C CAISE CS915

Operation Manual

Contents
Foreword (2) Series (2)
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Number.

Chapter One Use, Characteristics and Main Technical Performance Parameters. (3) I. Use and Characteristics . (3) II. Diagram of Outline Size. (4) III. The Main Technical Performance Parameters.. (5) Chapter Two Use and Operation .. (6) I. Control Device and Instrument..(6) II. (10) III. Test Run and Running-in of New Vehicle.......(14) IV. Use and Operation..(15) V. Precaution.....(19) Chapter Three Adjustment of Mechanical Structure and Trouble-shooting (22) I. Mechanical Structure and Adjustment ... (22) II. The Main Trouble and Removal Method .....(29) Chapter Four Lubrication and Maintenance..(33) I. Lubrication(33) II. (37) Chapter Five Transport, Protection and Storage (39) I. Transport (39) II. Protection and Storage.(40) Maintenance.. Regulations

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Foreword
Congratulations to you for possessing a set of full-hydraulic multifunctional mechanical loader. This manual includes the guidance and safe suggestion on driving, operation, lubrication, maintenance and adjustment. This manual is aimed at safe maintenance of this machine and enhancement of mechanical performance. For any information about this machine or any problem about this manual, please consult to the company.

Series Number At the time of ordering parts or seeking for data service, please use the series number of the mechanical loader. The previous or later machine types (distinguished by series number) might use different parts and need different process of maintenance and service. Series number of mechanical loader 1) The series number of mechanical loader is located at the nameplate, left side of vertical frame rail in front of the nameplate. 2) Series number of engine The series number of engine is on the engine body.

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Chapter One Use, Characteristics and the Main Technical Performance Parameters I. Use and Characteristics Cs series mechanical loader is suitable for urban construction, environmental sanitation, mine, harbor, hydraulic engineering, station, goods, railway, highway construction, timber processing plant, etc. It is mainly used for bulk cargo, clearing of ground and shortdistance transport of materials. It can also conduct light excavation work, auxiliary soil shifting, leveling, traction lifting, etc. There is wholly new and convenient quick-change device, changing of auxiliary tools, such as wood clamping machine, bottom fork, snow spade, pitch-fork, etc. can give scope to its multifunction characteristics, so as to realize the operation function of round log, board plate loading and unloading, snow removal, grass removal, and so on. The Cs series mechanical loader has the following features: 1. Static pressure driving is adopted, the mechanical loader can smoothly insert into the material pile, automatic gear shifting is available, extinction of the engine because of overload can be avoided, which can amply give scope to the power of engine, the impact of driving system is cushioned, and the life of machine is prolonged. The operation is stable, the working is reliable and it is highly-efficient and energy-saving. 2. 3. Dual Circuit Brake is adopted, shoe or inserted disc type brake is adopted, it can produce strong braking force, and it is safe and reliable. Hydraulic steering is adopted, the running operation adopts manual hydraulic reversing control, the control is convenient and flexible, it is safe and reliable, furthermore, it is convenient for repair and the production efficiency is high. 4. 5. 6. Hinged frame has small turning radius, and it is flexible. The all-wheel drive has strong driving force with high climbing capacity. Computer three-dimensional optimization is adopted for design of the working device, it has large lifting force, quick action time and high working efficiency, with single rocker-arm and single connecting rod mechanism, the bucket has the function of automatic smooth set. 7. Unique quick-change device with independent intellectual right is adopted, the time and labor intensity for auxiliary tools changing is greatly reduced, with wood clamping machine, snow spade and pitch-fork (etc.) through quick-change device, operation of wood grasp, snow removal and transportation can be realized, meanwhile, due to the convenient replacement and use of various auxiliary tools, the multi-function effect can be shown, and the utilization space is greatly expanded.

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II. Diagram of Outline Size

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III. The Main Technical Performance Parameters Table of Technical Parameters of CS Series Mechanical Loader
model item Rated Loading Weight (Kg) The minimal circle Diameter (mm) Rated bucket Capacity (m3) Track base (mm) Wheel base (mm) Min. Swerve diameter (mm) Min. Ground clearance (mm) Dump height fully Raised (mm) Reach fully raised (mm) Lifting time (s) Driving mode CS910 1000 320 0.46 1320 2040 4200 240 2700 900 3.5 Four-wheel full hydraulic drive 2 gear hydraulic variable speed changed CS912 1200 280 0.5 1400 1800 4000 270 2580 CS915 1500 300 0.54 1400 1950 4020 270 2580 CS920 2000 350 1.2 1640 2400 4600 310 2622 752 5 Four-wheel full hydraulic drive 2 gear hydraulic variable speed changed 5800 5633*2120 *2712 R4105G34 2300 30 45.4

860 860 4.5 4.5 Four-wheel full hydraulic drive 2 gear hydraulic variable speed changed

Transmission gear Box form

Operating weight (Kg) Dimension (mm) (L*W*H) Engine model Rated speed (rpm) Max. tilt angle (%) Max. bucket breakout (KN)

3020 4900*1685 *2520 ZN485Q 2300 35 32

3200 4600*1650 *2870 KM496 2400 30 42

3600 4850*1650 *2800 495BG 2400 30 45

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Chapter Two Use and Operation I. Control Device and Instrument 1.Dashboard Instructions (See Pic 1)

Pic 1

2.Display on Dashboard 2.1 Cooling Water TEMP of Engine

Green Area: Normal TEMP

Red Area: TEMP > 102. Abnormal. Water Temp Alert Shines, and monitor alarm rings. Please stop loader or switch to idle speed immediately, and check the cooling water

2.2 Fuel Level Indicator

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Green Area: Normal Fuel Level. Red Area(Only): Fuel Oil < 10%, Please check and refuel.

2.3 Working-Hour Meter

Indicate total working hours, unit: 6 minutes (0.1 h) Running when engine works, even not move. Maximum:9999 H

3.Indicators and Alarms. 3.1 Charging Indicator

Lighting or Twinkling: Generator works normally. No signal: Generator works abnormally, please check the condition of generator.

3.2 Oil Pressure Indicator

No signal: Normal Twinkling: Abnormal (Low Oil Pressure). Monitor alarm rings.

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3.3 Brake Condition Indicator

Lighting: Brake light is on.

3.4 Front Lamp Condition Indicator

Lighting: Front lamp is on.

3.5 Hydraulic Lamp Condition Indicator

Lighting: Hydraulic light is on.

3.6 Turning Light Condition Indicator

Lighting: Left Turning Light is on.

Lighting: Right Turning Light is on.

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4. Common Fault Diagnosis and Solution 1. Easy check if monitor works normal
a. When starting switch turns on, instrument has 3 seconds self-check. If not, something is wrong with monitor. b. When engine running, charging indicator is lighting all the time. If not, the generator work abnormally. Probably the generator breaks down, or wire harness is poorly connected. c. Check indicators by short circuit measure (1) No Signal on Cooling Water TEMP Indicator Unplug the Engine Water TEMP sensor. Flash-connect the wires. See if all the grids of water TEMP indicator are lighting, with warning. If so, the monitor works normal. If not, something is wrong with sensor. (2). No signal on Fuel Level Unplug the Fuel Level sensor. Flash-connect the wires. See if all the grids of Fuel indicator are lighting. If so, monitor works normal. If not, something is wrong with sensor.

