiles and
keep appropriate distance.
 Immediately brake to stop the machine in
case of flameout of the engine during
driving.

Warning

 The steering gear fails to work after flameout of the engine.

 Emergency braking may cause injuries.

 During high-speed driving, shift from forward to backward is very hazardous.

This operation is prohibited.

5.3 Full-load transport

 Do not transport with full-loaded bucket lifted because this is very hazardous. For full-load
transport, select proper speed, lower the bucket and put it backwards inclined against stop
dog, and drive with the bucket at proper height above the ground (400~500mm). This can
lower the center of gravity and guarantee stability of the vehicle.

 Cargo loaded shall not exceed rated bearing

capacity of the machine. Confirm that the
load of the machine is within the allowed
range to avoid overload. ENSIGN will
shoulder no liability for damage to the
machine or personal injury due to overload.

 Avoid rush running, emergency braking, sudden turn and roundabout during transport.

17
  Sudden stop and sudden fall of the working
device are very hazardous. In such cases,
the cargo may be thrown out or the machine
may be turned over. Therefore, such
operations shall be avoided.

5.4 No overspeed

 You shall be very familiar with vehicle performance. Proper driving speed shall be determined
as per actual conditions of working site. Besides, the route and working method for mechanical
operation shall be determined and announced to related personnel.

 Keep the vehicle at low speed to make it always controllable.

 Avoid high-speed driving, turning and emergency braking during driving on rugged or slip
pavement or hillside.

 It may be difficult to control steering wheel in unarranged place or on rugged pavement with
mess, and improper operation may cause accidents such as turnover. Therefore, the speed
must be reduced for passing.

 The engine shall run stably. Driving at high speed is prohibited during steering.

5.5 Guarantee good visibility

 Reduce the speed at places with poor front sight or at narrow crossings. If necessary, honk to
alert other vehicles, or let others guide to avoid blind operation.

 Sand dust, dense fog and rainstorm would impact visibility. Slow down in case of reduced
visibility. In case of poor visibility, stop working and put into operation again when the weather
gets better.

 The loader is a special vehicle. The vision is poor especially for handling long objects, which
requires special care for lifting, advance, reverse and gear shifting. Nobody is allowed to enter
the scope of working. Alternatively, special person shall be assigned for guidance.

 Illusions of distance and ground height tend to

occur at night. Do maintain lighting and drive
at proper speed.
 Turn on the headlamp, the tail lamp and the
working lamp for working in dark places.

5.6 Attention to obstacles

 For turning or driving at places with obstacles (building ceiling, upper part of the gate, etc.),
take care to prevent the vehicle and the loaded object from colliding with the obstacles.

18
 For turning or driving at narrow places, pay attention to safety around, reduce the speed and
confirm whether there are obstacles around.

 Loading/unloading is unstable in case of poor pavement conditions, so operations shall be

done with caution to avoid instability of loaded object.

5.7 Attention for driving in severe environment

 Pay special attention to safety for working
and driving in severe environment, and do
not carry out any work independently in
hazardous place. Perform in-advance
investigation for pavement condition, bridge
strength, terrain and geology of working site.
 Pay attention to subsidence of wheels and
braking effect in case of driving in humid or
soft places.

 Keep the bottom of the drive axle off water in case of working in water or swamp area. After
fording or rain, drive the machine at low speed, intermittently and gently tread the brake pedal
to dry the brake.

 Soil stacked on the ground or near the ditch is

soft, and it may collapse due to weight or
vibration of the machine, which will topple over
the machine.
 The machine shall be kept off suspension and
deep gully for these places may collapse due
to weight or vibration of the machine, which
will lead to machine tip-over, injury or death.
 Cabs preventing shall be installed if there’s
hazard of rock fall or turnover of the machine
in work site.
 Operate with caution in case of continuous working on rainy days for working environment will
change. Take special care for working at the site with accumulation after earthquake or blasting.

 For driving on snowy road, install tyre chain, drive at low speed, avoid sudden starting,
stopping or turning, prevent sudden braking, carry out intermittent braking, and lower the
bucket to the ground as necessary to stop the machine.

 The adhesive force of the ground may change a lot due to effect of snow in case of working
on the snowfield, so loading capacity shall be properly reduced to avoid slip during running.

 Special care shall be taken for shoveling snow since road shoulder or other objects buried
below snow are invisible.

5.8 Safe driving on the ramp

 Improper operation may cause turnover or slip when driving on steep hillside, dam or slope,
so special care shall be taken.

 Make the bucket close to the ground and about 200~300mm above the ground when

19
 longitudinally driving on hillside, dam or slope. Quickly lower the bucket to the ground in
emergencies to stop the vehicle or prevent it from turning over.

 Do not turn, horizontally drive or change

the direction on the ramp, otherwise
turnover may occur. Carry out such
operations after driving to flat ground.
 Avoid turning on the ramp, and do such
only after driving to flat ground. Reduce the
speed and turn at small angle when
working on mountain top, embankment or
slope.

 Prefer to drive up and down the slope rather than driving along alleys and sidewalks whenever
possible.

 Select proper shift before driving down the slope and avoid gear shift during driving down the
slope.

 Operate with caution and avoid sudden braking when driving on the ramp since the center of
gravity will move to front wheels or rear wheels.

 In case of full load at the ramp, drive at gear I, drive forward up the slope, drive backward down
the slope and avoid turning.

 Do not put the shift control lever at neutral gear in case of braking during downward driving.

 Slowly drive down the slope and prohibit flameout of the engine.

 Immediately tread the brake pedal, lower the bucket to the ground, apply parking brake, put
the shift control lever at neutral position and restart the engine in case of engine flameout on
a ramp with the gradient less than 15°.

 Keep the bucket upwards the slope in loaded

state; in other words, move forward when
driving up the slope and move backward
when driving down the slope.

5.9 Traction

Warning

Incorrect traction or selection of wire rope may cause injury or death.

 Operate as per instructions specified in “3.5.2 (7) Traction operation in Chapter 3”. Incorrect
traction method may cause hazards.

20
 Wear leather gloves for handling wire rope.

 Determine signals to be used through discussion before start of operations when preparing for
hauling together with other workers.

 Please contact designated dealer(s) of ENSIGN for maintenance if the engine of a problematic
loader fails to start or the braking system has faults.

 Traction of the machine on a ramp is hazardous. A place with gentle slope shall be selected.
 To tract a problematic machine by another
machine, the wire rope used shall be able to
bear the weight of the machine tracted, free
of strand cut off, twist or reduced diameter.
 Nobody is allowed between the tracted
Rope core Cage-
machine and the tracting machine in case of exposed shaped
need for tracting the machine.
 Do not stand on hauling rope.
 Keep the hook of the tracted machine and to
the tracted part of the machine in one
straight line and ensure that they are in right
places.
6 Safe Operation
6.1 Keep good habit of operation
 Always sit on the seat and buckle up safety
belt (if installed), and always keep the
vehicle in controlled state.
 Accurately operate control lever of the
working device and avoid misoperation.

 Inspect faults by careful listening and

immediately report for repair if any. Do not
repair parts in working state.
 Weight of loaded object shall not exceed
bearing capacity of the machine. Operations
beyond machine performance are very
hazardous. Therefore, weight to be loaded
or unloaded shall be determined in advance
to avoid overload. ENSIGN will not shoulder
any liability for damage to the machine or
personal injury due to overload.

21
  High-speed rush is a very hazardous and
wrong operation. It can not only damage the
vehicle and injure the operator, but also
damage the cargo.

 Keep the vehicle vertical to the object to be

loaded or unloaded. Forced operation from
inclined direction may worsen damage to
steering cylinder and differential
mechanism, unbalance the vehicle and
unsafety. Therefore, do not operate in this
way.

 For loading/unloading operation, conditions around shall be confirmed in advance.

 For operations in narrow spaces such as tunnel, overbridge and garage, cleanliness of the site
shall be inspected in advance. The working device shall not be cracked up during operation.

 For loading under heavy wind, operations shall be downwind.

 Operations with boom lifted to the highest point shall be done with caution. Loading operations
with boom lifted to the highest point may destabilize the machine. Therefore, the vehicle shall
be slowly moved and the bucket shall be slowly fore-raked.

 The bucket shall be prevented from colliding

with the truck or tipper for loading to a truck
or tipper. Anyone shall not stand below the
bucket and the bucket shall not be put above
the cab of the truck.

 Carefully and clearly observe the rear of the

vehicle before reversing.

22
  Stop operation in case lowered visibility due
to smoke, fog or dust. Install lighting
equipment in case of dim light at working
site.
 Pay attention to the key points below for
working at night:
 Make sure proper lighting equipment
have been installed.
 Make sure working light on the loader
works normally.
 Height of and distance of objects are
difficult to judge during working at night.
 Keep alertness during working at night,
and stop the vehicle often to observe
surroundings and inspect the vehicle.
 Confirm sufficient bearing capacity of
bridges or other buildings before passing.

 Do not use the vehicle for any application

other than specialized operations.
Operations such as lifting, grabbing, poking
or pushing with one head or any part of the
working device or tracting with the working
mechanism may lead to vehicle damage or
accidents.

6.2 Attention to surroundings

 Unauthorized persons are prohibited to be
within the scope of workin. Since the working
device rises, falls up and down, rotates left
and right and moves front and back, it is
hazardous all around (below, front, rear,
inside, both sides) the working device.
Therefore, entering into the surroundings of
the working device is prohibited.

23
  Adopt methods for guaranteeiing safety for
working on roadside, cliff or in a place with
potential collapse, assign a supervisor and
follow his commands.
 Pay full attention to safety of the dropping
points when releasing sandy soil or rocks
from high positions.

 The load will suddenly fall and the vehicle speed will be suddenly accelerated when loaded
object is pushed out of the cliff or the vehicle reaches top of the slope. Therefore, deceleration
must be done in advance.

 For banking, bulldozing or dumping soil on

the cliff, the soil shall be dumped for the first
pile which is used to push the second pile.

6.3 Adequate ventilation for working in closed space

 It is necessary to open doors and windows
to ensure adequate ventilation to prevent
harm to human body if operations or
processing of fuel oil or cleaning of parts or
paint must be done in a closed or
inadequately ventilated place. Ventilating
devices (e.g. fan) shall be installed if
ventilation is still insufficient after opening of
doors and windows.

 Prepare extinguishers in advance for

working in a closed space, keep in mind their
storage positions and operation methods.

24
6.4 No approach to hazardous place
Fire disaster will tend to occur if exhaust gas from
the muffler spurts to flammable, or exhaust pipe
is close to flammable. Therefore, special care
shall be taken for places with grease, raw cotton,
paper, withered grass, chemical product or other
flammables.

6.5 No approach to HV cable

Keep the machine off aerial cable. Approach to
HV cable may lead to electric shock.
Horizontal distance between the loader and
transmission line shall be as follows:
 At least 2m (6.5ft) for low voltage.
 4m (13ft) for 40KV HV line (usually
supported by a fixed insulator).

 6m (20ft) for 40KV HV line (usually supported by a suspended insulator).

Vertical distance between the loader and aerial transmission line shall be as follows:

 At least 2m (6.5ft) for LV line.

 4m (13ft) for HV line.

Well do the works below to avoid accidents:

 Inquire about the voltage of cables from power company before commencement of works, and
confirm the feasibility of actions determined according to current regulations in case of possible
contact between the machine and cables at working site.

 Wear rubber boots and rubber gloves. Put a piece of rubber gasket on operator seat and keep
any exposed part of the body off metal chassis.

 Assign one signalman to give alarm signal in case of too close approach of the machine to
cables.

 Once the working device contacts the cable, the operator shall not leave the cab but stay on
seat without contact with the machine until power supply is safely disconnected by someone
else on the ground.

 No one is allowed to get close to the machine when it works near the HV cable.

7 Safe Parking
7.1 Attention to self safety and that of others

 The machine shall be parked on flat ground whenever possible and the working device shall

25
 be lowered to the ground and laid flat.

 Do not park the machine on the slope. The slope gradient must be less than 20% if it is
necessary to stop on a slope. Put wedges under wheels to prevent movement of the machine
and lower the bucket to the ground.

 Fence, signal, flag or warning lamp shall be arranged and other required signals shall be
placed to make the machine visible for passing vehicles when the machine has faults or needs
to be parked in a crowded place. Moreover, the machine, fence and flag shall not block the
traffic.

 For parking, discharge materials in the bucket, lower the bucket to the ground, shut down the
engine, pull up the parking brake lever and put it to parking position. Lock all equipment with
the key and then take the key. For getting off, the operator shall face the machine, slowly climb
down and keep at least three-point contact with the handrail and the ladder. Jumping off is
forbidden.

Warning

Get on or off during driving of the vehicle is forbidden.

7.2 Cautions for cold region

 Completely remove water, snow and sludge on electric wires, wire connecting plugs, switches
or sensors and coverings of these parts after completion of working. Otherwise, moisture in
them will freeze, which will lead to machine failure and accidents.

 Sufficient preheat is necessary. The machine will lag in response without sufficient preheat
before operation of the control lever, which may lead to unexpected accidents.

 Operate each control lever to circulate hydraulic oil in the hydraulic system (increase system
pressure to set value of the system and release the pressure to return oil to hydraulic oil tank)
to heat hydraulic oil. This ensures good response of the machine and prevents failure.

 Do not charge the accumulator or start the engine with alternative power supply if electrolyte
in the accumulator is frozen. Start with alternative power supply is hazardous and may ignite
the accumulator. See “3.5.3 Operation under cold weather” in Chapter 3 for details.

26
8 Safety Inspection and Maintenance
8.1 General knowledge
 Operators and service technicians of the
machine shall be subject to training and
obtain corresponding qualifications. Anyone
irrelevant to ongoing maintenance and
repair is not allowed to enter working areas.
Special person shall be assigned for watch
as necessary. Danger!

 Carry out maintenance of the machine as per specified procedures and turn to ENSIGN for
help if you do not know how to do.

 Appoint responsible person in advance, prepare operation procedures and act step by step in
case of repair of the machine or assembly and disassembly of the parts.

 Wear work clothes with tightened cuffs and

trouser legs, as well as safety glasses.

 Use correct maintenance tools but no those damaged or with low quality.

 To avoid personal injury during maintenance, lower the working device to the ground, lay it flat,
shut down the engine, pull up the parking brake lever and well wedge the machine.

 Strictly follow the instructions on warning board. Follow safety sign attached to the vehicle as
for especially important matters. Supplement or wash the sign in case of breaking-off or
pollution of the sign.

 Attach the sign “No Operation” or an alternative warning sign to the start switch and the
instrument panel before maintenance to prevent others from starting the engine or operating
the control lever. Otherwise, injury or death may be caused.

27
  Fuel oil and engine oil are hazardous.
Fuel oil, engine oil, lubricating grease and
oily cloth shall not contact any naked
flame. Oily cloth shall not be stacked at
wall corners. Otherwise, spontaneous
combustion may occur.
 Smoking is prohibited during oil filling or
inspection of the accumulator.