Technical Parameters:
TableI Parameters Cooling Water TEMP Fuel Level Oil Pressure Unit L MPa Min 40 30 Warning Point 1025% 10 0.0845% Max 140 1.0

Table II Parameters Voltage Current Power Unit V A W Num. 14V-29V(DC) 0.6A 15W

II.Operation
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1. Starting switch 5: At the time of starting, insert the starting key into the starting switch,

clockwise rotate the key to the position of switching through, then clockwise rotate it to the starting position, switch on the starting electrode to start the diesel engine. Under low temperature, at the time of starting, after the starting key is inserted into the ignition switch, firstly counterclockwise rotate to the preheating position, after preheating for 5~10 minutes, repeat the above starting process, so as to start the diesel engine.
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2. Engine flameout switch 17: pull out the handle of switch for stopping machine, the oil supply to engine is cut off to cause its flameout. 3. High and low shift control handle 12: When the control handle is pushed forward, it is at the low shift, and when it is pulled backward, it is at the high shift, and the middle position is the neutral. The speed change mechanism is a speed change controller without clutch, at the time of shifting between high speed and low speed, the speed change can be conducted only after the vehicle has been stopped steadily, otherwise, the speed transforming gear might be damaged. 4. Reversing lever 13 for advancing and retreating: When the reversing lever for advancing and retreating is pushed forward, it is advancing, and when it is pulled backward, it is retreating, and the middle position is vacant position. At the time of advancing and retreating reversing, firstly tread down the brake pedal, conduct advancing and retreating reversing only after the vehicle is stopped steadily and the hydraulic running system is unloaded, otherwise, the service life of the vehicle might be decreased. 5. Brake pedal 15: Tread down the brake pedal to decelerate the vehicle, meanwhile, cut off the power for running, and the braking lamp at the tail of vehicle becomes light. 6. Accelerator pedal 14: The accelerator pedal controls the amount of fuel oil supplied to engine, at the time of loosening, the engine is at the deceleration position, the engine is in idling operation, at the time of treading down the pedal, with the increase of oil supply amount, the rotation speed of engine increases gradually. 7. Manual brake handle 1: When the handle is pushed down, it is at the loosening position, when it is pulled down, it is at the parking position, its effect is to park the vehicle instead of braking the vehicle in driving, but it can be used as emergency brake under emergency circumstance in driving. 8. Working device control handle 16: The left side is the operation handle of lifting arm, it descends when it is pushed forward, and it is elevated when it is pulled backward, the middle is bucket tipping handle, it tumbles when it is pushed forward, and it withdraws the bucket when it is pulled backward. The right side is the clamping and spreading handle of wood clamping machine, it is clamped when it is pushed forward, and it is spread when it is pulled backward. Other auxiliary tools, such as snow spade are separately described in the operating instruction manual for the auxiliary tool. 9. Accessory Operating Joystick 2 Two Functions 1 Operating Hydraulic Quick Change backward for installing, forward for uninstalling 2 Operating Accessoriessuch as wood clamp, grass fork, 4-in-1 bucket, etc. 10. Rocker switch 5, 6, 7, 8, 9, 10 and 11: It is used for controlling the lamplight and electric appliances including heater and fan, etc., operations will be done in accordance with electric mark on it. 11. Horn button 14: It is at the middle part of steering wheel, when it is pressed down, the power source is switched on, and the horn sounds. 12. The master switch 10 for power source: When it is pulled upward, the power source is switched off, when it is pressed downward, the power source is switched on, when the driver leaves the cab after stopping the machine, the switch of power source shall be pulled up to switch off the power source. 13. Combination switch 5: It is used for controlling the high-low beam, running lamp, passing lamp, left and right steering lamps etc. of the front light.
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III Regulations for Safe Operation The driver shall bear important responsibility for safe driving and working of mechanical loader. Before conducting the driving control, furthermore, the driver shall get acquainted with the performance structure, control method and technical maintenance of the mechanical loader, regulations for safe operation shall be strictly observed, so as to guarantee safe production, give scope to the efficacy of machine and prolong the service life of machine. 1. Before using the machine, the driver shall be well acquainted with and observe the traffic rules, anyone other than the formal driver of mechanical loader shall not drive, for studying the driving, you shall firstly study the operating instruction manual, under the guidance of formal driver together with the machine. 2. Before the starting work, the work of vehicle examination and preparation shall be done according to stipulation, if any part is found to have any trouble, the trouble shall be removed and it shall be repaired, otherwise, a vehicle shall not be dispatched. 3. Before starting or operating the working device, observe for whether there is anyone around the vehicle or any object obstructing the driving, meanwhile, drive a vehicle after sounding the horn to issue signal. 4. At the time of engine operation, anyone it strictly prohibited from standing between tires, under the lifting arm, between the front and rear frames and in the bucket. 5. At the time of engine operation, the vehicle shall not be overhauled and maintained, if it needs to be examined at the time of engine operation under any special circumstance, it shall be monitored by skillful driver on vehicle. 6. Anyone is strictly prohibited from getting on or off the mechanical loader in driving. 7. During operation of the mechanical loader, any personnel shall not sit on any place except the driver. 8. While driving of the mechanical loader, sharp turning shall be avoided, especially under the circumstance of driving under bad road condition or narrow road in the hilly area, steep slope and multiple tortuous path, only the low shift can be used, and the high shift shall be used on level and straight highway. 9. When the mechanical loader is running down a slope, neutral coasting of extinction engine is strictly prohibited, otherwise, the hydraulic steering might fail, and serious accident of running might be incurred. 10. At the time of taking material in the loading work, only the low shift can be used, and the high shift is strictly prohibited from impact to the material pile. 11. At the time of bucketing, excessive material stressing at one side shall be avoided, it shall be avoided to lift it to the highest point for transporting material. In case of any obstacle and if it must be lifted for passing, it shall be driven carefully, and after the passing, immediately lower the lowest point of bucket to the normal transport position about 290mm from ground. 12. At the time of overhauling the electrical system of engine, the power source shall be firstly switched off. 13. Before leaving the cab after work, the driver shall put the bucket to the ground, stop the engine and switch off the master switch of power source. 14. At the time of opening hot cover of water box and cover of hydraulic oil box of engine,
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wear gloves or slowly turn it loose with cloth, so as to prevent the hot water and hot oil from spurting out under pressure in the box to scald anyone. 15. Various kinds of oil in use shall be clean, and they shall conform to the stipulated brand and quality standard. III. Test Run and Running-in of New Vehicle 1. The work of examination and preparation before test run After the user purchases new multifunctional mechanical loader, test run and runningin must be conducted for 50 hours, and the following work shall be done before the test run. 1) Check each part of the machine being firmly installed or not, is there any phenomenon of loosening. 2) Check each operation handle having the phenomenon of loosened connection or seized lever system or not. 3) Check the cable end connection of accumulator being reliable or not. 4) Add lubrication oil, water and fuel oil according to the stipulated brand and quantity. 1. Test run 1) Operate it without load, put each operation lever to the middle position, pull tight the manual brake, then conduct idle running for 0.5 hour at 800~1000r/min, then conduct normal operation of engine for 0.5 hour, meanwhile, check the indication circumstance and sound of each instrument to be normal or not. 2) Loosen the manual brake, let it run for 1~1.5 hour at low and high shift advancing and retreating in proper order, usually steadily steer and operate the working device, check the action of working device being correct or not, each system having the phenomenon of water leakage or oil leakage or not, check the brake being reliable or not, the steering being flexible or not, the reading of various instruments being normal or not, the lamplight and steering signal being normal or not. 3) After running-in for 5 hours, conduct maintenance according to the stipulations for periodical technical maintenance. 2. Test run with load 1) With loading of 50% rated weight, the engine can run for up to 30 hours under the rated speed. After completion of running, conduct maintenance according to the stipulations for periodical technical maintenance. 2) With loading of 80% rated weight, test run for 30~50 hours is available. After completion of test run for 50 hours, the machine shall be examined and maintained in an all-round way, only after each part is normal can the loading of stipulated weight is allowable for the working stage. IV. Use and Operation 1. Examination before use The same as examination for test run. 2. Driving 1)Starting Let the neutral position (middle position) of handle advance or retreat, place each control handle to the middle position, put the manual brake to the braking position, clockwise rotate the starting switch to the position of switching on, tread on the accelerator slightly, the engine can be started, rapidly release the starting switch after starting. The time of starting each time shall not exceed 10 seconds, if it could not be started, there shall be a time interval of 30~60 seconds. If it could not be started for three times continuously, the reason shall be found out, and it shall be restarted after
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2.
1)

2)

3) 4)

5)

6)

7) 3. 1)

getting rid of the reason. After starting of engine, carefully observe the pressure of machine oil, if it is abnormal, the machine shall be stopped for examination. The accelerator shall be gradually increased after starting, so that the engine is at the rotating speed of 800~1000r/min, and conduct preheating. When it is difficult to start in cold weather, preheating and air entering shall be conducted to the engine, counterclockwise rotate the starting switch to the preheating position, preheat it for 5~10 minutes and then start. If the starting fails for several times continuously, pour hot water of 90~95 into the water radiator, especially for extremely cold region, the machine oil shall be heated to 60~100 and then poured into the oil pan, and then start the machine. In case of parking for a relatively long period, air might be mixed into the fuel oil pipe of engine, as a result, it might be difficult to start. It can be started after getting rid of the trouble through the following method, loosen the gas release plug screw of injection pump, pump oil and exhaust by oil pump manually, and fasten the gas release plug screw at the time of no bubble. Refer to the operating instruction manual of diesel engine for details of operation. Starting to move and the driving After the engine is started, at the rotating speed of 80~100r/min, it shall run idle for about 15 minutes and conduct preheating, when the water temperature and oil temperature reach over 40, it can start working when the reading of each instrument is in the normal status after examination. When the vehicle is parked for a relatively long period, the steering wheel shall be rotated reciprocally before starting, and the working device shall be controlled to perform various actions for 3~5 times, so as to remove the air in the system; if the steering wheel is felt to be heavy, the oil temperature is meant to be low, the engine shall operate continuously at the medium speed, and it can start to move only when the steering wheel is felt to be light and convenient. Appropriately increase the accelerator, steadily push forward (advancing) or pull backward (retreating) the advancing and retreating handle. In the driving after starting to move, the accelerator shall be steadily and evenly increased or decreased, it shall not be suddenly loaded or unloaded except under special circumstance. At the time of deceleration or braking, the accelerator shall be decreased, tread down the brake pedal, if continuous running is desired, the brake pedal shall be steadily lifted up. For the reversing running (changing the advancing to retreating or changing the retreating to advancing), the accelerator shall be firstly decreased, the brake pedal shall be treaded down, control the reversing handle after the vehicle is parked steadily, it is strictly prohibited to operate the advancing and retreating handle to the inverse direction when the vehicle is not yet parked steadily. Carefully observe the indicator light of each instrument, and the vehicle shall be immediately stopped for getting rid of any abnormality emerges. Shifting In the running of vehicle, automatic stepless speed change is available according to the ground drag, meanwhile, the pulling force shall be increased for overcoming the drag, therefore, in the process of long-distance running or working, it is enough to only control the accelerator, and usual shifting is unnecessary. On the contrary, in order to reduce wearing of machine and the impact by interruption of power, unnecessary
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2)

3)

3.
1)

2)

3) 4)

5.
1)

2) 3) 4)

5) 6. 1)

shifting between low and high shifts shall be avoided to the utmost. At the time of driving on flat and straight highway, the high shift can be used, the low shift shall be used in the working process, driving on highway in hilly area or at the time of cross-country running, as well as in case of abrupt slope or at the time of sharp turning. At the time of shifting or advancing or retreating reversing, the rotating speed of engine shall be reduced to about 800~1000r/min, tread down the brake pedal, conduct advancing or retreating reversing after the vehicle has been parked steadily. Otherwise, the service life of machine might be shortened. Stopping machine and parking After unloading of engine, let it keep idle running at medium speed for 3~5 minutes, so as to cool the engine, pull forward the stopping handing, and release it for resetting after the engine is surely stopped. Under the emergency circumstance, pull out the stopping handle forward, so as to force the engine stop, but stopping at high temperature is strictly prohibited except under emergency circumstance. Counterclockwise rotate the starting switch to the neutral, meanwhile, press the safety switch of key and take out the key. After stopping in winter, the water drain valve of radiator and the water drain valve of engine shall be opened in time, so as to fully discharge the cooling water. (it is not needed if anti-freeze fluid is added). Pull up the parking handle upward, so as to stop the vehicle. Use of quick-change device Put the movable arm to the lowest point, meanwhile, align it with the auxiliary tool in use. Drive the vehicle forward, so that the cross beam on the quick-change device is just below the lug of auxiliary tool. Lift the movable arm, that the quick-change cross beam is connected with the lug of auxiliary tool. Conduct operation of withdrawing bucket, so that the auxiliary tool reaches the limit position connected with the quick-change. Push and pull the handle of the quickchange for advancing or retreating of pin shaft, so that the pin shaft is threaded into the connective hole of auxiliary tool. Push the handle to the fixed position, then the pin shaft is just at a proper position. Tightly screw the fixing bolt for advancing or retreating of handle, and the installation of auxiliary tool is completed. Working Loading working At the time of loading working, the one time scraping method or composite scraping method may be adopted, there are concretely the following several working modes: slewing type, semi-slewing type or shuttle type, or other mode selected according to the practical circumstance of ground. The aim of selecting suitable working mode is to minimize the transport distance and the turning angle of mechanical loader, so as to improve the working efficiency. a. Loading 1 When the working device is at the status of preparing for loading material, put down the lifting arm and put the bucket to the level position. 2 Pushing forward the advancing and retreating handle gently.
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At the time of approaching the material pile, make the tooth of bucket contact the ground, increase the accelerator, spare no effort in inserting it into the material pile, then withdraw the bucket and lift the arm, so that the low point of bucket is about 290mm from ground. 4 In case of material with relatively big grain size or rigid and solid material pile, it is difficult to insert at one time, composite scraping method may be adopted, the arm can be lifted and the bucket can be withdrawn in the inserting process. b) Transporting material After the bucket has been fully loaded, decrease the accelerator, operate the reverse gear to withdraw from the material pile, then lift the arm to the status of transport position, and drive to the unloading position. c) Unloading Tip the bucket forward for unloading. When material is stuck to and accumulated at the bucket, the pivoted-bucket can be operated reciprocally, so as to shake it off and reduce the impact, and the pivoted-bucket shall be operated gently. 2) Bucketing working a. Put the bucket to the ground, and let it incline slightly downward by (3~5). Push forward the operating lever, meanwhile, operate the movable arm till it reaches the descending position, force the bucket to cut into the ground. b. When the bucket reaches the cutting depth, put the lifting handle to the middle position, continue to drive the vehicle forward. Meanwhile, the bucket can be turned over to adjust the excavation depth, so as to adapt to ground changes. c. When the bucket has been fully loaded or it has bucketed to the predetermined position, turn over the bucket to the position of withdrawing, meanwhile, lift the movable arm to the transport position. d. Transport the bucketed material to the predetermined place. 3) Soil shifting and leveling working This machine is not a wheeled bulldozer, at the time of soil shifting and leveling by the bucket, it only has the auxiliary effect of leveling, filling pit, clearing and piling up on soft ground. 4) Working of wood clamping The wood clamping fork can be mounted through the quick-change device, and the work of wood clamping can be conducted. a. The working device is at the status of preparation for taking material, put down the lifting arm, smoothly set the wood clamping machine, so that the upper fork on the wood clamping machine opens to the maximum position. b. Pushing forward the advancing and retreating handle gently. c. At the time of approaching the timber pile, make the lower fork of wood clamping machine contact the ground, appropriately increase the accelerator, insert it into the timber pile, and then withdraw the lifting arm of wood clamping machine, so that the lower point of wood clamping machine is about 290mm from ground. d. After the wood clamping machine is fully loaded, decrease the accelerator, operate the reverse gear to retreat from the timber pile, then lift arm to the status of transport position, and drive toward the position of unloading. e. Tip forward the wood clamping machine, stretch the upper fork of wood clamping machine for unloading. f. At the time of taking material from the middle part of timber pile and the transport truck, operate in reference to the above process.
3
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 V. Precaution 1. This machine adopts high speed direct injection diesel engine, the fuel oil shall be clean, it shall undergo sedimentation for over 24 hours, and it shall be used after filtration. At the time of continuous working, according to the oil quality, loosen the fuel oil plug screw before starting every 3-5 days, so as to discharge the water and dirt. 2. The cooling water for engine shall be clean softened water. The hard water that contains relative much mineral substance shall undergo softening treatment or boiling, and it shall be used after sedimentation. 3. When the cooling water for engine boils, let the engine operate at medium speed, let it flameout and supplement cooling water after the water temperature drops. 4. The engine shall not operate at high speed and with heavy load under the circumstance of no preheating, and it shall not operate at high speed for long period. 5. The instrument or indicator light for machine oil pressure and water temperature etc. shall be often observed in the working, and the temperature of hydraulic oil etc. shall be paid attention to. The pressure of machine oil is normally 300-500kpa. At the time of idle speed, it shall not be lower than 50 kpa. The normal water temperature is generally about 75-95, it shall not operate at high speed at the time of lower than 50, and the temperature of hydraulic oil is generally 40-80. 6. At the time of driving, carefully examine the work of braking system and steering system to see whether it is sensitive and reliable, the action of working device is normal or not, pay attention to various working circumstances and sound in working, it shall be timely stopped for examination and removal if any abnormality is found. 7. At the time of driving, the working device shall be at the transport status (at the status of bucket withdrawing, the lower point of bucket is about 290mm from ground); altitude transport or abrupt stopping are not allowable after loading; at the time of stopping (parking), the working device shall be at the status of taking material (lower the movable arm and put down the bucket). 8. The revolving of steering wheel shall be gentle, and that shall not be too hasty or too sudden. Try not to steer after stopping of engine. 9. The accelerator and each operating lever shall be controlled gently, do not suddenly start, suddenly stop or repeatedly operate a certain handle to take material, unload or accelerate and decelerate by means of shock. 10. At the time of lowering the arm with load, the operating lever shall be pushed forward gently, in the descending process of arm, it shall not be accelerated, decelerated, shaken or paused. 11. At the time of working on uneven surface or oblique slope, it shall be operated carefully, so as to avoid the occurrence of transverse overturning; starting to move on slope shall be gentle (especially at the time of going uphill without load or going downhill with heavy load), emergency stop is not allowable at the time of driving on slope; at the time of driving or working, if the phenomenon of front wheel or rear wheel away from ground emerges, it shall be unloaded in time, however, at the time of loading, the working can be continued in case of the phenomenon of wheel away from ground slightly. 12. The vehicle shall be cleaned before leaving off duty, any trouble or leakage shall be examined and removed. The cooling water shall be fully drained in winter, and it shall be put into the warm garage. 13. At any special site, pay attention to safety, fire prevention and explosion prevention, and it is prohibited to be used at any dangerous place, such as toxic or harmful place,
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etc.