 Parts removed from the machine shall be put in a safe place and prevented from falling.
Handrails shall be placed around the parts with the sign “No Admittance” hanged to prevent
approach of unauthorized person.

 Anyone unauthorized is allowed to approach the machine or its parts.

 Cleanliness and tidiness shall be kept around working site. There shall be no scattered
tarpaulin or lubricating oil (grease) around working site to avoid fire disaster and tumble.

 Front and rear frames shall be fixed with

frame locking lever before inspection and
maintenance of the machine to avoid injury
due to rotation.
 All control levers shall be put at neutral
position and required supports for boom
cylinder and rotating bucket cylinder shall be
adopted to prevent falling of the working
device if it is indeed necessary to overhaul
and maintain in state of lifted boom and
bucket.

8.2 Working in closed place

Gas exhausted by the engine may cause diseases even death. Exhaust device shall be used to
exhaust gas in the place if the engine has to be started in a closed place. Doors shall be opened
for ventilation in case of no exhaust device.

8.3 Maintenance in the state of jacked frame

 Nobody is allowed to enter the opposite side in the state of jacked frame.

 Before jacking, front and rear frames shall be locked with frame locking lever. The control lever
shall be put at neutral position and the machine shall be wedged from the opposite side. After
jacking, cushion block shall be put under the machine.

28
8.4 Working below the machine
 Park the machine on a firm flat ground and
lower the working device to the ground and
laid flat before maintenance or repair below
the machine.
 Fix tyres with wedge.
 Working below the machine is very hazardous
if the machine is only supported by the
working device, but with tyres lifted off the
ground.
 Never to work below the machine without
reliable support.
8.5 Working on the top of the machine

 Keep the foothold clean and free of obstacle and follow the requirements below to avoid fall
during maintenance on the top of the machine.

Caution

 Do not scatter lubricating oil or lubricating grease.

 Do not put tools around.
 Walk stably.

 Do not jump off the machine. To get on or off, you shall face the machine, hold the handrail
and tread the ladder to always keep three-point contact (two feet and one hand or two hands
and one foot).

 Use protective equipment when necessary.

 Do not stand on the top of engine hood since it is slip and hazardous.

 Do not stand on the top of the tyres since it is slip and hazardous.

 Stand on the fender of front frame and hold the handrail for cleaning front glass of the cab.

8.6 Maintenance during engine running

To avoid injuries, do not perform maintenance when the engine is running. Follow the following
cautions if it is necessary to maintain during running of the engine.

29
  Assign an operator to sit on the seat to
guarantee free communication with all
service technician and get ready to shut
down the engine at any time.
 Do not touch high-temperature parts such as
tail pipe and muffler to avoid scalding.
 Take special care if work point is close to
rotating parts since there is hazard of
involvement by them.
 Do not trigger any control lever. Issue
signals to others to alert them to go to a safe
place if it is necessary to trigger.
 Keep any tool or any part of body from contacting fan blade or fan belt, otherwise, severe injury
may be caused.

 Do not adjust any parts that you’re not familiar with .

8.7 Keep foreign materials from falling into the machine

 Take care to prevent any foreign materials (e.g. nut, bolt, cotton yarn and tool) from falling into
the machine when opening manhole or oil filler for overhaul. Falling of such thing into the
machine will lead to damage, misoperation or other faults of the machine. Any foreign materials
falling into the machine must be safely taken out from the machine end.

 Do not carry any unnecessary tool or parts in the pocket of clothes during overhaul.

8.8 Cleaning

 Wear antiskid shoes during cleaning of the machine to prevent slip on wet surface. Wear
protective clothing when using high-pressure water to wash the machine.

 Timely clean the machine to avoid splash of dirts or sludge on the machine into eyes or slip
and injury due to oil dirt on the machine.

 Use inflammable cleaning agent for cleaning the machine.

 Shut down the engine, put all control levers at neutral position, pull up the parking brake lever
and put it at parking position when cleaning the inside of the machine.

 Do not spray water directly onto electrical elements (sensor, wire connecting plug) or into the
cab. Entry of water into the electrical system may cause operation failure.

 Do wear protective clothing and safety glasses when cleaning filter element with compressed
air.

8.9 Heavy object

 Wear protective clothing, safety glasses and safety helmet when using hammers, and cushion
a piece of copper bar between hammers and hammered part.

 Hammering hard parts (pin, bearing, etc.) may bring fragment into eyes and cause injuries.

 Use tools and heavy objects with caution and prevent falling.

8.10 Welding repair

Electric welding shall be done by welders with required qualifications and skills and in a place with

30
proper equipment. Gas produced by electric welding may cause fire disaster and electric shock.
Therefore, electric welding shall not be done by unqualified person. Follow the cautions below for
welding operation:

 Disconnect the terminals of the accumulator to prevent explosion.

 For a loader installed with ZF control unit, disconnect wire terminals on computer control panel
of the transmission before welding to prevent computer control panel from burning out due to
impulse current during welding. After completion of repair, well insert wire terminals on
computer control panel, otherwise, the machine will fail to start and move forward.

 Remove paint at the position to be welded to prevent generation of harmful gas.

 Avoid electric welding on or nearby hydraulic equipment or pipelines or places very closed
because there will be flammable steam and spark which will bring risks of fire or explosion.

 Sparks produced during welding may directly

fall onto rubber hoses, electric wires or
pressure pipelines. These pipes may
suddenly break and insulation of electric wires
may be damaged. Therefore, they shall be
covered with fire dampers.

 Take special care for welding nearby tyres since they may explode when heated.

 Wear protective clothing for electric welding.

 Ensure good ventilation in workplace of electric welding.

 Clear all flammables and prepare extinguishers in the workplace.

 Modification that may impact performance, safety or strength of the machine and working
devices is prohibited.

8.11 Overhaul of cooling system

 Early after work, hydraulic oil, oil in the engine and oil and water in the radiator are hot and
have a certain pressure. Therefore, opening cover of the fuel oil tank or the radiator to drain
oil or water or replacing the filter can cause serious burns. Such operation can be put into
practice after cool-down, and shall be done as specified procedure.

 To prevent ejection of hot water, the engine shall be shut down to let water cool down, and the
cover shall be slowly loosened to release pressure. For inspecting whether water temperature
falls, put hands close to the front of water radiator to inspect air temperature. Take care to
avoid contacting with the radiator.

31
  To prevent ejection of hot oil, the engine
shall be shut down to let oil cool down, and
the cover shall be slowly loosened to release
pressure. For inspecting whether oil
temperature falls, put hands close to the
front of the radiator of hydraulic oil/torque
converter oil to inspect air temperature. Take
care to avoid contacting with the radiator.
 Do not touch the engine, the muffler, the tail
pipe and the relay during vehicle warm-up to
avoid scalding.

 Do not remove water temperature sensor,

torque converter oil temperature sensor and
air conditioning water pipe on the engine
during warm-up to avoid scalding.
 Keep skin and eyes off the devices of cooling
system since they contain alkali substance.
 Select proper container for replacing
coolant, engine oil or transmission oil or
parts (e.g. filter). See “8.20 Waste” in this
chapter for details of disposal of waste liquid,

 Prohibit approaching to naked flame when removing connecting pipeline of air condition
compressor.

8.12 Overhaul of hydraulic system

 Safely lock oil cylinder and other hydraulic devices, cool down hydraulic oil and release the
pressure of hydraulic system before overhaul of hydraulic system.

 Do not bend or hammer high-pressure pipeline. Do not install abnormally-bent or damaged

hard or soft pipes onto the machine.

 Timely repair or replace any loosened or damaged fuel oil pipeline, lubricating oil pipeline and
hard and soft pipes of the hydraulic system. Leakage may cause fire disaster. Carry out timely
repair or replacement in case of leakage.

 Please carefully inspect pipelines (hard pipes and soft pipes) and tighten all joints as per
specified torque. Do not inspect leakage with naked hands, but with plates or paperboards.
Even a needle-sized leakage of pressurized liquid may puncture the muscle or even cause
injury or death. If solution is jetted to skin, a surgeon familiar with such injury shall be called
for treatment within a few hours.

Caution

32
 Make replacement if any of the problems is found:

 Joint damage or leakage.

 Wear or cut-up of exterior layer of the hose or exposure of reinforced

layer of steel wire.

 Local rise of the hose.

 Obvious distortion or flattening of the hose.

 Embedment of steel wire of reinforced layer into the exterior layer.

 Ensure correct installation of all pipe clamps, fenders and heat-shield covers to avoid shock
and overheat due to friction with other parts.

 Select proper container for replacing oil of hydraulic system or parts (e.g. filter). See “8.20
Waste” in this Chapter for details of disposal of waste liquid.

8.13 Avoid fire disaster

 When filling fule oil, the engine must be shut down, and smoking and approaching to naked
flame is prohibited

 Fuel oil, lubricating oil and other flammables need to be stored away from naked flame

 Clear away flammable materials accumulated on the machine (fuel oil, lubricating oil, fragment)
and make sure there is no tarpaulin or any other flammable.

 Explosive gas may be produced nearby the

accumulator. Therefore, the accumulator
must be kept off open flame, and maintained
and used strictly as per product instruction
manual.
 Pay attention to the environment when
parking the vehicle. High-temperature parts
(e.g. muffler) shall be kept off any place with
flammables (e.g. withered grass, old paper).
 Inspect leakage of fuel oil, engine oil and
hydraulic oil. Replace damaged hose in case
of leakage, repair and clean before operating
again.
 Inspect breakage and current leakage of electric wire, repair or replace if any.

 Use fire retardant solvent for cleaning parts but no gasoline or other flammable liquid.

 Do not carry out electric welding or flame cutting on pipes with flammable liquid. Clean such
pipes with nonflammable liquid before electric welding or flame cutting.

 Inspect extinguishing system, know positions and operation methods of extinguishers and first-
aid packet before maintenance.

 Do not use naked flame (match, lighter) for inspecting dark places.

33
8.14 Gas storage tank
 Open the water drain valve at the bottom of gas
storage tank to drain off water everyday, and at
least once each day in winter. Make sure the
water drain valve is closed before starting the
loader.
 There is high-pressure gas in the tank, so outside
inspection of the tank shall be performed. Inspect
anticorrosive layer and weld joint for ensuring
safe service.

Water drain valve

8.15 Electrical system

 Maintenance of the electrical system shall be undertaken by personnel with professional

qualification.

 Finally connect ground cable when adjusting external power supply so as to prevent explosion
due to sparks produced around batteries.

 Do take down the key of start switch before maintenance of the electrical system.

8.16 Maintenance of the accumulator

Electrolyte of the accumulator contains sulfuric acid and can produce hydrogen and oxygen during
charging of the accumulator. Therefore, incorrect treatment of the accumulator can cause serious
injury or fire disaster. The cautions below must be followed:

 The accumulator contains sulfuric acid with strong corrosivity, so the accumulator shall be kept
off children. The user shall wear protective glasses and rubber gloves for operating the
accumulator. Once sulfuric acid splashes into eyes or onto skins and clothes, a large quantity
of clean water shall be used for flushing, and those injured severely shall be sent to the hospital
for treatment.

 Hydrogen and oxygen will be produced when the accumulator is charged. These gases will
lead to explosion once they come across naked flame or exhaust port is blocked. Therefore,
the accumulator shall be kept off naked flame and short circuit shall be avoided.

 The shell of the accumulator is flammable, so it shall be kept off naked flame.

 The accumulator shall be stored in a dry, clean and well-ventilated environment under 5~25℃,
protected against direct sunshine, and kept off heat source by more than 2m. Too high ambient
temperature will significantly impact performance of the accumulator.

 The accumulator shall not be inverted or laid horizontally, and shall be protected against any
mechanical impact and heavy load.

 The accumulator can be stored for 6 months under room temperature, and can be put into use
without need of charging within this period. If stored for more than 6 months, it can be put into
use after charging.

 Pay attention to safety sign on its label before installation of the accumulator to avoid accidents.

34
 Coat the end post with a small quantity of Vaseline before installation of the accumulator to
prevent corrosion. Wiring shall be firm and reliable. Prohibit knocking end post to prevent
seepage of the acid due to looseness of end post.

 Before installation, positive pole of the accumulator shall be connected to positive pole of the
engine. Afterwards, negative pole of the accumulator shall be connected to negative pole of
the engine.

 The accumulator shall be firmly laid flat on the battery rack by means of upper fixing or lower
fixing to avoid damage due to looseness.

 There is an indicator installed on the battery cover to display the state of charge. The
accumulator can be normally used when the indicator is green. The accumulator shall be timely
charged when the indicator is black. The accumulator shall be immediately replaced when the
indicator is white.

 The accumulator getting under-power for any reason shall be timely charged to avoid
decreased performance due to sulfate efflorescence.

 The accumulator that has been installed to a loader shall be removed from the loader and
stored in ventilated and dry place if it is to be out of service for long time (>15 days), and it
shall be charged every 3~6 months (depending on whether the indicator becomes black).

8.17 Charge of the accumulator

There is explosion hazard if the accumulator is incorrectly treated during charge. Therefore, the
accumulator shall be charged as per the specifications on accumulator treatment and the provisions
on charge in the instruction manual. The cautions below shall be followed:

 Constant voltage charge is recommended for the accumulator.

 Supplementary charge: 16 hours charge under constant voltage of 16.0V (max. current:
≤25A)

 Normal charge: 24 hours charge under constant voltage of 16.0V (max. current: ≤25A)

 Positive pole of the charger shall be connected to positive pole of the accumulator for charging,
and negative pole of the charger shall be connected to negative pole of the accumulator.
Reverse charge is prohibited.

 Gas will be produced during charge of the accumulator. The vent on the accumulator shall be
inspected periodically against blocking to avoid explosion.

 Charge voltage or charge current shall be lowered as appropriate during charge if electrolyte
of the accumulator gets hotter than 45℃ to avoid splash of electrolyte due to overheat.

 Over-charge shall be strictly prevented during service and charge of the accumulator to avoid
earlier failure of the accumulator due to over-loss of water, growth of slab lattice or peel-off of
lead plaster.

8.18 Start with booster cable

Any incorrect connection method of booster cable may cause fire disaster. Therefore, the
connection shall be done as per the method below.

 Two operators shall be assigned for start (one sits on operator seat).

 There shall be no contact between two machines when starting another machine.

35
 Start switches of both the normal machine and the faulty machine shall be closed when boost
cable is connected.

 Positive (+) cable must be first connected when boost cable is installed. Ground wire or
negative (-) cable shall be first disconnected when boost cable is removed.

 Finally, ground wire shall be reliably connected to the frame of the faulty machine. Such
connection shall be kept off the accumulator as far as possible.

 For removing boost cable, clamps of boost cable shall be prevented from contacting with each
other or the machine.

8.19 Maintenance and storage of tyres

8.19.1 Maintenance of tyres

 Explosion of tyres can push tyres, rims and drive axles out 500m or farther from the machine.
Exploding and splashing fragments can cause serious injury even death. Therefore, tyres must
be kept at normal pressure and shall not be inflated above nominal pressure. See “8. Technical
performance and parameters” in Chapter 2 for inflation pressure.