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Chapter Three Adjustment of Mechanical Structure and Trouble-shooting I. Mechanical Structure and Adjustment 1. Engine system 1) Refer to Operating Instruction Manual for Diesel Engine for the performance, structure and maintenance of this diesel engine. 2) Air filter The model KW1532 air filter shall be adopted. Air shall enter the shell from the air intake window at the upper part, because of the effect of centrifugal force, over 80 of dust is deposited at the upper part of the shell, and it is automatically discharged from the dust exhausting bag. After the air through separation is filtered by inner and outer layers of filter elements, it enters the engine via air intake tube. According to the circumstance of working environment, regular maintenance shall be conducted to the air filter, open the shell of air filter, take out the filter element, after brushing with brush, blow from interior to exterior with compressed air, so as to eliminate the dust. If the filter paper is broken or seriously polluted, the filter element shall be replaced. 3) Fuel tank The fuel tank is located at the right front part of rear frame, and it is connected to the frame with four bolts. There is oil filling port on the top, and oil discharge plug screw at the bottom, and there is filter screen at the oil filling port, after it works for a certain time, the filter screen shall be cleaned periodically, and the oil discharge plug screw at the bottom shall be opened for discharging the sediment. 4) Radiating system It is composed of water radiator and hydraulic oil radiator, and it is connected together from the stand and rear frame by bolt. The water radiator cools the circulating water for engine, and the oil radiator cools the hydraulic running system. Any circumstance of water leakage or oil leakage shall be examined periodically at the cooling system, the loose or tight extent of fan leather belt shall be examined periodically, and necessary adjustment shall be conducted. 2. Driving system The hydraulic machine driving system is composed of hydraulic pump, hydraulic motor, gearbox, drive shaft, front axle and rear axle, etc. The output power of engine is transmitted by hydraulic pump, hydraulic motor, gearbox and drive shaft to the front and rear axle, which drive the wheels to realize advancing and retreating. 1) Hydraulic pump Refer to the instruction manual of hydraulic pump for details of the performance, structure and maintenance of hydraulic pump. 2) Hydraulic motor Refer to the instruction manual of hydraulic motor for details of the performance, structure and maintenance of hydraulic motor. 3) Gearbox The gearbox is a stationary shaft type mechanical shifting gearbox, it has two shifts: high shift and low shift, if the shifting handle is pushed forward, it is at the low shift, and if is pulled back, it is at the high shift, the shifting system is a shifting without clutch, it is strictly prohibited to conduct conversion between high and low shifts during running of vehicle, at the time of shifting, conversion between high and low shifts can be conducted only when the vehicle is stopped steadily. 4) Drive shaft
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5)

3. 1)

2)

3)

4. 1)

There are two drive shafts at the front part and rear part, they are respectively connected with the gearbox and front axle and rear axle. The structural pattern of drive shaft is the same as BJ130 automobile drive shaft, and the only difference is the length. At the time of overhauling, disassembling and assembling the driveshaft, the universal joint yoke at both ends of drive shaft shall be in the same horizontal plane, otherwise, the rotation of drive shaft might be imbalanced. Front and rear driving axle Four wheel drive is adopted for this series of mechanical loader, i.e., the front and rear axles are both driving axles, so as to facilitate the increase of tractive force of mechanical loader, and the working capacity can be improved. The basic structure of front and rear axles is basically identical, the difference is that the rotation direction of driving and driven helical gears of the front and rear axles is contrary. Steering system This series of mechanical loader adopts whole hydraulic steering system, which has the following features: a. The structure is compact to facilitate repair and use. b. All parts are self lubricated with hydraulic oil. c. The control is convenient and flexible, but after stopping of engine, the steering is very difficult, and drivers shall be very careful at the time of using. d. Under the circumstance of change in rotating speed of engine, the pressuregradient control valve can preferably guarantee the oil supply amount of steering gear, and ensure the steering safety of host machine. The steering system is composed of steering oil pump (one is for common use by the steering pump and working pump), pressure-gradient control valve, one-way valve and steering cylinder, etc. The pressure of steering system has been well adjusted before the host machine leaves the factory, at the time of using, please do not regulate it at will. At the time of necessary adjustment, manometer must be connected and it shall be adjusted according to the stipulated numerical value. Braking system The braking system includes two systems for running braking and parking braking. Braking system for running braking The braking system for running braking is an oil pressure type braking, and it is composed of brake pedal, oil storage cup, brake master cylinder, brake pipe and wheel cylinder, etc. For the reliable braking, the maintenance must be conducted carefully to the braking system, in the using process, the phenomenon of leakage shall be mainly eliminated, oiling, oil change and air release of the braking system shall be frequent. a. Before using vehicle everyday, the leakage circumstance of braking system shall be carefully examined. For the examination to oil leakage, the mode of direct observation may be used. If any phenomenon of leakage is found, it must be overhauled and removed, and the vehicle can be used only after all troubles have been removed. b. In the oil storage cup of the braking pump, braking oil of stipulated brand shall be fully added by stipulation, within the entire working period, the oil in the oil storage cup shall be at least kept at half level. Do not add any other mineral oil or degenerative braking oil into the oil storage cup of braking pump, otherwise, the
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rubber seal in the braking system might be damaged, if the color of braking oil is found to be dark, or it is found to contain water or it is odorous, or it is found to lack of lubricating oil film through twisting with hand, the braking oil must be replaced. At the time of replacing the braking oil, all the braking oil shall be thoroughly drained, and the braking system shall be cleaned, the steps are as follows: (1) Release the air escape valve on the brake. (2) Repeatedly tread down the brake pedal till no oil liquid flows out of the hole of air escape valve. (3) Add alcohol into the braking oil cup, repeatedly tread down the brake pedal, and flush the brake pipe and brake, till clean alcohol liquid flows from the hole of each air escape valve. (4) Add stipulated braking oil into the oil storage cup, and clean the braking system with the same method, and discharge it completely. (5) Finally add oil into the oil storage cup to the full by the stipulated braking oil. c. Air release of the braking system In case of leakage in the system or the oil surface in the braking pump is too low, air might enter the braking system. Any air in the system might make the braking powerless, the brake calipers might not clutch thoroughly, now the system needs air discharge. The discharge shall be done by two persons, one shall tread on the brake pedal, and the other person shall release the air escape valve, the operation steps are as follows: (1) Wipe the oiling cover of brake oil storage cup, detach the cover and fill braking oil to the full. (2) Tread down the brake pedal, release the air escape valve, so as to discharge air. Repeat for several times, till no bubble goes out, at that time, do not release the brake pedal, immediately screw tight the air escape valve, and braking oil shall be incessantly supplemented in the process of air discharge. (3) The braking frictional plate and braking disc shall be usually kept clean, oil dirt shall be avoided, when the braking frictional plate is seriously worn, it shall be replaced. d. For the gap between the braking calipers and the braking disc, the self-locking nut on the braking calipers may be adjusted, so as to guarantee that the sum of gap at the two surfaces is less than 0.4mm. e. The gap between brake pedal push rod and the braking pump piston shall be adjusted to 0.8mm-1.2mm, when the brake pedal is too low, the pipe system shall be examined for any oil leakage or existence of air, and that shall be got rid of in time. 2) Parking system Parking system is used by the driver for stopping machine after leaving the machine, it can also be as emergency use at the time of failure of running braking. The parking braking is flexible shaft control pattern, when the parking braking control lever is pulled tight, the pulling force is transmitted to the crank through the flexible shaft, so that the shoe opens to brake the drive shaft for the aim of parking. Adjustment of parking brake: release the handle of parking brake, prop up a rear wheel, take down the rubber stopper, and move the adjustment nut toward interior with a small screwdriver or special-purpose adjustment tool, till the extent of hand force not capable of rotating the brake hub. Then move the adjustment nut in the reverse
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5. 1)

2)

3)

6.

7.

1)

direction, reversely rotate it by 6-7 teeth till the extent of hand force not capable of rotating the brake hub. Working device and the frame The working device is mainly composed of auxiliary tools, such as quick-change device, connecting rod, lifting arm, rocker arm, bucket, and so on. The bucket tipping device adopts single oil cylinder Z shaped reversing with single rocker arm and single connecting rod structure, and it has the following features: the unloading height and unloading distance are great, the lifting force is great, the translation character of bucket is excellent, it has the function of automatically smoothly setting the bucket, the bucket can be easily loaded full, and the material is usually not scattered in the lifting process. The quick-change device adopts the mode of manual quick-change, it is simple and reliable in changing various auxiliary tools, such as bucket, wood clamping machine, pitch-fork, bottom fork, snow spade, etc., so as to realize the operation of loading soil, stone and sand, timber, grass, forking of goods and snow removal etc. The quick-change device is manual quick-change, it is an characteristic organization device of the machine, the upper hung shaft with connecting rod is linked with the rocker arm, and the lower part quick-change pin spindle is connected with the movable arm. The frame is the base for connection and installation of all parts in the entire machine. It is mainly composed of front frame and rear frame, and hinged mechanism is adopted for the front and rear frame. The front frame is the base part for installation of the working device, and it is mounted on the front axle. The rear frame is mounted on the rear axle, the main parts, including engine, gearbox and each operation device etc. are mounted on it. The hydraulic system is mainly composed of the main parts, such as hydraulic oil tank, hydraulic pump, hydraulic motor, multiplex reversing valve, pressure-gradient control valve, oil filter, hydraulic oil cylinder and oil pipe, etc. It is composed of three parts, namely the steering hydraulic system, hydraulic running system and working hydraulic system. The hydraulic pump is a twin high-pressure pump, axial compensation and radial tracking compensation are adopted, and it has the advantage of simple structure, reliable performance and long service life, etc. The multiplex reversing valve is a plate structure, and it has the advantage of simple structure, reliable performance, excellent sealing and convenient repair, etc. Electrical system The master switch of power source can switch off the entire line. This system adopts single line system with negative earthing. The electrical system of this machine is a 24V system with engine, the capacity of accumulator is 100AH, two accumulators are put at the right rear place in the cab, when it is detached for charging, it shall not be idle for long time, so as to prevent the pole plate from vulcanization and damage. The master switch of power source is at the left rear place in the cab, and the fuse box is mounted at the exterior side of the operation desk. Metal object shall not be placed on the accumulator, so as to avoid short-circuit. It is prohibited to directly connect metal tools including screwdriver or wire onto the pole of accumulator, the accumulator shall be examined for being live or not by means of producing spark from short-circuit, so as to avoid burning of accumulator pole and too much loss in the electrical capacity of accumulator.
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At the time of doing any repair work in the electrical system or detaching the accumulator line, for avoiding short-circuit or catching fire, the master switch of power source shall be firstly switched off. 2) Silicon rectifying motor and regulator The generator and regulator installed in this machine are both matched products of diesel engine, the voltage of generator is 28V, and the current is 12.5A. The generator charges the accumulator under normal circumstance, meanwhile, it supplies power to the power consuming equipment. Precautions for maintenance and use of generator and regulator: a. The generator requires the accumulator to be negative earthed, and it shall not be earthed inversely. If it is earthed inversely, the accumulator will discharge in short circuit status through the diode, the diode in the generator will be immediately burnt, and relevant line will also be burnt. b. The line on the terminal posts marked with ignition and magnetic field on the regulator shall not be connected inversely, otherwise, the junction might be burnt because of the regulator frequently switching off the load current, which might cause damage to the regulator. c. In the operation of engine, it is not allowable to examine the generator being generating or not by means of short-circuiting the generator armature terminal post with the shell to see any spark or not, so as to avoid burning of the diode. d. At the time of examining the insulation performance of generator, if 220V AC current or megohmmeter is used, the lead wire of diode shall be separated from the connecting part of each part, otherwise, it can only be examined with the high resistance range of universal meter. e. When the generator has been used for about 1200 hours, the generator shall be assembled for overhaul once. The contents of overhaul: 1 Clean the exterior of generator and remove the internal oil dirt. 2 Clean and examine the bearing and slip ring, if the bearing becomes loose, it shall be replaced, and the slip ring shall be ground by 00 sand cloth. 3 The wearing circumstance of carbon brush shall be examined, and it shall be replaced if it is seriously worn. 4 Examine the carbon brush holder to be intact and insulated from the shell or not. If the carbon brush spring loses elasticity, it shall be replaced. 5 Examine the diode one by one, examine with the high resistance range of universal meter, if the forward resistance value is close or differs greatly, the diode is meant to be damaged, and it shall be replaced. 6 Examine the contact of each wiring end in the interior to be reliable or not. 7 If the regulator has trouble, the outer cover shall be opened, examine the contact to have been burnt or not, if it has been slightly burnt, it can be ground with sand cloth, if the voltage of regulator is too low, it shall be readjusted, and the gap shall be adjusted according to the stipulation of the factory. 3) Starting motor Precautions for use of the starting motor: a. Usually examine the wiring to be excellent or not, and whether the terminal post to be firm or not. b. It shall be kept clean in use, and the intrusion of moisture shall be avoided. c. The starting motor shall be maintained periodically, and the maintenance
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shall be combined with the machine repair, clean the oil dirt in it with gasoline, grind the rotor and electromagnetic switch contact with No. 00 sand cloth. 4) Lamp light device The mechanical loader is equipped with front and rear head lamp, front lamplet, front and rear steering lamp, braking lamp, reversing lamp, cab lamp, instrument panel illumination lamp, steering indicator lamp and braking indicator lamp, etc.