 Heat produced during high-speed driving can increase tyre pressure. Such increase is normal,
and efforts shall not be made to eliminate it, but the machine shall be decelerated or parked
for cooling of tyres. However, continuous high-speed driving can cause overheat and explosion
of tyres, so due attention shall be paid.

 For adjustment of pressure, the operator shall keep away from tyres and stand behind tyre
surface.

 The tyre and the rim shall be inspected everyday. Low-pressure operation is not allowed. Tyres
shall be inspected against crack and bubble.

 Inspect whether connecting bolt and nut of rim are lost and whether tightening torque of
connecting nut of the rim is in accordance with the value recommended by the manufacturer.

 Inspect tyres from its side, rather than front or rear. For removing a tyre, other tyres must be
fixed with wedges.

 Special care shall be taken when welding near tyres since tyres may explode.

 Repairing tyre and rim is very hazardous, and it can only be done by trained professionals with
special tools as per correct procedures.

 Tyres shall be replaced according to specified specifications. Tyre specifications and patterns
shall be consistent.

36
8.19.2 Cautions for storing tyres
 As a basic rule, tyres shall be stored in a
warehouse inaccessible for unauthorized
person. Fences and the sign “No Admittance”
shall be set around tyres if they are stored
outdoors.
 Tyres shall be stored in a dry and clean place.
Moisture can accelerate oxidation of rubber, and
dirt or oil can corrode tyres. During storage,
tyres shall be shielded against light and heat,
and airiness shall be prevented. Stored tyres Wedge
shall be covered with canvas, plastic cloth or
other dustcloth. Incorrect storage can badly
impact quality and service life of tyres.

 Tyres shall be erected on level ground and firmly wedged. On this basis, tyres will not fall even
if they are touched by unauthorized person. If one side of tyres touches the ground, the tyres
will be flattened and get lower in quality. Tyres shall be rotated (by 90°) at least once a month.

 If a tyre is falling, everyone shall evade immediately. Tyres of all engineering machines are
very heavy. Attempt to hold the falling tyre may cause serious injury.

8.20 Waste

The procedures below must be followed to prevent pollution.

 Waste oil shall never be dumped to sewers or rivers.

 Oil drained from the machine shall be put in containers, rather than directly drained to the
ground.

 Related laws and regulations shall be obeyed for disposing hazardous substances (e.g.
lubricating oil, fuel oil, coolant, solvent, filter, and accumulator).

9 Safe Transport
9.1 Loading/unloading of the machine

 There are always potential hazards for loading/unloading of the machine, so special care shall
be taken. For loading/unloading, the engine shall run at low speed and the machine shall travel
at low speed.

 The machine shall be loaded or unloaded on firm and flat ground, with safety distance to road
side.

 For loading/unloading, tyres of transport vehicle shall be always fixed to keep transport vehicle
unmoved. Cushion block shall be put below gangplank.

 Wobble plates with sufficient strength, width and length shall be used to offer a ramp for safe
loading/unloading. Included angle between the wobble plate and the ground shall not exceed
15°. Distance between wobble plates shall be matched with wheel track of the machine.

 The wobble plate shall be firmly positioned, with both sides at the same height.

 The wobble plate shall be kept clean and free of lubricant, oil stain, ice and discrete material.
Dirts on tyres of the machine shall be removed.

37
 The machine shall not be turned on the wobble plate. If turning is required, the machine shall
be driven away the wobble plate and driven to the wobble plate after direction is well adjusted.

 After loading onto the vehicle, lock connecting and steering mechanism, wedge the tyres and
fasten the machine with ropes.

9.2 Road transport

 If the machine is delivered by trailers, provisions of national laws and regional regulations on
weight, height, width and length, as well as all related traffic rules shall be obeyed.

 Weight, height, width and length of the machine shall be considered for determining route of
transport.

 It is necessary to inspect whether the bridge or the building can bear weight of the machine in
advance for passing a bridge or a building on private land. Related provisions shall be
observed for travel on public road.

 It may be necessary to disassemble the machine if other means of transport are considered.
Please contact ENSIGN or designated dealer(s).

9.3 Lifting
Lifting hooks on front and rear frames shall be A direction
used if it is necessary to handle the loader to a Such
wrapping is
ship or train. prohibited

Proper slings shall be selected as per the

weight of the loader. Use beyond load limit of
the sling is very hazardous, so special care
shall be taken.

 Cautions for lifting:

 Front and rear frames must be aligned and fixed with frame locking lever if the loader is
running before lifting as to avoid relative rotation between front and rear frames.

 All control levers must be put at neutral position.

 The engine is allowed to be shut down. The key shall be taken down after locking of all
equipment.

 Nobody is allowed to be in the cab.

 The machine shall not be lifted by connecting hooks of front and rear frames with a piece
of wire rope.

 The machine can be lifted with 4 pieces of wire ropes of the same length.

 The machine shall be horizontal after lifting.

 The hood, the cab and the hydraulic pipeline shall be protected against damage.

 Pedestrians and vehicles shall be prevented from entering the space below the loader
during lifting.

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  After completion of lifting, the loader can be rotated only after frame locking lever is
retracted.

 After loading to the ship (vehicle), steering mechanism shall be locked and connected with
frame locking lever, and tyres shall be wedged and firmly bound with a rope with sufficient
strength to prevent movement of the loader during transport.

39
 Chapter II Product Introduction

1 Appearance and Names of Parts

Boom Front frame Hood

Cab

Bucket Rear frame Counterweight

Tyre Drive axle

Fig. 2-1 Appearance of YX618 and Names of Parts

40
2 Figure of Overall Dimension

Fig. 2-2 Overall Dimension of YX618 Loader (equipped with

YN4102 engine and standard boom)

41
3 Composition and Meaning of Product Model
YX 6 1 8

Model code (blank)

Rated load

Wheel loader

ENSIGN

4 Label
The label is nailed at front left of the rear frame, describing model, product No., delivery date and
manufacturer.

Fig. 2-3 Label of YX618 Loader (equipped with YN38GBZ engine and standard boom)

42
5 Applications
The loader is a large multi-purpose engineering
machine mainly for loading/unloading bulk
materials. It is suitable for mine, infrastructure,
road building, enterprise, goods yard and port. It is
used for shoveling and transshipping bulk
materials such as loose soil, sandy soil, gravel,
coal and garbages, and it is capable of traction,
site leveling, piling and stack transfer.
The loader can grapple wood, grasp grass, clear
snow and fork block materials stored in cases after
switch of working tools.

See “3.5 Work” in Chapter 3 for details.

Warning

The operations below are prohibited for the loader.

1. Overload

2. Eccentric load

3. Excavation of hard materials

4. Direct hang of ropes on bucket tooth for lifting heavy object

5. Elevation of the bucket for excavation above the machine

6 Requirements for Working Environment

The loader is suitable for the environment below.

1. Altitude: ≤1500m

2. Ambient temperate: -15~40℃

3. Fording depth: ≤350mm

The loader is an ordinary engineering machine for applications specified in the manual under
normal conditions. Special regulations on safety must be observed if it is used for any other purpose
or an environment with hazards (areas with flammable or explosive air or asbestos dust), and the
loader shall be equipped with devices for corresponding applications.

7 Characteristics
 Load sensing hydraulic steering system contributes to portable operation, flexibility and reliable
performance.

 Articulated frame is adopted for big steering angle and small turning radius, which is adaptable
for working in narrow site.

 Pilot hydraulic control is easy and comfortable, effectively reducing the driver’s fatigue.

 High performance engine is adopted. Single stage and three elements type hydraulic torque

43
 converter can give full play to the power of engine.

 Fixed-shaft power shift transmission with large torque increases the overall traction.

 High tensile integral frame structure is adopted for cab, providing high safety.

 Optimized layout of interior cab increases the operating space, which better conforms to
ergonomic design.

 Cab with good seal and shock absorption improves the operating comfort.

 Reinforced drive axles are adopted for large bearing capacity, high reliability and long service
life.

 Large wheel base contributes to good overall stability.

 Optimized working devices provide large breakout force and high load ratio.

 Optimized hydraulic system reduces the total cycle time, increasing work efficiency.

 Reasonable match of power transmission system improves the engine fuel efficiency,
increasing the efficiency.

 High travel speed enables the average working speed to be 5%-15% faster than that of the
similar products in this industry.

 It is equipped with a combination instrument of pointer + indicator light alarm which integrates
indication and display.

44
8 Technical Performance and Parameters
8.1 Performance parameter
Equipped with standard boom
Bucket Capacity 1.0 m3
Rated Load 2000 kg
Lift arm Lift Time (full load) ≤4.8 s
Total cycle time (lift, dump & lower) ≤8.7s
Speed
Forward Gear Ⅰ 0~9 km/h
Forward Gear Ⅱ 0~17 km/h
Forward Gear Ⅲ 0~23 km/h
Forward Gear Ⅳ 0~40 km/h
Reverse gear R1 0-8 km/h
Reverse gear R2 0~16 km/h
Reverse gear R3 0~22 km/h
Reverse gear R4 0~38 km/h
Max. Breakout Force ≥40 kN
Max. Traction ≥62 kN
Gradeability 25°
Min. Turning Radius (at outer side 4775mm
of the rear wheel)
Min. Turning Radius (at outer side 5515 mm
of the bucket)
Max. Steering Angle 35°
Inflation pressure
Front Wheel 0.34 MPa
Rear Wheel 0.28 MPa

8.2 Main dimensions and weights

Length (keep bucket flat on the groud) 6270 mm
Width (wheel outside) 2060mm
Bucket Width 2280 mm
Loader Height 2855 mm
Wheel Tread 1650 mm
Wheel Base 2390 mm
Ground Clearance 295 mm
Maxi dump Height (43°dump angle) 3085 mm
Dump distance (43°dump angle ) 960 mm
Overall operating weight 5740 kg
8.3 Product standard
Product implementation standard: Q/YXJ 001-2012 Tire loader

45
 Chapter III Operation
1 Be Familiar with the Machine
1.1 Operation mechanism and instruments

1. Gear shift lever 2.High/low speed control lever 3. Instrument panel 4. Steering wheel 5. Horn button
6. Brake pedal 7. Accelerator pedal 8. Parking brake control lever 9. High and low speed joystick
10. Pilot valve

Fig. 3-1 General View of Operation Mechanism

Fig. 3-2 View of Instrument Panel

46
1.2 Introduction to instruments and operation mechanism

Instruments and operation mechanism for operating the machine are described below. Their
operation methods and effects must be full learned.

1.2.1 Instruments and indicators

 Engine water thermometer
Thermometer indicates the temperature of engine cooling
water.
The pointer within the green area (60℃~100℃) means normal
water temperature.
Cautions:
The machine shall be shut down for inspection if the pointer is
within the red area.
 Torque converter's oil thermometer
This thermometer indicates the temperature of hydraulic
transmission oil of the torque converter.
The pointer within the green area (60℃~120℃) means normal
oil temperature. The machine shall be shut down for inspection
if the pointer is within the red area.

 Work hour meter

This meter indicates the work hour of engine. Value on this
meter can be used as the basis for repair and maintenance.

 Transmission oil pressure gauge

This gauge indicates the pressure of hydraulic oil of the
transmission system.
The pointer within the green area (1.1MPa~1.5MPa) means
normal oil pressure. The machine shall be shut down for
inspection if the pointer is within any other area.

47
  Brake pressure gauge
This gauge indicates air pressure in the braking system.
The pointer within the green area (0.4MPa~0.8MPa) means
normal air pressure. The machine shall be shut down for
inspection if the pointer is within any other area.

 Indicator lamp
Refer to “1.1 Operation mechanism and instruments Fig. 3-2 of this Chapter”.
Steering lamp: When steering switch is connected, the lamp will flash, meanwhile the steering
lamp will flash to indicate steering signal has been given. The left indicator lamp will flash for left
steering and the right indicator lamp will flash for right steering.
Parking brake indicator lamp: The lamp will be on when the parking brake control lever is pulled
up, and the lamp will go out when the parking brake control lever is released.
Charge indicator lamp: Indicator lamp will be on when start switch is open, and be off when
engine is in working state. Otherwise, the battery charging system has fault and shall be
inspected and repaired.

1.2.2 Switch
 Start switch
The switch is placed on the instrument panel, used for opening
and closing of electrical system of the entire vehicle and start of
engine.
Position “HEAT”
This position is reserved for preheating start system. The basic
model is not equipped with preheating start system which is
optional for users.
Position “OFF”

The key can be inserted or pulled out at this position. Start circuit is disconnected when the key is
rotated to this position.

Position “ON”

Please keep the key at the position “ON” when the electrical system is started and the engine is
running.

Position “START”

This position is for starting the engine. The key shall be kept at this position during start. The key
shall be immediately released for automatic return to the position “ON” when the engine is started.

 Radio/CD player (optional)

The control panel of radio/CD player is located

below the right of the cab.

48
 combination switch

The left steering lamp will be on when the switch is

pushed forward and the right steering lamp will flash

when the switch is pulled backward.

 Rocker switch
Located on the instrument desk, rocker switch will function to
control front work lamp, windscreen wiper, big tail lamp,
warning lamp (optional) and emergency alarm lamp when the
start switch is at the position “ON”.

 Windscreen wiper switch

The first press of lower end of the switch triggers slow gear. The second press triggers fast gear.
Press of upper end of the switch stops the windscreen wiper.
 Front work lamp switch

The front work lamp will be on when lower end of the switch is pressed and the front work lamp
will go out when upper end of the switch is pressed.

 Tail lamp switch

The tail lamp will be on when lower end of the switch is pressed.

The tail lamp will go out when upper end of the switch is pressed.

 Alarm lamp switch

All steering lamps will simultaneously flash to alert other vehicles and pedestrians by giving warning
light in case of emergency when lower end of the switch is pressed. All steering lamps will not
simultaneously flash when upper end of the switch is pressed.

 Ceiling lamp switch

It is located at the rear of ceiling lamp in the cab.
The ceiling lamp will be on if it is pressed towards
the position “ON” and will go out when the switch is
pressed towards the position “OFF”. Ceiling lamp
must be closed during driving.

 Fan switch
Moving the switch upwards brings low wind speed and
moving the switch downwards brings high wind speed. The
fan will stop when the switch is moved to neutral position.

 Horn button

The horn will sound when the button in center of the steering wheel is pressed. See Fig. 3-1 "1.1

49
Control mechanisms and instruments" in this chapter.

1.2.3 Steering wheel

The steering wheel is located in the cab (see Fig. 3-1). It is connected to the steering gear. The
machine will turn right during normal work of the machine if the steering wheel is rotated clockwise;
the machine will turn left if the steering wheel is rotated anticlockwise.

Characteristics are as follows:

 Rotation angles of the steering wheels are unequal to that of the machine. Continuously
rotating the steering wheel can increase steering angle up to intended position.

 Faster rotation of the steering wheel results in faster steering of the machine.

 After rotation, the steering wheel does not automatically return, and steering angle of the
machine is changeless. Therefore, the steering wheel shall be reversely rotated to drive the
machine straightly when steering is completed.