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II. The Main Trouble and Removal Method Trouble reasons and features 1. Shifting fails 2. Half shaft or the drive shaft is broken 3. The opening pressure of motor and safety valve is too low oil seal leaks to cause insufficient oil supply 5. Motor is damaged 1. Engine power is insufficient 2. Pump or motor is damaged 3. Rotating speed of engine is insufficient 1. Adjustment of safety valve is improper 2. Element of safety valve is damaged 3. Failure of oil pump 1. Position of shifting lever is incorrect or the shifter shaft is deformed 2. Spline shaft is worn 3. Operation is improper 5. Repair or replace motor 1. Repair in accordance with instruction manual of engine 2. Repair or replace 3. Examine the engine 1. Readjust 2. Replace and repair 3. Replace the oil seal <IV> Shifting fails or it is difficult for shifting 1. Readjust the position of change speed lever, or replace the shifter shaft 2. Repair or replace 3. Operate according to the operation instruction <V> The sound of gearbox is abnormal and temperature is too high 1. Oil surface is too low or the brand is not suitable 2. Gear or key is worn 3. The bearing or spacing sleeve is worn or the gap is inappropriate 4. Oil surface is too high 5. Oil is dirty 4. Oiling by the stipulated oil surface 5. Replace
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Trouble-shooting method 1. Push the reverse gear position again or examine the accuracy of shift position 2. Examine and replace 3. Detach, examine and adjust, or replace the overload valve

<I> Engine operates but it does not run

4. The running oil pump is damaged, or the 4. Replace the oil pump or oil seal

<II> The driving force is insufficient, and the vehicle speed is slow

<III> Pressure of safety valve of motor is too low

1. Supplement or replace 2. Replace 3. Adjust or replace

6. The fastener is loose 1. Oil level at the oil tank is too low 2. Traveling pump or motor is seriously worn 3. Time of continuous working at high temperature is too long 4. Oil return line is locally blocked 5. The radiating efficiency of radiator is low

6. Fasten 1. Supplement to the stipulated oil level 2. Examine, repair or replace 3. Temporary stopping vehicle for lowering temperature 4. Clear the pipeline for smoothness 5. Clean the radiating oil channel against oil dirt

<VI> Temperature of hydraulic oil is too high

<VII> At the time of running, there is phenomenon of wheel wobbing and deviation 1. Gap of hub bearing is too great 2. Tire installation is poor 3. The hub fastening bolt is loose 4. Air pressure at left and right tires is different or the oil distribution shaft bush is jammed <VIII> Overheat of the driving axle, or abnormal noise 1. Bearing fit up gap is too small 2. Too much or too little lubricating oil 3. the ventilation hole is blocked 4. The sealing part is damaged with oil loss or there is impurity 6. The clearance of driving and driven 6. Readjust spiral taper gear is adjusted improperly, the engagement of tooth face is poor <IX> The steering moment is insufficient, failure of the steering 1. The working hydraulic oil surface is too 1. Add in accordance with the stipulation low 2. Oil leakage emerges in pipeline, sealing 2. Replace the sealing part part is damaged
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1. Adjust the clearance, the hub shall be capable of flexible rotation 2. Reinstall 3. Fasten 4. Supplement air pressure to make it identical

5. The spring leaf of steering gear is broken 5. Overhaul the steering gear

1. Readjust the gap 2. Appropriately discharge oil or add oil 3. Clean the ventilation hole 4. Replace the sealing part, add oil

5. Specification of lubricating oil is improper 5. Replace with qualified standard oil

3. Leakage in the oil cylinder, oil amount is 3. Replace the sealing part insufficient 4. Steering gear or rotor is worn brand is improper 6. The steering pressure is too low 7. Seizure of rotor and stator, mutual seizure of valve core, valve body and valve liner 8. Connective pin is broken 9. Spring leaf is damaged 10. Steering pump is worn 1. Oil leakage at the braking hydraulic pipeline and caliper disc brake 2. Air in the braking hydraulic pipeline 3. Oil inlet hole of brake master cylinder is blocked 4. Too little braking oil 5. Frictional plate of brake is worn 6. Frictional plate of brake is fully immersed by oil 7. Brake master cylinder or wheel cylinder oil seal or piston is damaged <XI> Brake could not be normally released 1. There is air in the braking hydraulic system <XII> Action speed of working device is slow, lifting force is insufficient 1. Adjustment of safety valve is improper 2. Internal leakage of gear pump is serious, the clearance of valve body is worn, internal leakage is serious 3. Internal leakage of oil cylinder is serious 4. Oil surface is too low or the brand is improper 3. Overhaul 4. Add qualified oil to the stipulated oil surface
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4. Replace

5. Viscosity of oil material is high, use of oil 5. Replace 6. Readjust 7. Decompose, examine, clean, grind or replace the part 8. Replace 9. Replace 10. Repair or replace <X> Braking force is insufficient 1. Examine and repair 2. Air release 3. Clean 4. Oiling, air discharge 5. Replace 6. Replace 7. Replace

1. Air release

1. Adjust to the rated pressure 2. Overhaul or replace gear pump or valve body

5. Oil filter is blocked 1. Oil inlet tube or oil filter is blocked 2. There is bubbles in the oil 3. Oil surface is too low, and air-suction is produced

5. Clean 1. Clean for its smoothness 2. Add oil or change oil 3. Add oil and release air

<XIII> Noise of oil pump is great, motion of oil cylinder is unstable, there is vibration

<XIV> The generator does not generate power or the charging current is low 1. Driving belt is too loose and slips 2. The regulator has trouble 1. Adjust the belt 2. When the diesel engine operates at low speed, short-circuit once the two wiring terminals ignition and magnetic field of the regulator with conductor, observe the spark when it is disconnected, if any spark emerges and the ammeter indication is charging, the regulator trouble is proved, and it needs repair. 3. The generator is damaged 1. Accumulator power is insufficient 2. The connector lug of starting motor is loose 3. Carbon brush is excessively worn or of 3. Overhaul or replace carbon brush poor contact 4. Starting switch is damaged poor <XVI> Lamp light or indicator light troubles Line trouble 1. Examine the fuse 2. Examine the line and repair 3. Check the electric bulb 4. Replace the switch 5. Broken circuit in the line or contact is 5. Examine and repair 3. Overhaul or replace 1. Charge or replace accumulator 2. Refasten <XV> The diesel engine is difficult for starting

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Chapter Four Lubrication and Maintenance I. Lubrication Proper lubrication can greatly reduce the wearing and the frictional drag at each part of the machine, so as to guarantee excellent using status of machine and prolong the service life. The lubrication shall be conducted strictly in accordance with the lubrication cycle table, it shall be examined strictly in compliance with the stipulation on examination before dispatching a vehicle everyday. 1. Lubrication cycle No. Lubrication Portion part Point number Lubricating oil Tool Lubrication cycle Week Month Half a 1 2 3 4 Driving box Front axle Rear axle Braking system 5 6 7 8 Hydraulic oil tank Drive shaft Butt hinge of frame Butt hinge of hydraulic 9 10 cylinder Working device Butt hinge of control Oil cup Machine oil 9 Oiler Oiling orifice Oiling orifice Oiling orifice Oil storage cup Oiling orifice Oil cup Oil cup Oil cup 1 4 2 8 Hydraulic oil Lubricating Oil 1 3 3 1 Brake fluid Driving oil year One year

grease wheel Lubricating Oil grease wheel Lubricating Oil grease Lubricating grease wheel Oil wheel

mechanism Note: A. For lubrication of engine and other accessories with machine, refer to relevant instruction manual for diesel engine. B. Symbol in the table is the supplementing or checking for supplementing, and is cleaning for replacing.
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C. The week in the table is marked in accordance with normal using status, the lubricating period shall be equal to or less than the value listed in the table under general circumstance, and any special circumstance shall be treated at ones discretion. 2. Specification and brand of lubricating oil (grease) and fuel oil No. Name of working fluid 1 Light diesel oil 0# light diesel oil GB252 -10 light diesel oil -20 light diesel oil -35 light diesel oil 2 Diesel engine oil 15W/40CD grade 10WCD grade 5W/30 grade 3 4 Cooling fluid Gear oil -30 blue 90 Above -10 Brand Air temperature for use Above 4 Above -5 -14~5 -29~14 Above -10 -5~20 Above -25 oil pan Water tank and engine body Front and rear axles and transmission 85W/90 80W/90 5 Universal lithium base lubricating 6 grease Synthetic brake fluid 7 Hydraulic oil L-HM46 GB01119 L-HM32 GB11119 L-HS46(YC-N46D) Note: In case of no wear-resisting hydraulic pressure listed in the table, it may be substituted by
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Part

Fuel tank

Engine

Above -12 Above -25 Hub and each hinged point

2 # GB7324

719 Type

Braking system

25~40 -10~25 Below -30

Hydraulic system

machine oil or ordinary hydraulic oil of corresponding brand (viscosity), i.e., N46 may be used in summer and winter, after ordinary machine oil or ordinary hydraulic oil is used, the service life of hydraulic elements might decrease accordingly. In summer at a hot region, L-HM68 wear-resisting hydraulic oil shall be used, and in winter at a bitter cold region, L-HM32 wear-resisting hydraulic oil shall be used. Precautions in use of oil 1) For the fuel oil and machine oil for engine, different brand of diesel oil and machine oil shall be selected in winter according to different region and air temperature. Refer to Table 1. The diesel oil in the diesel oil box must be supplemented in time, so as to prevent running out. The diesel oil shall be examined once each month to see whether it is polluted or not, is there any deposit or not, and the oil filter shall also be cleaned. The machine oil for diesel engine must be replaced regularly, since the mechanical impurity in the oil might increase with time, the reason for increase of impurities is: There is resultant after oxidation and wearing of parts, there is residue after combustion in cylinder, and foreign dust falls into it. When the content of those reaches 0.4-0.5, the oil becomes black, and the physical and chemical indexes worsen. Oil replacement shall be conducted in the hot status. 2) The cleanliness of hydraulic oil shall be examined periodically. The method is: take a drop of oil from oil tank, drip it into 240-mesh filter paper, if a flaxen loop appears on the paper, the continued use of the oil is proved to be available; if the outer ring of the yellow loop on the paper is obvious and its center is black colored, the oil is proved to have been polluted and need replacing. Instrument can be used for examination if possible. At the time of adding new oil, it must pass through oil filter, and it is not allowable to mix several hydraulic oils for use. 3) At the time of using 719 or 7100 automobile brake fluid, the material of sealing element in the braking system is oil-resistant acrylonitrile-butadiene rubber, it is strictly prohibited to use brake fluid, and mixed use of different category of brake fluid is not allowable. 4) In order to protect gear and save engine fuel, for the main driving in the driving axle and the wheel reductor, heavy-duty vehicle gear oil shall be selected and used in reference to Table1.2.
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Please be careful: You should pay more attention to the oil material in use for it has close relation with service life and performance of mechanical loader, the gear oil shall not be substituted at will, and that is even more serious for machine oil, hydraulic oil and gear oil for diesel engine working at high speed under high temperature. Due to the incessant development of new oil materials, the above oil specification and brand are not all-inclusive, and the users shall pay attention at the time of use 3. Precautions for lubrication
1) The oil pan of engine and the trapped fuel amount of hydraulic oil tank are just between

the upper and lower limits of oil scale. The oil surface for driving box, rear axle and front axle shall be added to the oil orifice (observation orifice). 2) Before filling of oil, the oil orifice or oil cup shall be cleaned.
3) For clearing and replacing oil at the driving box, front axle and rear axle, the old oil

shall be fully discharged at the hot machine status, then light diesel oil or kerosene (blended with 5% machine oil) shall be added, then start the engine for operation without load at low speed for 2-3 minutes, discharge the cleaning oil, fill in clean lubricating oil, meanwhile, the air plug and drain plug etc. shall be cleaned. 4) For new vehicle or 500 hours of working after overhaul, the hydraulic oil shall be replaced, oil shall generally be replaced once every half a year before and after running-in. If the oil fluid is not denatured or not discolored, it can be prolonged appropriately, but that shall not exceed one year. At the time of replacing oil, the oil tank and fine filter shall be carefully cleaned, the fine filter is mounted at the oil suction orifice in the oil tank, the filter element (filter screen) shall be replaced when necessary. After sedimentation for 48 hours, hydraulic oil passes through the filter screen at oiling orifice (it is suggested to use silk fabric for filtration), meanwhile, the pipe joint and other connective part shall be fastened, and the sealing part shall be replaced when necessary. The filter shall generally be cleaned once every month. If the filter element is broken or there is much dirt, it shall be replaced. 5) Lubricating grease shall be applied once about every month for the exposed part of hydraulic cylinder piston rod. 6) After overhaul inspection, repair or replacement of parts, relevant parts shall be lubricated.
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II. Maintenance 1. Maintenance of engine Refer to the operation instruction of diesel engine. 2. Daily maintenance (routine maintenance) For the routine maintenance and daily maintenance before work, in the work and after offrunning everyday, examination shall be given priority to. The following work shall be done: 1) Various oil fluids and cooling water shall be examined to be sufficient or not, is there any phenomenon of leakage at each oil tank, piping, hydraulic element, etc., the lubrication circumstance of each hinged point shall be examined, and add oil (grease) or fasten when necessary. 2) Check the pressure of tire to conform to the stipulated value or not. 3) Is the operation of engine normal or not, is there any abnormal sound or not, is the pressure of machine oil normal or not. 4) Is the steering, braking and other control mechanisms sensitive and reliable or not, is the instrument signal normal or not, is the connective part fastened or not, is the action of working device flexible or not, is the structure of working device obviously deformed or sealing off. 5) If any abnormality is found, it shall be removed in time, and it shall not work under the circumstance of poor status of machine. 6) The cleaning work after shift shall be done well, and the cooling water shall be fully discharged in winter. 3. Primary maintenance (50 hours every week), giving priority to lubrication. 1) Finish various work of daily maintenance. 2) Add lubrication oil (grease) to the forced-feed oil cup (grease fitting) of the whole vehicle, and drip machine oil to the exposed hinged point of operation mechanisms, such as accelerator, advancing and retreating handle, etc. 3) Check the height of liquid surface, and supplement when necessary. 4) Use barometer to check the pressure of tire, and add air when necessary.
5) Clean the accumulated water and dirt in the air filter, machine oil filter and fuel oil filter