1.2.4 Control lever, pedal

 Shift control lever
The lever controls travel direction and speed of the
loader.
When the lever is in position N, the loader is in
neutral position. When the lever is in postion F,
push the high/low speed control lever to: 1) position
L, the loader will be in gear I and move forward
slowly; 2) position H, the loder will be in gear II and
move forward fast. When the lever is in position R,
push the high/low speed control lever to: 1) position
L, the loader will be in reverse gear I and move
backward slowly; 2) position H, the loder will be in
reverse gear II and move backward fast.

 Bucket control lever

Neutral
position Neutral Lift
The lever is for operating the bucket, with 3 Fore-rake Rear-rake Lower position
gears. Float

Rear rake: for retracting the bucket

Neutral position: for keeping the bucket at a
certain position
Fore rake: for unloading
 The boom’s control lever
Bucket control
The lever is for operating the boom, with 4 shifts. Boom control lever
lever
Lift: for elevating the boom
Neutral position: for keeping the boom at a certain position

Lower: for lowering the boom

Float: The boom freely moves upon effect of external force.

Brake pedal

50
Brake pedal is for braking. See Fig. 3-1 of 1.1 Operation mechanism and instruments.

 Accelerator pedal

This pedal controls the engine accelerator. See Fig. 3-1 of 1.1 Operation mechanism and
instruments.

Speed of the engine can be adjusted between idle and full speed without limitation.

 Parking brake control lever

The lever, located at the left side of seat, is used for control of parking braking,
 Flameout control flexible shaft
Flameout control flexible shaft is behind the parking brake control
lever at the left side of seat. For flame-out of the engine,
pull up the flexible shaft.

1.2.5 Frame locking lever Parking brake

control lever

Warning

 Front and rear frame locking levers must be used for

maintenance or transport of the machine.

 Frame locking levers must be opened for normal travel.

The lever functions to lock front and rear frames during maintenance or transport of the machine
to prevent their revolution.

1.2.6 Traction pin

The traction pin shall be inserted into the counterweight for traction.

51
1.2.7 Fuse

Fuse box

The fuse box is installed on the right side of the steering wheel assembly in the cab, and the
electrical system 9-way fuse is integrated in the box. When any one or several lines of loads or
wires are short-circuited, the corresponding fuse will be fused, and the function instructions are
shown in the sticker on the cover.

Caution

 Start switch must be disconnected before replacing fuse. Fuse functions

to protect electrical equipment and cable to avoid burnout. Fuse shall
be timely replaced if it is corroded, oxidized or loosened.

 Fuse shall be replaced with that of the same specification.

1.2.8 Adjustment of the seat

Warning

 For adjusting the driver’s seat, the loader shall be parked

in a safe place and the engine shall be shut down.

 The driver’s seat shall be adjusted before start of

operation or replacement of driver.

 Make sure you’re capable of fully treading the brake

pedal when your back is against the driver’s seat-back.

Adjustment of weight

52
 The load bearing adjustment handle (A) is located to
the lower center of the seat. Damping rigidity will
decrease when handle A is rotated anticlockwise.
Damping rigidity will increase when handle A is rotated
clockwise. The operator shall rotate handle A according A:Load bearing
to his weight until he feels comfortable. adjustment
handle
 Front-rear adjustment
C:Backrest
adjustment handle
The front-rear adjustment handle (B) is located in front
of the lower left of the seat. Handle B shall be lifted with
hands for adjusting the seat front and rear, and it shall B:Front-rear
be released for automatic locking when ideal position is adjustment handle
reached.

 Adjustment of backrest angle

The backrest angle adjustment handle (C) shall be moved upwards for pushing backrest, and
released for locking when proper angle is reached,

 Adjustment of height

The height of the seat is divided into 3 levels (3 locking positions), and it can be adjusted by
operators as necessary. For adjustment, operators’ hands shall hold the base below seat cushion,
and pull the base up hard and stably. During up-movement of the seat, grille will be touched and a
click will be heard. At this time, the seat will stop at the position if hands are released. The seat can
lower to the lowest position if it is pulled up and pressed down when it is adjusted to the highest
position.

 Adjustment of headrest height

For adjustment of headrest height, operator’s hands shall hold the headrest and pull up or press
down hard and stably.

1.2.9 Use of safety belt (if installed)

If the seat is installed with safety belt, the driver shall buckle up for operation. Before buckle-up,
wear and firmness of safety belt shall be inspected and it shall be replaced timely when necessary.

Before use, length of safety belt shall be adjusted to ensure effect of safety protection and comfort.
Length of safety belt can be adjusted by moving locking bolt on safety belt. Locker of safety belt is
located to rear left of the seat. Locking bolt will get stuck when it is inserted into opening of the
locker. There’s a red button next to the opening of the locker. Locking bolt will jump out of the locker
when the button is pressed. Before using the safety belt the operators need to check if the locker
can lock and unlock normally.

1.2.10 Rearview mirrors

Rearview mirrors are installed at upper left and upper right of the cab. Rearview mirrors must be
adjusted before working. Elevation angle of rearview mirror must be adjusted to offer good rearview
for drivers.

1.2.11 Keys

The loader is equipped with 3 sets of keys.

53
 Cab door key & engine start switch key

 Engine hood left/right screen plate key

 Engine hood rear door key

2 Running-in of New Loader

For sufficient running-in of the friction parts to ensure long service life, the operators need to have
running-in to the loaders, starting from idling and gradually increasing the load. Running-in shall be
done for totally 60 hours. Within running-in period, the do’s and don’ts below shall be followed.

 After startup, the new loader shall run for 5min at low speed and neutral gear for sufficient
preheating of the engine.

 The engine shall not be suddenly accelerated during preheating.

 Unless for emergencies, sudden start, sudden acceleration, sudden turning and sudden
braking shall be avoided.

 At each gear with no load, the new loader shall be driven from low speed to high speed. During
driving, left steering, right steering and braking shall be done stably.

 Running-in shall be arranged evenly for forward gear I, forward gear II, reverse gear I and
reverse gear II within the period.

 For running-in, the new loader shall be loaded with bulk materials, while over-work and sudden
work shall be avoided. Loading weight shall not exceed 70% of the rated weight, and driving
speed shall not exceed 70% of the maximum speed.

 Attention shall be paid to lubrication of the machine. Lubricating oil shall be changed or added
as per specified time.

 Temperatures of transmission, torque convertor, front & rear axles, rims and brakes need to
be frequently checked. If overheat occurs, the causes shall be made clear and removed.

 Bolts and nuts of the parts shall be inspected for fastening.

The tasks below shall be done after running-in for 10 hours and after the running-in period is over.

1. Bolts and nuts of the parts shall be fully inspected for fastening. Especially, diesel engine
cylinder cover bolt, exhaust pipe bolt, front/rear axle fixing bolt, rim nut and transmission shaft
connecting bolt shall be inspected for at least once.

2. Primary oil filter, secondary oil filter and fuel oil filter shall be cleaned.

3. Fan belt, power generator belt and air condition compressor belt shall be inspected for firmness.

4. Ratio and storage of electrolyte in the accumulator shall be inspected. Connectors of the
accumulator shall be tightened.

5. Oil level in the transmission shall be inspected (see 3.6.3 Oil filling into transmission).

6. Sealing of the hydraulic system and the braking system shall be inspected.

7. Firmness and flexibility of connection of each control lever and accelerator linkage shall be
inspected.

54
8. Temperature and connection of the parts in the electrical system, supply state of the power
generator and work of instrument, lighting and steering signal shall be inspected.

9. The drain valve on the bottom of the gas storage tank shall be opened for drainage.

When the running-in period is just over, below tasks need to be done as well:

1. Clean filter screen of transmission oil sump and element of torque converter oil filter.

2. Clean element of return oil filter on the hydraulic oil tank.

3. Replace engine oil (see “3.6.1 Supply of engine oil”).

3 Operation of the Loader

3.1 Cautions for operation

1. Diesel oil for the loader must be pure and precipitated in advance for at least 72 hours. Choice
of different types of oils shall be in accordance with specific requirement.

2. Hydraulic transmission oil for the transmission and the torque converter and hydraulic oil for
the hydraulic system must be cleaned.

3. The loader must be regularly maintained and lubricated as specified.

4. Do not start to move forward before the breaking pressure reaches 0.4MPa after the startup
of engine.

5. Under a temperature lower than -5℃, the engine needs to be preheated with hot water or
vapor to 30~40℃ before start.

6. During driving, it is unnecessary to park the machine or tread the brake pedal for shifting to
forward gear. For shifting from low speed to high speed, the accelerator shall be shortly
released meanwhile the shift control lever shall be operated, followed by treading of the
accelerator. For shifting from high speed to low speed, the accelerator shall be released for
slow deceleration, followed by gear shifting.

7. The control lever shall be pushed (pulled) back to neutral position when the boom and the
rotating bucket reach the required positions.

8. Before shifting from forward to reverse and vice versa, the loader needs to be stopped.

9. The engine can be put into full-load running only if water is hotter than 60℃ and engine oil is
hotter than 50℃. During work of the engine, both water and engine oil shall not exceed 95℃,
and torque converter oil shall not exceed 120℃. The machine shall be parked for cooling when
any temperature exceeds allowed value.

10. Materials shall not be transported with the bucket lifted to the highest position. During transport
of material, lower hinge point of the boom shall be kept 400~500mm above the ground for the
purpose of stable driving.

11. Power of the diesel engine for the loader will fall with increase of altitude, ambient temperature
and relative temperature. Therefore, the user must pay attention to local environment when
using the loader, and obtain actual power of the diesel engine under local conditions as per
the requirements in the power correction table of Instructions for Operation and Maintenance
of Diesel Engine.

55
3.2 Start

3.2.1 Thorough inspection before start

 Bottom and periphery of the loader shall be inspected for bolt looseness, dirt, oil leakage,
coolant leakage, and parts damage. And status of the accessories and hydraulic parts shall be
inspected.

 Inspection before start:

1) Inspect oil level in the fuel oil tank (see “3.6.2 Filling into fuel oil tank”)

2) Inspect oil level in the hydraulic oil tank (see “3.6.5 Filling into hydraulic oil tank”)

3) Inspect oil level in the engine oil sump (see “3.6.1 Supply of engine oil”)

4) Unscrew the cover of water tank to inspect water level therein

5) Unscrew oil cup of the booster pump assembly to inspect level of brake fluid

6) Inspect sealing of oil pipe, water pipe, gas pipe and parts

7) Inspect sealing of and near pipeline of the hydraulic system

8) Inspect wiring of the accumulator

9) Inspect whether tyre pressure is normal (see “8.1 Overall performance” for tyre inflation
pressure)

10) Inspect whether each control lever is flexible and put at neutral position

11) Adjust position of seat for comfort; see “1.2.10 Adjustment of seat” for adjustment of seat.

12) Inspect whether safety belt (if installed) and safety devices are normal

13) The engine can be started when normality of all parts is confirmed after inspection.

3.2.2 Start of the engine

Cautions for start of the engine:

 Before start, all control handles of the loader must be put at neutral position, and the shift
control lever shall be put at neutral gear and the switch shall be put at the original position.

 At the moment of start, the accelerator shall not be treaded to the bottom to avoid damage to
the parts of the diesel engine.

 The engine shall be started as per correct procedures.

 Other operations on the engine shall follow Instructions for Operation and Maintenance of
Diesel Engine.

Procedures for engine start:

 Put the shift control lever to lower left of the steering wheel at neutral position

 Clockwise rotate the start key to the position “ON”, connect the general power switch, honk
the horn

 Tread the accumulator a bit, rotate the start key to the position “start”; after start, release the

56
 start key (At this, it will automatically return to the position “ON”. Each start shall be not longer
than 5~10s. Continuous work of the start motor shall be not longer than 15s.)

 The interval shall be longer than 1 minute if restart is needed after start failure. The causes
shall be made clear if start failure occurs three times continuously, and the engine can be
started only if removal of fault is confirmed.

3.2.3 After start of the engine

 Put the engine under low-speed rotation, start the engine after making clear the cause if pointer
of engine oil pressure gauge fails to fall in normal range within 10s, (otherwise, failure of the
engine can be caused)

 Use control levers of the working device in turn to put preheated hydraulic oil into circular flow
in hydraulic cylinder and hydraulic pipeline so as to improve temperature of hydraulic element
quickly.

 After start of diesel engine, idle the engine for a few minutes, gradually improve the speed to
1000~1200r/min, followed by entry into running under partial load. During running, continuous
attention shall be paid to change in reading of the gauge.

 At neutral gear, the engine shall not run at high or low speed longer than 20min.

 Load shall be frenquently applied or the engine shall be put into running at medium speed if it
is necessary to put the engine into running at neutral gear.

3.3 Driving

3.3.1 Start

It is necessary to make sure there are no unrelated personnel on or around the loader and the
loader is always controlled before driving to avoid accidents.

 Lift the boom, tip back the bucket and keep

gesture of travel

 Put the shift control lever at forward gear I or

reverse gear I

57
  Tread the brake pedal, press the parking
brake control lever and release parking
brake
 Release the brake pedal, slowly tread the
accelerator pedal and start the loader for
advance or reverse.

 The loader can be driven safely only if braking pressure exceeds the specified value (0.45MPa).

 Materials shall not be transported with the bucket lifted to the highest position. During transport
of material, lower hinge point of the boom shall be kept 400~500mm above the ground for the
purpose of stable driving.

Caution

 The loader shall not be driven at high speed on a slope or a

pavement with poor conditions.

 Proper gear shall be selected before downgrade, and the gear

shall not be shifted during downgrade.

 Overspeed is prohibited for downgrade. The brake pedal can

be treaded for deceleration.

3.3.2 Shifting between advance and reverse

 For shifting gear, the accelerator shall be treaded properly to avoid over-impact from the
transmission system.

 Change of driving direction (between advance and reverse) shall be done after parking to offer
comfort for driver and maximize service life of transmission element.

 It is unnecessary to park the machine or tread brake pedal for gear shifting during driving. The
accelerator shall be released meanwhile the shift control lever shall be operated, followed by
treading of the accelerator, for shifting from low speed to high speed. The accelerator shall be
released for slow deceleration, followed by gear shifting, for shifting from high speed to low
speed.

3.3.3 Steering

 During driving, the loader can be turned by rotating the steering wheel to the intended direction.

 Centered to the hinge pin, the loader turns with front and rear frames bowed.

Warning

58
  The loader at high speed shall not be turned suddenly or on a steep
slope.

 The loader will turn failure if flameout of the engine occurs.

3.3.4 Braking

 Do not put feet on the brake pedal unless necessary.

 Do not repeatedly tread the brake pedal unless necessary.

 During downgrade, the engine shall not be shut down and the shift control lever shall not be
put at neutral gear.

Warning

A moving loader shall not be decelerated or parked with the

parking brake control lever, unless in case of emergencies.

3.4 Parking

3.4.1 Parking steps

 Release the accelerator pedal, tread the
brake pedal to stably park the loader and put
the shift control lever at neutral position
 Pull up the parking brake control lever to put
the parking brake to braking mode when the
loader safely stops.

 Lower the bucket (or alternative working

device) to the ground and lay it flat.
 Park the machine on flat ground where there
is no risk of fall rock, landslide or flood;
wedge wheels to prevent movement of the
machine if the machine has to be temporarily
parked on a slope.
 Cooling water (not mixed with antifreeze)
shall be drained after parking in winter if air
temperature is lower than 0℃ (see “3.5.3
Operation under cold weather”).
3.4.2 Steps for stopping the engine

 Idle the engine for 5min or so at low speed to cool different parts evenly.

 Pull up the flameout control flexible shaft to shut down the engine.

59
 Rotate the key to the position “OFF”, take the key and carefully keep it.

Caution

Before cooling of the engine, the engine shall not be shut down
by pulling up the flameout control flexible shaft.

3.4.3 Leaving the loader

 For getting off, ladder and handrail shall be used in face of the loader. Anyone shall not jump
off.

 Parts of the engine shall be inspected to see if there is accumulation of fragment. If there is
such accumulation, it shall be immediately eliminated to prevent fire disaster.

 All flammables around the loader shall be removed to prevent fire disaster.

 The door, the window and the side door shall be locked, and the key shall be taken down and
carried away.

3.4.4 Tasks below are required after completion of daily works

 Inspect storage of fuel oil.

 Inspect level and cleanliness of oil in the engine oil sump, find and remove the cause if oil is
at higher level and gets dilute.

 Inspect oil pipes, water pipes, air pipes and parts for leakage.

 Inspect the transmission, the torque converter, the hydraulic oil pump, the steering gear, the
front axle and the rear axle to verify their fixing and sealing and whether there is overheat.

 Inspect rim bolt, transmission shaft bolt and pin shafts for looseness.

 Drain cooling water (not mixed with antifreeze) in case of air temperature lower than 0℃ (see
“3.5.3 Operation under cold weather”).

 Inspect whether the working device is normal.

 Inspect whether appearance and air pressure of tyre are normal (for tyre pressure, see “8.1
Overall performance”).

 Fill grease to each oil filling point of the working device.

 Unscrew oil cup of the booster pump assembly to inspect level of brake fluid.

 Clean appearance of the machine and clear mud and foreign materials in the bucket.

3.5 Working

3.5.1 Preparations for working

Clean work site, fill and level up pit and remove obstacles that can damage tyre or obstruct work
(sharp stone, etc.).

60
3.5.2 Working mode

(1) Loading

 Cooperation between the loader and lorry can improve work efficiency, especially for long-
distance transport.

 In case of cooperation, the loader shovels materials, while lorry undertakes long-distance
transport and unloading.

Generally, there are two loading/unloading modes:

 Crossed loading
The loader fully shovels materials in face of material
pile, and then reverses. Then, the dumper enters the
gap between the loader and material pile. This
method consumes the shortest time and can shorten
cyclic time most effectively.

 V-shaped loading
Position of the dumper shall be set to keep 60°
between the dumper and reverse direction of the
loader. After full loading of the bucket, the loader
shall be turned by an angle for return and driven to
the dumper.
Smaller V-shaped angle for working of the loader
brings higher work efficiency.
(2) Shoveling

 Shoveling and loading soil blocks or stones

The vehicle shall directly face the stockpile and be
operated according to the following requirements
when it is used for loading soil blocks or stones.
To lower the bucket during vehicle moving forward,
the vehicle shall be stopped when the bucket is 30cm
above the ground and the bucket shall be slowly
lowered.
If the bucket hits against the ground, front wheel will
get off the ground and slips.
Immediately shift gears to slow down before material
pile, depress the accelerator pedal while completion
of speed change and insert the bucket into material
pile.
 Keep the bucket horizontal in the case of
crushed material, or downward with a dip angle
in the case of stone blocks. Rock pile

Caution:
Prevent stone blocks from entering the space under

61
the bucket. Otherwise, front wheels will go off the
ground and slips.
Try to maintain the load at the center of the bucket.
Imbalance will occur if the center of gravity is at one
side of the bucket.
 The boom shall be lifted to avoid over-depth of
the insertion when the bucket is inserted into
material pile. By lifting the boom sufficient
traction force will be generated via the tyre.

 The bucket control lever shall be used to retract

the bucket to fill it with materials if there are
sufficient materials in the bucket.
Remarks:
The front wheels will leave the ground and slip will
be caused if edges of the bucket move up and down
when the bucket is inserted into material pile or
excavates.

 If the bucket is overloaded, materials therein

shall be quickly dumped and the bucket shall be
quickly retracted to avoid falling of materials
during transport.

 Shoveling materials on flat ground

For shoveling materials on flat ground, edges of the
bucket shall be slightly inclined to the ground, as
shown on the figure. However, care shall be taken to
avoid unbalance by concentrated load at one side.
The shoveling shall be carefully done at gear I.

 Edges of the bucket shall be slightly inclined

downwards.

 During advance of the loader, the boom control

lever shall be raked forwards so that thin layer
of soil can be cut off anytime during excavation.
 During advance of the loader, the boom control
lever shall be slightly moved front and rear to
reduce resistance.

62
 Caution

For shoveling, two sides of the bucket shall cut in evenly, and
unilateral cut-in shall be avoided. The loader shall face the front, and
there shall be no angle between front frame and rear frame.

(3) Carrying

Independent Carrying can be done in the circumstances below.

 Road surface is so soft and worksite is not leveled that lorries cannot be used.

 Distance for carrying is shorter than 500m, and handling by lorries is not cost-effective.

 Speed for carrying shall be determined according to the carrying distance and road conditions.

 To maintain safety, stability and good vision, the bucket shall be rotated upwards to limit (where
the bucket contacts the boom limiting stopper), and lower hinge point of boom shall be kept at
position of transport (400~500mm above the ground).

(4) Unloading

 For dumping materials to lorry or goods

yard, the boom shall be lifted to the position
of the bucket (fore-raked to limit) until it is
kept off carriage and material pile. The
bucket control lever shall be fore-raked to
fore-rake and unload the bucket. Full or
partial unloading can be done through the
bucket control lever. For unloading, action
shall be gentle to reduce shock of material
to the lorries.

63
 If material is adhered to the bucket, the rotating bucket control lever can be handled back and
forth to vibrate the bucket thus detach the material.

 After unloading, the bucket lay-flat mechanism can be used to back-rake the bucket to flat
position and push forward the boom control lever for next cycle

(5) Bulldozing
The bucket shall be flat against the ground,
and the accelerator shall be treaded for
advance. If an obstacle is found during
advance, the boom can be slightly lifted.
When the boom is lifted, the boom control
lever shall be put between lowering position
and elevation position to keep smooth
proceeding of bulldozing, but shall not be
moved to either of the two positions.

Caution

For bulldozing, full attention shall be paid to temperature of hydraulic

oil. If hydraulic oil is too hot, the loader shall be halted and put into
work after cooling of hydraulic oil.

(6) Strickling
The bucket shall be overturned to the bottom
to bring bucket blade into contact with the
ground. For hard pavement, the boom control
lever shall be put at floating position; for soft
pavement, it shall be put at neutral position.
Reverse gear shall be connected to strickle
the ground with bucket blade.

(7) Traction

Warning

64
  Before traction, the parking brake must be used to lock the wheels
to avoild rolling of the loader

 During traction, special care must be taken to avoid serious or even

fatal injury.

 If possible, the engine of the hauled loader shall be kept running so that both braking and
steering are feasible.

 The front and the rear transmission shaft can be removed if it is impossible to start engine of
the hauled loader. The steering cylinder shall be removed if steering is impossible.

 The connection hole on the rear frame inside the rear wheel is only for lifting and binding, but
can not be used for traction.

 If the hauled loader has no brake, soft traction shall not be adopted. Fixed draw bar shall be
connected to the traction pin at the rear of the loader.

 If the hauled loader can not be turned or braked and it shall not be accessed by anyone.

 Whether tow cable or traction pin is bearable to weight of the hauled loader shall be inspected.
2 pieces of tow cables or draw bars if the hauled loader has to pass exposed earth or upgrade,
and each bearable to at least 1.5 times of the weight, shall be used.

 The angle of tow cable shall be minimized to keep the included angle between tow cable and
the two loaders less than 30°. Traction points of the two loaders shall be at approximate heights.

 The connection between hauling equipment and the loader shall be firm.

 The hauling loader or machine shall not be lighter than the hauled loader, and have sufficient
traction and braking capacity so that two loaders can be hauled and braked during upgrade or
downgrade.

 For hauling downgrade, a loader with sufficient traction and braking capacity shall be used,
and rear of the hauled loader shall be hauled with another loader. This can avoid out-of-control
and turnover of the hauled loader.

 For hauling, start and stop shall be gentle, and the loader shall be driven at low speed with
alarm flasher turned on.

 For hauling a loader, hauling speed shall be controlled below 2km/h, and the hauled loader
shall be hauled to the nearest repair factory. Front and rear transmission shafts must be
removed, or the hauled loader shall be transported on trailer if traction distance is longer than
10km or traction speed is higher than 10km/h.

3.5.3 Operation under cold weather

Cautions for low temperature

If the temperature is too low, start of the engine may be difficult, and the radiator may freeze.
Therefore, the requirements below shall be followed.

 Low-viscosity fuel oil, hydraulic oil and lubricating oil shall be used. Coolant shall be added
into antifreeze. For oil type, see “2.2.1 Selection of oils”

 Cautions for use of antifreezes:

65
1. Antifreeze containing formaldehyde, alcohol or propyl alcohol shall not be used.

2. Any waterproof agent shall not be used independently or jointly with antifreeze.

3. Antifreezes of different marks shall not be mixed.

4. For replacing antifreeze, ratio of antifreeze shall be in accordance with the specifications (see
“2.1.2 Coolant”).

Caution

Addition of antifreezes shall be kept off naked flame.

 Cautions for use of the accumulator:

1. When ambient temperature falls, capacity of the accumulator will also fall. Electrolyte may
freeze if charge rate of the accumulator falls. Therefore, charge rate shall be kept close to 100%
and the accumulator shall be heat-insulated so that the engine can be easily started next day.

2. If the accumulator freezes, it shall be removed as the method specified in “8.16 Maintenance
of accumulator” instead of charge or start of the engine, and it shall be put in greenhouse or
warm water (protected against entry of water) for slow heating to 15℃, otherwise explosion
may occur.

3. Frost-resistant accumulator shall be used for service in high and cold region.

 Cautions after completion of daily works:

The requirements below shall be followed to prevent freeze adhered to the machine and avoid
impact on start of the loader next day.

1. Completely remove sludge and water on the machine to avoid freezing and damage of sealing
element due to entry of sludge or water into seal.

2. Park the loader on dry hard ground; park it on wooden board if parking the loader on dry hard
ground is impossible. Parking on wooden board can prevent the loader from being frozen on
the ground and avoid impact on start of the loader next day.

3. Under low temperature, capacity of the accumulator significantly falls. Therefore, the
accumulator shall be covered or moved to a warm place and installed for working next day.

4. When air temperature falls below 0℃, drain valves at side of the engine, bottom of the water
tank and the transmission oil radiator shall be opened to drain cooling water and prevent frost
crack of parts if no antifreeze is added in cooling water. If antifreeze is added, instructions on
antifreeze label shall be followed.

66
 Switch of water
drain valve

Engine water
drain valve

After cold weather

When the weather warms up, engine oil, fuel oil and hydraulic oil at related positions shall be
replaced with those adapted to ambient temperature.

3.6 Supply of oils

3.6.1 Supply of engine oil

① Oil level inspection

Caution

Oil level inspection must be done before working or 15min after shutdown
of the engine.

 Park the loader on a flat field, put the shift control lever
at neutral position, pull up the parking brake control
lever and place stop dog in front and rear of tyres.
 Open engine hood side door to the right of the engine
hood.
 Pull out dipstick, clean and insert it and pull out it
again for inspection.
 Engine oil shall be added if oil level is lower than the
scale “L”. The causes shall be made clear and
removed if oil level is higher than the scale “H”.
Dipstick shall be put back and engine hood side door Engine dipstick
shall be closed if oil level is between “H” and “L” (oil
level is proper). For selection of engine oil, see “2.2
Oil selection” (the same below)

② Replacement of engine oil

67
  Park the loader on a flat field, put the shift control lever
at neutral position, pull up the parking brake control
Engine oil drain plug
lever, place stop dog in front and rear of tyre and start
the engine for idling; shut down the engine when
engine oil reaches 20℃~40℃.
 Screw off the drain plug on the bottom of the engine
to drain oil, receive oil with container and replace the
engine oil filter.

 Fully drain old oil, screw on the drain plug, open the
left door of the engine hood, fill specified engine oil (c.
13L) from the engine oil filler, put the engine into idling
and inspect the engine oil filter and the drain plug for
oil leakage.
 Shut down the engine for about 15min to let the
engine oil sufficiently flow back to the oil pan and re-
inspect engine oil level.
③ Replacement of engine oil filter

Removal

 Clean areas nearby fitting seat of the engine oil filter and remove the filter with filter element
wrench.

Installation

 Fill the filter element with diesel and coat rubber seal ring with engine oil.

 Tighten it by 3/4~1 turn when the seal ring contacts the base.

 Start the engine and inspect whether the sealing gasket has been sealed; if not sealed, remove
the filter element to inspect sealing face

Caution

 After replacement of filter element, the engine must be put into idling for 1
minute at least to ensure that the engine has been lubricated before
working.

 Mechanical over-tightening may damage thread or seal of the engine oil

filter element.

3.6.2 Filling into fuel oil tank

Oil level inspection
 Park the loader on a flat field and observe the
upper and the lower liquidometers from outside of
the oil tank to inspect oil level. Add fuel oil from the
filler on the top of the oil tank if reading of the lower
liquidometer is lower than scale 5. See “2.2 Oil

68
 selection” for selection of fuel oil.

3.6.3 Filling into transmission

① Oil level inspection

 Park the loader on a flat field, put the shift control lever
at neutral position, pull up the parking brake control
lever and place stop dog in front and rear of tyres.
 Start the engine and run it at idle speed for several
minutes. Open transmission filler cap, pull out the
dipstick, wipe it and put back, and then pull up again
Dipstick upper limit
for checking.
If oil level is between the dipstick upper limit and lower Dipstick lower limit
limit, it indicates oil amount is proper
If oil level is under the dipstick lower limit, the specified
hydraulic transmission oil shall be added. Refer to
“Chapter IV 2.2 Oil selection” for selection of hydraulic
transmission oil, which applies also to the following.
② Replacement of oil

 Park the loader on a flat field, put the shift control lever at neutral position, pull up the parking
brake control lever and place stop dog in front and rear of tyre.

 Start the engine for idling for a few minutes, shut down the engine, screw off the drain plug at
the side of the transmission to drain oil and receive oil with container.

Warning

Hydraulic transmission oil is hot. Protective equipment shall be worn and

care shall be taken for operation to avoid personal injury.

 Full drain old oil, clear iron scrap attached on the

drain plug and oil dirt on the transmission, re-wrap the
drain plug with new thread seal tape and install the
drain plug.
 Screw off the transmission filler cap to the right of
hinge of frame and fill specified hydraulic
transmission oil (about 45L).
 Start the engine for idling for 5 minutes, shut down
the engine and re-inspect oil level in the transmission.
 Screw on filler cap.

69
 Caution

 If the old oil is dirty, do not directly add oil but take out the primary filter
at the side for cleaning all its parts. Please contact service technician
if a lot of metal powders or fragments are found.

 Reinstrall all removed the parts in order, add a small quantity of

hydraulic transmission oil, start the engine for idling for 3~5 minutes,
full drain oil in the oil sump and add specified oil

3.6.4 Oil filling into drive axle

① Oil level inspection

 Drive the loader to a flat field, put the shift control lever at neutral position, pull up the parking
brake control lever and place stop dog in front and rear of tyre. Screw off the filling plug in
center of the rear drive axle housing. Add specified gear oil unless oil level is at the lower edge
of the filler (mean oil is proper). After adding oil, observe oil level about 5min and screw on the
filling plug if oil level is kept stable. See “2.2 Oil selection” (the same below) for selection of
gear oil.

Axle housing filling plug Axle housing drain Drain plug of hub

② Oil Replacement

 Drive the loader to a flat field for idling about 10min and slowly move the loader by the
accelerator to bring the drain plug on hub end face of the front drive axle to the lowest position

 Shut down the engine, put the shift control lever at neutral position, pull up the parking brake
control lever and place stop dog in front and rear of tyre

 Screw off the drain plugs on the two hub end faces of the front drive axle and the drain plug
on the center bottom of the housing to drain oil and receive oil with containers.

Warning

Gear oil may be hot. Protective equipment shall be worn and care shall
be taken for operation to avoid personal injury.

70
 Fully drain old oil and screw on the drain plug on the center bottom of the housing.

 Start the engine, press the parking brake control lever and slowly move the loader by the
accelerator to bring the oil drain hole on hub end face to horizontal axis of tyre. Shut down the
engine, put the shift control lever at neutral position and pull up the parking brake control lever.

 Add specified gear oil (about 15L) from the oil drain holes on the two hub end faces of the front
drive axle and the drain plug in center of the housing and re-inspect oil level.

 Tighten the drain plugs on the two hub end faces of the front drive axle and the filling plug in
center of the housing.

 Replace gear oil for the rear drive axle as per the steps above.

3.6.5 Oil filling into hydraulic oil tank

① Oil level inspection

 Park the loader on a flat field, lay the bucket flat

on the ground and align the front and the rear
frames without included angle.
 View the liquidometer on the hydraulic oil tank to
the left of the loader (Oil level within the
intermediate scale ±2 is proper. If oil level is
lower than the intermediate scale-2, please add
specified hydraulic oil). For selection of hydraulic
oil, see “2.2 Oil selection” (the same below).

② Oil Replacement

Warning

During oil replacement, different operations are needed for the

machine. Operations shall follow related safety specifications, and
attention shall be paid to safety.

Caution

During oil replacement, special attention shall be paid to cleanliness

of hydraulic oil, and foreign materials shall be prevented from
entering into the hydraulic system.

 Clear foreign materials in the bucket, park the loader on a flat field, put the shift control lever
at neutral position, pull up the parking brake control lever, start the engine for 10 minutes idling,
repeatedly lift the boom, lower the boom, fore-rake the bucket and back-rake the bucket.

 Elevate the boom to the highest position, farthest back-rake the bucket and shut down the
engine.

 Push forward the boom control lever to turn the bucket forward upon its dead weight, drain oil

71
 in the rotating bucket; when the bucket is turned to required position, push forward the boom
control lever to lower the boom upon its dead weight and drain oil in the boom oil cylinder.

 Clean the oil drain hole at the bottom of the hydraulic oil tank, screw off the drain plug, drain
dirty oil, receive it with container and screw off filler cap to accelerate oil drainage.

 Drain plug Filler cap

Warning

Hydraulic oil may be hot. Protective equipment shall be worn

and care shall be taken for operation to avoid personal injury.

 Remove the flange cover on the bottom of the oil tank, clean interior and filler of the oil tank,
suction port filter elements and return port filter elements (If a filter element is damaged, it shall
be replaced.)

 Re-tighten the flange cover and the drain plug.

 Add specified hydraulic oil through the filler on the top of the left rack up to center scale of the
liquidometer and screw on filler cap (Filler filter element shall not be removed for direct oil filling
into the oil tank.)

 Start the engine, lift and lower the boom twice or three times, fore-rake, back-rake, turn left
and turn right the bucket to the maximum to fill the oil cylinder and oil pipes with hydraulic oil
and idle the engine for 5min to exhaust air in the system

 Shut down the engine, open filler cap of the hydraulic oil tank, inspect oil level and add oil if oil
level is lower.

 Tighten the filler cap.

 3.6.6 Prevent leakage of hydraulic oil when repairing the hydraulic system

 The loader uses a hydraulic oil tank with a leak-proof structure, which can reduce hydraulic oil
leakage during maintenance and disassembly.When repairing and disassembling, follow the
steps below.

 Park the loader on a flat field, the bucket is flat on the ground, and the front and rear frames

72
 are aligned without angle.

 Put the shift lever in the neutral position and pull up the parking brake lever.Operate the
joysticks repeatedly to remove the oil pressure in the hydraulic system.

 Clean the oil suction port of the working pump, unscrew the oil filler cap on the top of the
hydraulic oil tank, and then loosen the hose clamp at the oil suction port to make the hydraulic
oil flow back to the hydraulic oil tank.Then disassemble any oil port of the component at the
suspected problem point. At this time, there is still a small amount of oil (remaining oil in the
pipeline) flowing out. When there is no oil flowing out from the dismantling place, the
maintenance operation can be officially carried out.

 After the repair is completed, add hydraulic oil to the specified position of the level gauge. Then
tighten the oil drain plug on the top of the hydraulic oil tank and make sure it is well sealed
here.

3.7 Long-term storage

3.7.1 Before storage

The steps below shall be followed if it is necessary to store the loader for long term.

 Clean all parts of the loader, dry the loader in the air, store it in dry room rather than in the
open air; if the loader has to be stored in the open air, park it on concrete ground easy for
drainage and cover it with canvas

 Before storage, add lubricating grease and replace hydraulic oil.

 Coat exposed part of piston rod of the hydraulic oil cylinder with a thin layer of lubricating
grease.

 Remove negative pole of the accumulator and cover the accumulator, or remove the whole of
the accumulator from the loader for independent storage.

 Drain cooling water (except that mixed with antifreeze) if air temperature is lower than 0℃(see
3.5.3 Operation under cold weather).

 Lay the bucket flat on the ground, put all control levers at neutral position, pull up the parking
brake control lever and lock the door of the cab.

3.7.2 During storage

Warning

If antirust agent is used indoors, doors and windows shall be

opened to keep ventilation to exhaust toxic gas.

The loader shall be started once every month. On this basis, moving parts and partial surface can
be coated with new lubricating oil and the accumulator can be charged.

Before operation and work, clear lubricating grease on piston rod of the hydraulic oil cylinder.

73
3.7.3 After storage
When long-term storage ends, the operations below shall be done.
 Clear lubricating grease on piston rod of the hydraulic oil cylinder.
 Add lubricating grease to all parts needing lubrication
3.8 Common faults and troubleshooting
 3.8.1 Problems of circuits
No. Faults
Lamp is not on fire during
I
high-speed running of engine.
Lamp flashes during running
II
of engine.
Ammeter doesn’t act during
III
running of engine.
AC generator has abnormal
IV
sound.
At connection of start switch,
V 2
start motor fails to rotate.
Pinion gear of start motor
VI engages fails or engages
without rotation.
VII Powerless start of start motor
Start motor separates before
VIII
start of engine.
Analysis of causes
1. Defects of cable (poor
contact of line or open
circuit)
2. Improper tightness of fan
belt
1 Failure of AC generator
2 Defect of cable
3 Improper tightness of fan
belt
Failure of engine
1 Failure of cable
Insufficient charge of
accumulator
Insufficient charge of
accumulator
1 Insufficient charge of
accumulator
2 Motor start failure
1 Failure of cable
2 Insufficient charge of
accumulator
74
Solution
Inspect and repair loose terminal
and line, adjust tightness of fan
belt as specified in Instructions for
Operation and Maintenance of
Diesel Engine
1 Replacement
2 Inspection, repair
3 Adjust tightness of fan belt as
specified in Instructions for
Operation and Maintenance of
Diesel Engine
Replacement
1 Inspection, repair
2 Charge
Charge
1 Charge
2 Replacement
1 Inspection, repair
2 Charge
3.8.2 Transmission system

No. Faults Analysis of causes Solution

1 Lower oil level in transmission oil
tank
2 Oil leakage on main oil duct
3 Blocking of transmission filter
4 Failure of variable-speed pump
Shift pressure at 5 Improper adjustment of pressure
I
each gear is low. regulating valve of shift control valve
6 Failure of spring on pressure
regulating valve of shift control valve
7 Jamming of pressure regulating
valve of shift control valve or piston
of energy accumulator
1 Damage of piston seal ring at the
Shift pressure at gear
II
one gear is low. 2 Damage of seal ring in the oil duct
3 Oil leakage on oil duct of the gear
1 Lower oil level in transmission oil
tank
2 Higher oil level in transmission oil
tank
Overheat of torque 3 Low shift pressure, slip of clutch
III
converter oil 4 Blocking of torque converter oil
radiator
5 Longer continuous work of torque
converter under high load
6 Poor effect of radiator
1 Return failure of shut-off valve stem
The loader fails to of shift control valve
move during high- 2 Gear engagement failure
IV
speed running of 3 Breakage of spring on pressure
engine. regulating valve of shift control valve
4 See “1”, “2”, “3” and “4” of “I”
1 Lower transmission oil pressure
2 Overheat of torque converter oil
Insufficient driving 3 Damage of impeller of torque
V
force converter
4 Damage of large overrun clutch
5 Insufficient output power of engine
1 Add oil to specified oil level
2 Inspect main oil duct
3 Clean or replace oil filter
4 Remove variable-speed pump
for inspection or removal
5 Re-adjustment as specified
6 Replace spring on pressure
regulating valve
7 Remove and inspect and
eliminate jamming
1 Replace seal ring
2 Replace seal ring
3 Inspect the position of oil
leakage, eliminate the leakage
1 Add oil to specified oil level
2 Drain oil to specified oil level
3 See “I” and “II”
4 Clean or replace radiator
5 Halt the loader for proper
cooling
1 Remove shut-off valve to find
cause of return failure, remove
the cause
2 Re-engage gear or adjust shift
control lever
3 Replace spring on pressure
regulating valve
4 See “1”, “2”, “3” and “4” of “I”
1 See “I” and “II”
2 See “III”
3 Remove and inspect torque
converter, replace impeller
4 Remove and inspect large
overrun clutch, replace
damaged part (s)
5 Repair engine

75
3.8.3 Braking system

No. Faults Analysis of causes Solution

1 Replace rectangular seal ring of
1 Oil leakage on piston of brake brake cylinder
caliper 2 Exhaust air
2 Air in brake hydraulic pipeline 3 Inspect sealing of air compressor,
Insufficient 3 Low brake pressure control valve, air storage tank and
I
braking power 4 Wear of cup leather of booster pipeline
pump 4 Replace cup leather
5 Oil leakage from hub to brake block 5 Inspect or replace oil seal of hub,
6 Badly wear of brake block clear oil dirt
6 Replace brake block
1 Dislocaton of brake valve stem,
jamming of piston road, failure or 1 See “II”
Release
damage of return spring 2 Inspect booster pump
II abnormality of
2 Adverse action of booster pump 3 Inspect or replace rectangular seal
brake
3 Return failure of piston of brake ring
caliper
1 Jamming of inlet valve of parking 1 Brake for a few continuous times to
Quick fall of
brake valve by dirt, or damage of blow away dirt, or replace the inlet
pressure of air
the inlet valve valve
storage tank (by
2 Looseness of pipe joint or 2 Tighten joint or replace brake pipe
III more than
breakage of pipeline 3 Inspect cause of poor sealing,
0.1MPa within
3 Poor sealing of check valve on timely replace the check valve
30min) after
combination valve of oil-water when necessary
parking
separator
1 Looseness of pipe joint 1 Tighten pipe joint
2 Abnormal work of air compressor 2 Inspect work of air compressor
3 Sealing failure of inlet valve or 3 Inspect and clean interior of brake
Slow rise in brake membrane of brake valve valve, find cause of sealing failure,
IV
pressure gauge 4 Blocking of vent hole of pressure remove the cause
control valve, or air leakage of 4 Clean vent hole, inspect cause of
check valve and membrane sealing failure of check valve and
drum, remove the cause

76
3.8.4 Hydraulic system of working device

No. Faults Analysis of causes Solution

1 Replace oil seal of oil
1 Wear or damage of oil seal of oil cylinder cylinder
2 Over-wear of multi-way valve, larger fit 2 Replace multi-way valve
clearance between valve stem and valve 3 Find out and repair position
body of oil leakage
Insufficient
3 Oil leakage of pipeline system 4 Replace pump
I elevating force of
4 Serious internal leakage of working 5 Inspect suction pipeline,
boom
(steering) pump exhaust air
5 Suction failure of working (steering) pump 6 Adjust system pressure to
6 Lower system pressure of safety valve specified value
7 Blocking of suction filter 7 Clean suction filter, replace
oil
1 Damage of oil seal on piston of rotating
bucket cylinder 1 Replace oil seal of oil
2 Over-wear of multi-way valve, larger fit cylinder
Powerless rotating
clearance between valve stem and valve 2 Replace multi-way valve
bucket, tendency to
II body 3 Adjust system pressure to
fall or climbing of
3 Lower adjustment pressure of safety specified value
bucket
valve 4 Remove, clean and re-
4 Jamming of overload valve or oil install the valve
replenishing valve by dirt
Flow of hydraulic oil into transmission due to
Entry of hydraulic Replace oil seal of oil pump or
III ageing or breakage of working (steering)
oil into transmission oil pump, replace oil
pump
1 Inspect suction pipeline,
1 Air leakage on or damage of suction repair position of air
Numerous foams in
pipeline, suction of air into the system leakage, replace pipeline
IV oil of hydraulic oil
2 Lower oil level in oil tank, suction of air when necessary
tank, harsh noise
into the system in quantity 2 Add hydraulic oil to required
height

77
3.8.5 Steering system

No. Faults Analysis of causes Solution

1 Short supply of oil for working
(steering) pump
1 Inspect oil pump for abnormality
2 Entry of air into steering system
2 Exhaust air in the system, inspect
3 Failure of ball check valve in valve of
suction pipeline
steering gear, difficulty in both fast
I Steering difficulty 3 Repair valve block, clean valve
and slow rotation of steering wheel,
block jammed by dirt
no pressure
4 Replace priority valve
4 Failure of priority valve
5 Adjust pressure to specified value
5 Excessive low pressure of safety
valve
1 Excessive lower oil level in hydraulic
1 Add oil to specified range
oil tank
2 Replace sealing element of
2 Oil leakage on pipeline, poor sealing
pipeline
Increase in 3 Internal leakage of steering oil
II 3 Replace sealing element of oil
steering turns cylinder
cylinder
4 Wear of steering gear
4 Replace steering gear
5 Higher viscosity or incorrect mark of
5 Replace oil as specified
oil
1 Damage of spring piece on steering
gear 1 Replace damaged spring piece
2 Breakage of release pin or opening 2 Replace release pin or universal
of universal driving shaft driving shaft
Failure of 3 Failure of two-way overload valve 3 Repair two-way overload valve
III
steering 4 Seizure between rotor and stator, 4 Disassemble steering gear for
seizure among valve spool, valve inspection, clean and grind or
body and valve sleeve replace parts
5 Damage of working (steering) pump 5 Replace damaged elements
or priority valve
1 Non-concentricity between steering
column and valve spool
2 Axial dead jacking of valve spool by
steering column
Failure of
3 Axial over-resistance of steering
automatic
IV column Troubleshooting as cause
alignment of
4 Breakage of spring price: increase in
steering gear
pressure drop at neutral position,
unloading failure of steering gear at
stop of steering wheel (deflection of
loader)

3.8.6 Engine

Please refer to the associated document Instructions for Operation and Maintenance of Diesel
Engine.

78
 Chapter IV Maintenance
1 Maintenance Guideline
Before maintenance of the loader, the contents below shall be carefully read.

1.1 Cautions before maintenance

 Maintenance shall be done on firm and flat ground.

 The working device shall be close to the ground and the bucket shall be laid flat.

 All control levers shall be put at neutral position.

 The parking brake control lever shall be pulled up.

 Stop dog shall be placed in front and rear of tyres.

 Front and rear frames shall be locked with frame locking lever.

1.2 Hanging of warning sign

For maintenance, warning sign shall be put nearby the start button to prevent anyone from starting
the engine.

1.3 Preparation of fittings

For replacement in maintenance, fittings designated by us shall be used.

1.4 Preparation of oils

Oils designated in the manual shall be selected as per ambient temperature.

1.5 Use of specified oils

Oil tank shall be kept clean and specified oils shall be used.

1.6 Cleanliness of machine

The whole machine shall be kept clean. In particular, positions for oil filling (lubricating oil cup, filler,
etc.) shall be kept clean to prevent entry of foreign materials.

1.7 Caution for hot oil and oil coolant

Draining hot oil or coolant or removing oil filter immediately when the engine stops is very hazard.
The engine must be waited for cool-down. Oil for drainage shall be in the range 20~40℃. If lower
than the range, oil shall be heated to the range for drainage.

1.8 Inspection of oil and oil filter

After replacement of oil or oil filter, drained oil and replaced oil filter shall be inspected. Please
contact service technicians if metallic particles or other foreign materials are found by quantity.

1.9 Fuel oil primary filter

For adding fuel oil, do not remove the fuel oil primary filter.

1.10 Replacement of oil

Oil shall be replaced in a clean place to prevent oil from being contaminated during replacement.

79
1.11 Guideline for welding

 Start switch of the engine shall be disconnected and cables of the accumulator shall be
removed.

 Distance between welding area and grounding cable shall be shorter than 1m.

 Welding shall be prevented nearby seal ring and bearing.

 Pipeline and oil tank with oil shall not be welded.

1.12 Fire prevention

Parts shall be cleaned with inflammable cleanser or light oil and protected against approach of
spark and flame.

1.13 Sealing element

For replacing O-ring or sealing gasket, sealing face shall be cleaned first and new O-ring or sealing
gasket shall be installed to positions accurately.

1.14 Inspection of frames

After long-time shoveling of stone, frames shall be inspected for damage and connecting bolts and
nuts shall be inspected for looseness and damage.

1.15 Cautions for loader washing

 The loader shall be washed only if the engine is sufficiently cooled.

 Water shall be prevented from splashing on electrical element.

1.16 Inspection under rainy or snowy condition

After working under rain or snow condition, the loader shall be cleaned as soon as possible and
more parts shall be lubricated and coated with oil for antirust purpose.

1.17 Dusty environment

For working in dusty environment, attentions shall be paid to aspects below.

 Frequently inspect and clean the air filter to avoid blocking.

 Frequently clean the radiator to avoid blocking.

 Frequently clean and replace the fuel oil filter.

 Clean electrical devices (especially start motor and power generator) to avoid impact of dust
accumulation on dissipation.

 See the associated document Instructions for Operation and Maintenance of Diesel Engine for
specifics of replacement and maintenance of the air filter.

1.18 No use of mixed oil

Oils of different brands shall not be mixed. If there’s only one type of oil available but the type is
different from the oil being used, the oil being used shall be full replaced with the type.

80
2 Maintenance Rules
2.1 Rules for use of oil and coolant

Caution

 Oil may deteriorate easily because the loader is used under relatively bad
conditions (high temperature and high pressure) and its external
environment is dusty. The oil shall be renewed in time once it is found that
oil deteriorates or there are much foreign materials in oil.

 Oil shall be filled according to the specified quantity. Oiling too much or
too little will cause a fault.

 When renewing the oil, the oil filter concerned shall be cleaned or
replaced.

2.1.1 Fuel oil

 Fuel oil pump is a precision device. Fuel oil pump will not work properly if water or dirt is mixed
in fuel oil.

 Be careful when changing or adding fuel oil and do not mix any foreign materials in it.

 Fuel oil shall be used strictly according to the brand specified in this manual.

 Fuel oil may be hard to set under low temperature (especially below -15℃), so fuel oil shall be
changed according to the ambient temperature.

 After completion of work, fuel tank shall be filled with fuel oil in order to prevent water vapor in
the air from condensing into water and entering into fuel tank.

 Air in the circuit shall be discharged first if fuel oil fails to be sucked when starting, or oil filter
is just renewed.

2.1.2 Coolant

 Clean soft water, rain water or tap water shall be used as coolant. Well water or spring water
shall be boiled and settled before use as coolant in order to avoid scale deposit affecting heat
dissipation.

 If the engine is overheated, it shall be cooled down before filling coolant.

 Coolant shall be filled to the specified height. Too low coolant level will cause such problems
as engine overheating and corrosion of cooling system, etc.

 When ambient temperature is below 0℃, anti-freezing fluid shall be added to coolant. If there
is no anti-freezing fluid in coolant, coolant must be discharged after the vehicle is parked (see
“3.5.3 Operation under cold weather”); coolant shall be refilled before next starting.

 Antifreeze is combustible, so keep away from open flame when filling anti-freezing fluid.

 100% antifreeze shall not be used as coolant and specific formula concentration is described
in the table below.

81
 Composition %
Solidifying point
Name Ethylene Glycero Unit of composition
Alcohol Water ≤℃
glycol l ratio
60 40 -55
Ethylene glycol
55 45 -40
anti-freezing
50 50 Volume ratio -32
fluid
40 60 -22
Alcohol and 30 10 60 -18
glycerol anti- 40 15 45 -26
Weight ratio
freezing fluid 42 15 43 -32

2.1.3 Lubricating oil

 Lubricating oil can prevent junction surface from wear and noise.

 The connectors (e.g. joints and connecting sleeves) unmentioned in this manual are handled
at the time of overhaul and they need not to be lubricated. If some parts move stiffly due to
longer service time, please lubricate them.

 The spilling lubricating oil shall be cleaned away when lubricating oil is applied.

2.1.4 Oil storage

 Prevent water, dirt and any other foreign material from entry into oil.

 To guarantee the quality of long-time stored oil, the first-in first-out principle shall be followed
(the oil of which storage time is longest and within expiration date shall be used first)

2.1.5 Filter

 Filter is an important safety part and it can prevent foreign materials in fuel oil from entering
into important devices and causing a fault. Filter shall be replaced periodically. Maintenance
period of filter is described in this Chapter 3 Maintenance Content. When working environment
is worse, time internal of replacing filter shall be shortened.

 After paper element filter is used, the paper element must not be cleaned and it shall be
renewed.

 When replacing with a new filter, the old filter shall be inspected whether there are metal
particles. If any, please contact maintenance personnel.

 Do not unpack the new filter before use.

 Do use authentic filter accessories.

2.2 Oil selection

2.2.1 Oil selection table

ENSIGN oil shall be preferred for users. Users may select oil according to the oil type and
classification in the table below.

82
 Charge
Classification Recommended type and standard Oil position
quantity
Ambient temperature≥-15° CF 15W-40 GB11122
Engine oil 11L Engine
Ambient temperature<-15° CF 5W-30 GB11122
Hydraulic Torque converter
transmission 8# hydrodynamic drive oil Q/SH303 064 26L and transmission
oil case
Main drive of axle
Gear oil Gear oil for heavy duty vehicle (GL-5) 85W-90 GB13895 2×16 L
Hub reduction
Ambient temperature≥-5° L-HM46 hydraulic oil
GB11118.1
Ambient temperature≥-10° L-HM32 hydraulic oil
GB11118.1
Hydraulic oil 100L Hydraulic oil tank
Ambient temperature≥-30° L-HV46 hydraulic oil
GB11118.1
Ambient temperature<-30° L-HS46 hydraulic oil
GB11118.1
Ambient temperature≥4℃ 0# light diesel oil GB252
Ambient temperature≥-5℃ -10# light diesel oil GB252
Fuel oil 120L Fuel tank
Ambient temperature≥-14℃ -20# light diesel oil GB252
Ambient temperature≥-29℃ -35# light diesel oil GB252
Brake fluid HZY3 brake fluid (DOT3) GB12981 4L Brake oil cup
Pin shaft at each
Lubricating
2# or 3# lithium base grease GB7324 2.8kg articulated point of
grease
working device
Anti-freezing
Ethylene glycol engine coolant SH0521 24L Radiator
fluid

2.2.2 Domestic and foreign oil reference table

 Engine oil

Similar foreign-brand oil grade (grading by America SAE)

Domestic oil grade
CALTEX SHELL MOBIL ESSO

Diesel engine oil

RotellaSX 40; Delvac Super
CD and above Essolube XT-3;
Rotella TX 40, 20W/40; 1300(SAE15W-40)
15W-40 Essolube XT-2
Rotella DX 40 (-15℃~50℃)
GB11122
Delo Gold
Diesel engine oil Multigrade Delvac Super
CD and above 15W-40 Rotella SX30, 10W/30; 1300(SAE10W-30)
5W-30 Rotella TX30; (-20℃~40℃); Essolube XT-5
GB11122 Rotella DX30 Delvac 1#
(Above -40℃)

83
 Hydraulic oil

Similar foreign-brand oil grade

Domestic oil grade
CALTEX MOBIL SHELL CASTROL ESSO
Hydraulic oil L- DTE25 Hyspin AWS 32;
Tellus 27;
HM46(-5℃~40℃) (- Hyspin AWS 46 Nuto H46
Tellus 29
GB11118.1 RANDO HDZ46 10℃~40℃)
Hydraulic oil L- (-25℃~40℃) DTE15M
Hydro-kinetic Hyspin AWH46;
HV46(-30℃~40℃) (- Vnivis N46
Tellus T27 46 Nuto
GB11118.1 26℃~40℃)

 Hydraulic transmission oil (for torque converter-transmission case)

Domestic oil Similar foreign-brand oil grade

grade CALTEX MOBIL FUCHS ESSO SHELL
8# hydraulic
Delo Gold Delvac Super Titan
transmission Standard Torque
Multigrade 15W- 1300 (SAE15W- universal Rotella 10W
oil Fluid G7
40 40) HD15W-40
Q/SH303 064

 Gear oil (for driving axle)

Similar foreign-brand oil grade (grading by America SAE, GL-5)

Domestic oil grade
CALTEX FUCHS MOBIL ESSO SHELL
MOBIL gear oil
Gear oil for heavy HD80W-90 Gear oil GX Spirax EP
duty vehicle Thuban GL5 EP (-20℃~40℃); 85W-90 Heavyduty
Titan Gear LS90
(GL-5) 85W-90 90 MOBIL gear oil HD90
GB13895 HD85W-90 HD80W-90
(-10℃~50℃)

 Brake fluid

Similar foreign-brand oil grade

Domestic oil grade Grading
MOBIL ESSO BP SHELL
Motor vehicle brake Super brake Brake Fluid
SAE
vehicle HZY3 fluid Brake Fluid Disc-Brake Donax B
1703C
GB12981 DOT3 fluid

 Lubricating grease

Domestic oil Similar foreign-brand oil grade

grade MOBIL CALTEX CASTROL ESSO BP SHELL
2# or 3# Marfak
Mobil MP； Retinax A ；
grease multi LM grease Energrease L
XHP222 Beacon EP 2 Alvania
GB7324 Purpose

84
2.3 Schematic diagram of lubrication position of the loader

2.4 Maintenance rules for electrical system

 If electric wires are in humid environment or the insulator is damaged, electrical system may
be leaky easily, which may cause a hazardous accident.

 Maintenance of parts related to electrical system:

1) Check the tightness and damage of fan belt.

2) Check the height of electrolyte level in the accumulator.

 Do not dismantle any electric part installed properly.

 Do not increase any electric part, unless otherwise specified by our company.

 Do keep electrical system dry when cleaning the complete machine or using it in the rainy and
snowy environment.

 Do prevent electrical system from sea water corrosion during construction nearby the sea.

2.5 Maintenance tools

For maintenance tools, see the accompanying tools in the product packing list.

85
3 Maintenance Details
3.1 Daily (10-hour) maintenance

 Check the sealing of hydraulic, steering and braking systems of working device.

 Check the reliability and flexibility of brake.

 Check electrical system line and electrical elements whether they are in good condition.

 Check oil level in fuel tank and water level in water tank.

 Apply lubricating grease to diesel engine fan shaft, articulated points of front and rear frames,
transmission shaft, rear axle swing articulated point and each articulated point of working
device.

 Check whether there is any other abnormity.

 Do maintain diesel engine strictly according to the requirements of diesel engine operation and
maintenance instructions.

3.2 Weekly (50-hour) maintenance

10-hour maintenance proceeds simultaneously.

 Check the oil level in transmission case, hydraulic oil tank and brake booster pump.

 Check and fasten the connecting bolt of each transmission shaft.

 Check and fasten the connecting bolts of wheel rim and brake tongs.

 Check and fasten the connecting bolts of bucket teeth.

 Check and lubricate accelerator control, parking brake and gear shift control systems.

In addition, add the following maintenance for the first 50 hours.

 Check and clean the ventilation opening of transmission case; check and clean the filter
element of torque converter-transmission case oil way system.

 Check hydraulic system whether there is leakage; check and clean the ventilation opening of
hydraulic oil tank; check and clean the return oil filter element of hydraulic oil tank.

 Check braking system whether there is leakage; clean the filter screen of oil storage cup of
booster pump; clean the ventilation opening; check brake fluid and fill it when not enough.

3.3 Monthly (250-hour) maintenance

10-hour maintenance and 50-hour maintenance proceed simultaneously.

 Check the accumulator and clean the surface and binding posts, and moreover, coat a thin
layer of vaseline.

 Check the connecting bolts on the working device and front and rear frames whether there is
looseness, and check the welds whether there are cracks.

 Check the connection between front and rear axles, diesel engine, transmission case and
frames whether it is loose.

 Measure the tyre pressure. Front tyre pressure shall be 0.333~0.353MPa and rear tyre

86
 pressure shall be 0.275~0.294MPa.

 Open the water drain valve of air storage tank to drain water.

 Check braking system whether there is leakage; clean the filter screen of oil storage cup of
booster pump; clean the ventilation opening. Check brake fluid and fill it when not enough, and
replace it when necessary.

1. Maintenance of the whole machine (excluding engine)

S/N Contents of regular maintenance in first working time of 100‐200 h

1 Check and tighten connecting bolts of all drive shafts, rims and brake calipers.

2 Check and tighten connecting bolts of bucket teeth or wear plates.

3 Check accelerator control system, park brake system and variable speed control system.

4 Check that circuits and electrical parts in the electrical system work normally

5 Check that fuel level in fuel tank and coolant liquid level in radiator are normal.

6 Check the brake system for tightness, reliability and flexibility.

7 Check that the oil level in brake booster pump is normal.

Check that each position of brake system leaks; clean filter screen of booster pump oil reserve
8
cup; clean vent ports; check brake liquid and fill with it if necessary.

9 Check and clean the vent ports of transmission.

Clean the transmission oil pan and replace the elements of suction filter mounted on the
10
transmission oil pan.
11 Replace the filter element of torque converter‐transmission oil circuit system.

12 Replace transmission oil.

13 Check the hydraulic system and steering system of working mechanism for tightness.
Check that leakage occurs in any parts of hydraulic system and check the oil level of hydraulic
14
reservoir.
15 Clean the vent ports of hydraulic reservoir and the oil return filter element of hydraulic reservoir.

Grease each link point of working mechanism, diesel engine fan shaft, link points of front and
16
rear carriage, drive shafts and swinging link points of rear axle.

17 Check that other abnormalities occur.

Maintain and care the diesel engine in strict accordance with Manual of Diesel Engine Use and
18
Maintenance.
It is required to maintain axles and transmission manufactured ZF according to instructions of
19
ZF.
Other items requiring check and adjustment, such as drain the residual liquid in the bottom of
20
the reservoir and drain water from oil lines.

87
S/N Contents of regular maintenance in first working time of 400‐600 h

1 Check that circuits and electrical parts in the electrical system work normally
Check the battery and fill it with electrolyte; clean the battery surface and terminals and
2
apply a thin layer of Vaseline on the terminal surface.
3 Clean muffler of brake solenoid valve
4 Check and tighten connecting bolts of all drive shafts, rims and brake calipers.
5 Check and tighten connecting bolts of bucket teeth or wear plates.
Check that connection between the front axle/rear axle, diesel engine, transmission and the
6
carriage is secure.
Check that connecting bolts on working mechanism and front/rear carriage are loose and
7
that welding seams are cracked.
8 Check accelerator control system, park brake system and variable speed control system.
9 Measure tire pressure
10 Check that fuel level in fuel tank and coolant liquid level in radiator are normal.
11 Check the brake system for tightness, reliability and flexibility.
12 Check and regulate the brake clearance of parking brake system.
13 Check wear of brake discs and friction linings of service brake system. Replace it if necessary.
14 Check all positions in the brake system for leakage.
15 Screw off the water drain valve of air reservoir to drain water
16 Clean the filter screen of booster pump oil reserve cup、the vent ports of booster pump.
17 Replace the gear oil of front and rear axle
18 Replace brake fluid.
19 Check the hydraulic system and steering system of working mechanism for tightness.
20 Check all positions in the hydraulic system for leakage.
21 Check and clean the vent ports of hydraulic reservoir.
Check the hydraulic oil amount and cleanliness. Filter the hydraulic oil if conditions allow it;
22
fill with hydraulic oil when the hydraulic oil is insufficient; replace it if necessary.
23 Check and clean the vent ports of transmission.
Clean the transmission oil pan and replace the elements of suction filter mounted on the
24
transmission oil pan.
25 Replace the filter element of torque converter‐transmission oil circuit system.
26 Replace transmission oil.
Grease each link point of working mechanism, diesel engine fan shaft, link points of front and
27
rear carriage, drive shafts and swinging link points of rear axle.
28 Check that other abnormalities occur.
Maintain and care the diesel engine in strict accordance with Manual of Diesel Engine Use
29
and Maintenance.
It is required to maintain axles and transmission manufactured ZF according to instructions
30
of ZF.
Other items requiring check and adjustment, such as drain the residual liquid in the bottom
31
of the reservoir and drain water from oil lines.

88
S/N Contents of regular maintenance in first working time of 900‐1100h
1 Check that circuits and electrical parts in the electrical system work normally
Check the battery and fill it with electrolyte; clean the battery surface and terminals and
2
apply a thin layer of Vaseline on the terminal surface.
3 Clean muffler of brake solenoid valve
4 Check and tighten connecting bolts of all drive shafts, rims and brake calipers.
Check that connection between the front axle/rear axle, diesel engine, transmission and
5
the carriage is secure.
6 Check and tighten connecting bolts of bucket teeth or wear plates.
Check that connecting bolts on working mechanism and front/rear carriage are loose
7
and that welding seams are cracked.
8 Check accelerator control system, park brake system and variable speed control system.
Check the clearance and wear existing between the pin shaft and the bushing in each
9
hinge point.
Grease each link point of working mechanism, diesel engine fan shaft, link points of front
10
and rear carriage, drive shafts and swinging link points of rear axle.
11 Measure tire pressure
12 Check that fuel level in fuel tank and coolant liquid level in radiator are normal.
13 Check the brake system for tightness, reliability and flexibility.
14 Check all positions in the brake system for leakage.
15 Check and regulate the brake clearance of parking brake system.
Check wear of brake discs and friction linings of service brake system. Replace it if
16
necessary.
17 Screw off the water drain valve of air reservoir to drain water
18 Clean the filter screen of booster pump oil reserve cup
19 Clean the vent ports of booster pump.
20 Replace brake fluid.
21 Check the hydraulic system and steering system of working mechanism for tightness.
22 Check all positions in the hydraulic system for leakage.
23 Check and clean the vent ports of hydraulic reservoir.
24 Replace the oil return filter element of hydraulic tank.
25 Replace the pilot oil filter element.
26 Clean the vent ports of transmission.
Clean the transmission oil pan and replace the elements of suction filter mounted on the
27
transmission oil pan.
28 Replace the filter element of torque converter‐transmission oil circuit system.
29 Replace transmission oil.
30 Replace gear oil of front and rear axles
31 Check that other abnormalities occur.
Maintain and care the diesel engine in strict accordance with Manual of Diesel Engine
32
Use and Maintenance.
It is required to maintain axles and transmission manufactured ZF according to
33
instructions of ZF.
Other items requiring check and adjustment, such as drain the residual liquid in the
34
bottom of the reservoir and drain water from oil lines.

89
S/N Contents of regular maintenance in first working time of 1400‐1600 h
1 Check that circuits and electrical parts in the electrical system work normally
Check the battery and fill it with electrolyte; clean the battery surface and terminals and
2
apply a thin layer of Vaseline on the terminal surface.
3 Clean muffler of brake solenoid valve
4 Check and tighten connecting bolts of all drive shafts, rims and brake calipers.
Check that connection between the front axle/rear axle, diesel engine, transmission and
5
the carriage is secure.
6 Check and tighten connecting bolts of bucket teeth or wear plates.
Check that connecting bolts on working mechanism and front/rear carriage are loose
7
and that welding seams are cracked.
8 Check accelerator control system, park brake system and variable speed control system.
Check the clearance and wear existing between the pin shaft and the bushing in each
9
hinge point.
Grease each link point of working mechanism, diesel engine fan shaft, link points of front
10
and rear carriage, drive shafts and swinging link points of rear axle.
11 Measure tire pressure
12 Check that fuel level in fuel tank and coolant liquid level in radiator are normal.
13 Check the brake system for tightness, reliability and flexibility.
14 Check all positions in the brake system for leakage.
15 Check and regulate the brake clearance of parking brake system.
Check wear of brake discs and friction linings of service brake system. Replace it if
16
necessary.
17 Screw off the water drain valve of air reservoir to drain water
18 Clean the filter screen of booster pump oil reserve cup
19 Clean the vent ports of booster pump.
20 Replace brake fluid.
21 Check the hydraulic system and steering system of working mechanism for tightness.
22 Check all positions in the hydraulic system for leakage.
23 Check and clean the vent ports of hydraulic reservoir.
24 Clean the vent ports of transmission.
Clean the transmission oil pan and replace the elements of suction filter mounted on the
25
transmission oil pan.
26 Replace the filter element of torque converter‐transmission oil circuit system.
27 Replace transmission oil.
28 Replace gear oil of front and rear axles
29 Check that other abnormalities occur.
Maintain and care the diesel engine in strict accordance with Manual of Diesel Engine
30
Use and Maintenance.
It is required to maintain axles and transmission manufactured ZF according to
31
instructions of ZF.
Other items requiring check and adjustment, such as drain the residual liquid in the
32
bottom of the reservoir and drain water from oil lines.

90
S/N Contents of regular maintenance in first working time of 1900‐2000 h
1 Check that circuits and electrical parts in the electrical system work normally
Check the battery and fill it with electrolyte; clean the battery surface and terminals and
2
apply a thin layer of Vaseline on the terminal surface.
3 Clean muffler of brake solenoid valve
4 Check and tighten connecting bolts of all drive shafts, rims and brake calipers.
Check that connection between the front axle/rear axle, diesel engine, transmission and
5
the carriage is secure.
6 Check and tighten connecting bolts of bucket teeth or wear plates.
Check that connecting bolts on working mechanism and front/rear carriage are loose
7
and that welding seams are cracked.
8 Check accelerator control system, park brake system and variable speed control system.
Check the clearance and wear existing between the pin shaft and the bushing in each
9
hinge point.
Grease each link point of working mechanism, diesel engine fan shaft, link points of front
10
and rear carriage, drive shafts and swinging link points of rear axle.
11 Measure tire pressure
12 Check that fuel level in fuel tank and coolant liquid level in radiator are normal.
13 Check the brake system for tightness, reliability and flexibility.
14 Check all positions in the brake system for leakage.
15 Check and regulate the brake clearance of parking brake system.
Check wear of brake discs and friction linings of service brake system. Replace it if
16
necessary.
17 Screw off the water drain valve of air reservoir to drain water
18 Clean the filter screen of booster pump oil reserve cup
19 Clean the vent ports of booster pump.
20 Replace brake fluid.
21 Check the hydraulic system and steering system of working mechanism for tightness.
22 Check all positions in the hydraulic system for leakage.
23 Check and clean the vent ports of hydraulic reservoir, and clean the hydraulic reservoir.
24 Replace the oil return filter element of hydraulic tank, replace the hydraulic oil.
25 Replace the pilot oil filter element.
26 Replace the hydraulic oil of the hand pump
27 Clean the vent ports of transmission.
Clean the transmission oil pan and replace the elements of suction filter mounted on the
28
transmission oil pan.
29 Replace the filter element of torque converter‐transmission oil circuit system.
30 Replace transmission oil.
31 Replace gear oil of front and rear axles
32 Check that other abnormalities occur.
Maintain and care the diesel engine in strict accordance with Manual of Diesel Engine
33
Use and Maintenance.
It is required to maintain axles and transmission manufactured ZF according to
34
instructions of ZF.
Other items requiring check and adjustment, such as drain the residual liquid in the
35
bottom of the reservoir and drain water from oil lines.

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2;. For engine maintenance

daily check on the fuel level, engine oil level, liquid coolant level, belt, drainage of oil-
water separator, and air inlet pipes (if there is any wear, looseness, leakage) shall be done.
When the engine works to 50-70 hours, replace the engine oil and oil filter. Then every 250-
300 hours, change the engine oil, oil filter, fuel filter and air filter (shorten the replacement
period in bad working conditions, and regularly check the cleanness of the filter). For the
model equipped with the oil bath type air filter, clean the filter regularly. Generally, the
frequency is whenever changing the engine oil, but in severe working conditions, the
cleaning period shall be shortened.

3;After service time of air storage tank reaches three years, the air storage tank
must be replaced.

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 Chapter Ⅴ System schematic
1 Transmission system
Transmission system consists of hydraulic torque converter, transmission case, transmission shaft,
front and rear driving axles and wheels, etc. The schematic diagram of transmission system is as
shown in Fig. 5-1

1. Engine 2. Torque converter 3. Pump 4. Transmission 5. Drive shaft 6. Front axle

7. Rear axle
5-1 Schematic diagram of YX618 transmission system

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 2 Hydraulic system
As shown in Figure 5-2, the hydraulic system includes working device hydraulic system and
steering hydraulic system. The pilot hydraulic system consists of working pump, multi-way valve,
pressure selector valve, boom cylinder, bucket cylinder, pilot pump, pilot valve, Composed of
hydraulic oil tank and pipeline accessories, it is easy and flexible to operate. The bucket linkage is
divided into three positions: unloading, neutral position, and bucket; the boom linkage is divided
into three positions, descending, neutral, and lifting.The set pressure of the safety valve of the
hydraulic system is 16MPa.

Fig. 5-2 Schematic Diagram of YX618 Hydraulic System

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3 Braking System
Braking system is used for speed reduction when traveling or stop, as well as relatively long time
parking on the flat ground or ramp. The schematic diagram of braking system is as shown in Fig.
5-3. Braking system of the loader includes service braking system and parking braking system.

1. Air booster pump 2. Parking brake valve 3. Air storage tank

4. Oil-water separator combination valve 5. Air compressor

Fig. 5-3 Schematic Diagram of YX635 Braking System

1. Service braking system

The system is single-pipeline and air-over-oil four-wheel tongs disc braking system.

When moving forward, depress brake pedal and compressed air in air storage tank 3 enters into
air chamber of air booster pump 1 through brake valve 2, to push booster pump piston and convert
to oil way (oil pressure is about 14Mpa); brake fluid pushes the piston of tongs disc brake and
makes friction plate press on brake disc to brake wheels, to attain the purpose of speed reduction
or stop.

Release brake pedal and compressed air in booster pump is discharged into atmosphere through
brake valve, and braking state is released.

2. Parking brake system

The system is hand tongs disc braking system.

Pull up control handle and lift the brake through flexible shaft to attain the purpose of braking. At
the same time, control parking brake indicator light through giving electric signal, to remind the
operator that the loader is in braking state now

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4 Electrical system
Electrical system consists of accumulator, starting motor, charging generator, instruments, switches,
lamps, air conditioning circuits and other electrical devices.
The voltage of the whole loader system is DC 24V, with minus earth and single-wire system adopted.
For the interrelations between electrical devices and their working principles, please read the
schematic circuit diagram of electrical system (see attached drawing).

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