discharge fuel oil tank (when the oil quality is relatively bad, it shall be discharged before shift everyday). Start the engine, listen to the engine for any abnormal sound while it is operated at low speed, medium speed and high speed, pay attention to
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relevant part of engine for any phenomenon of oil leakage, water leakage or electrical leakage. 6) Check and fasten the fastener and connective part at each part, pay special attention to the fasteners at moving parts, such as driving axle and wheel hinge pin, etc. 7) Check the travel of brake pedal, and adjust when necessary. 4. Secondary maintenance (2000 hours each month) 1) Finish various work of primary maintenance. 2) Clean each filter in the hydraulic system and engine system, check the height of liquid surface in each container, and supplement when necessary. 3) Examine the working circumstance of each driving part and traveling part, adjust or fasten when necessary, and conduct universal examination and fastening to fasteners and connective parts of the whole vehicle. 4) Check and adjust the free travel of braking pedal, the travel of accelerator, as well as the clearance between the main brake and parking brake. 5) Check the working pressure of hydraulic system, and adjust when necessary. 6) Check the electrical instrument system of the whole vehicle, lubricate the engine and motor, etc., clean the dirt at the joint of accumulator. 5. Grade III maintenance (half a year, 1000 hours) In the Grade III maintenance, cleaning, oil pumping and removal of wearing shall be given priority to, it shall generally be seasonal service, and it shall be done once in spring and autumn respectively. Clean the oil pan of engine, the fuel tank, fuel oil pipeline and filter, and clear the dust and dirt in the crevice of water radiator. Replace the lubricating oil at driving box, front and rear axles, check the using circumstance and the matching clearance of gear bearing, etc., adjust or replace when necessary, and clean and dredge the air plug. Check the bearing clearance of front and rear wheel hub and it shall be adjusted when necessary. Check the using circumstance of lubricating grease, and it shall be replaced if it is denatured or polluted; if the oil quality is relatively good, it may be appropriately supplemented for continuous use, but the cycle of replacing shall not exceed one year. Conduct quick-change to the following two pin spindle (here is near to ground and it might be easily polluted), disassemble and examine other pin spindle when necessary (it shall be cleaned at least once every year), clean and replace oil, in case of any scar on the pin
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spindle, it shall be used after repair. When the using condition is poor (much dust or soil), all pin spindles (including hinged point of frame) shall be cleaned once every half a year. Replace the brake fluid (when the oil quality is relatively good, the using time can be prolonged as appropriate, but not exceeding one year at most). Disassemble, examine and clean the brake master cylinder and wheel cylinder. Clean the hydraulic system, replace the broken sealing part, replace the hydraulic oil, and adjust when necessary.

Chapter Five Transport, Protection and Storage I. Transport For the transport of this series mechanical loader, according to the distance of road and the geographical condition, railway, highway or water transport may be selected. At the time of transport, besides observing the stipulations of traffic department, users shall also observe the following stipulations: Anti-rust oil shall be applied to the exposed movable part, so as to prevent corrosion. Fully drain the cooling water, and detach the earth wire of accumulator. Pull up the parking brake pull rod. The movable arm shall be put at the lowest position to the ground, and smoothly set the bucket. Steadily pad the wheel with triangle wood block, use rope or iron wire to fix the mechanical loader onto the transportation vehicle. II. Protection and Storage For the mechanical loader that needs storage for a relatively long period, it shall be protected and stored in accordance with the following stipulations: Clean and maintain in an all-round way, so as to reach the aim of no corrosion, no oil dirt and no other pollutant, fully discharge the cooling water, and conduct anticorrosion and protection treatment to the machine. 1. Anti-corrosive method 1) The preservative coating generally includes: non-corrosive paper, alcohol, alcohol water solution preservative and powdery preservative, etc. The anti-corrosive method is as follows:
a.

Non-corrosive paper: the parts of machine may be packed with non-corrosive

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paper, and there shall be enough overlapping amount at the boundary of package. At the time of packing parts with complicated shape and relatively great weight by non-corrosive paper, protective layer of plastic film or metal foil product can be added externally. b. At the time of anticorrosion to the cavity on the machine that needs enclosing in the operation process, gas preservative or powdery preservative of alcohol, water solution stirred with alcohol may be selected and used. After the internal surface of cavity is treated with preservative, surplus preservative solution shall be removed, and drying treatment shall be conducted. After the preservative forms crystal, seal all orifices of the cavity with non-corrosive paper or binder. 2) Applying oil paint a. For the external surface of machine parts, oil may be coated by means of spraying or brushing immersion, etc. After full dripping of surplus oil, the oil film shall be even.
b. For the internal surface of machine parts, oil fluid may be poured in, or it can be

filled into the cavity bore by oil pump, then rotate corresponding movable parts of the machine, so that the oil film is even, and let the surplus oil drip fully. c. For the internal surface of hydraulic system whose anticorrosion depends on hydraulic working oil, hydraulic working oil shall be filled to the full. d. At the time of antirot treatment to the machine surface with dissolved antirot coating or paint, it shall be conducted by means of spraying or brushing, etc.
e.

When any defect on the antirot layer is detected, the surface at the defect part shall be cleared, and then apply the same paint or oil material.

3) At the time of using antirot polymer, the coating shall be guaranteed to be continuous and even, and there shall be no inclusion. 4) In order to prevent the influence of sunlight on the quality of rubber, a layer of lightproof compound shall be applied on the surface of rubber part by means of spraying or brushing, and it can also be wrapped with black neutral wax paper. 5) Besides the above single item of antirot method, other methods or two or many of the above antirot methods can be used for joint anticorrosion. For whichever method that is used, the machine and parts shall not be damaged. 6) Remove the antirot matter with the method listed in Table 1 Antirot method Apply preservative on surface Strip the non-corrosive paper, use dry hot air to
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Apply oil or paint onto the surface

purge clean or alkali solution of soap to flush. Use detergent and hot water to clean, or firstly use organic solvent to wipe clean, and then flush

with detergent and hot water. Apply antirot polymer onto the surface At the appropriate part, cut off the polymer membrane and strip it. Apply light-proof compound onto the Use detergent to clean the light-proof compound surface, or wrap with black neutral coating that shall be removed, or strip the lightwax paper 2. Storage proof wax paper.

1) A storage period over two months is long-term storage. The long-term storage is divided into two categories: a. Two months to one year b. Over one year 2) The storage ground for machine can be divided into: outdoor ground, sheltered ground, closed thermal insulation warehouse, and warehouse with air-conditioning.
a. Before long-term storage of machine, protection treatment shall be conducted to it,

the circumstance of package sealing etc. shall be examined carefully in an allround way; b. The stored machine shall be padded levelly with support, and the distance between each wheel and each supporting object shall not be less than 8cm. c. The orifice on machine, such as adjustment orifice, air inlet, discharge orifice, etc., shall be tightly sealed with lid, stopper, waterproof adhesive plaster or other special-purpose device. d. Put the operating handle and pedal at the position where no danger would occur even if the machine operates occasionally. e. The accumulator on the stored machine shall not be open-circuited, the concentration of electrolyte and the height of liquid surface shall conform to the stipulations of manufactory. When the storage of machine exceed one month, the accumulator shall be detached from the machine, and shall be put to a specialpurpose place for storage. f. The fuel oil, lubricating oil, hydraulic oil, cooling fluid and water etc. on the stored machine shall be added or discharged according to the stipulations of manufactory or relevant managerial department.
g. For the machine stored for long period, the circumstance of its appearance quality,
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protective surface and preservative matter shall be examined periodically, and the interval of examination shall be as follows: In the season and region with warm climate, it shall be examined once every six months; In the tropical zone, temperate zone when it is cold or in the coastal region in the frigid zone, it shall be examined once every three months.

Conclusion You have studied the instruction manual about the use, mainatenance and safe operation of CS series full-hydraulic wood clamping machine, including the metohd of various operations by means of the unique convenient quick-change device. This manual basically includes various operation maintenance and safety issues that might appear in your working process. But only with correct judgment to various working environments and working status, and operation surely following the operation regulaiton and careful caring and maintenance to the vehicle can you safely complete various work. Therefore, our objective is to help you to cultivate excellent and normal working habit for becoming an excellent driver of engineering machine vehicle.

Finally, please remember Safety is supreme forever, that is your responsibility and obligation

Checking items: Before delivery Please examine the following important items Was the equipment damaged or not in the transport process. Check to see whether it has any pit or not, does it loose or lack part: if it is damaged, please repair or replace
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part. Is the installation of accumulator firm without rupture. The connection of accumulator cable shall be firm, the liquid surface height of electrolyte shall be appropriate, and accummulator fluid needs not to be added to maintenance-free accumulator. The lifting and inclining oil cylinder, hose and joint shall have no damage, oil leakage or looseness. The filter shall have no damage, oil leakage or looseness. The radiator hose and joint shall have no damage, leakage or connection looseness. The wheels shall be installed correctly and firmly, and the tire shall have been inflated properly. The joint bearing of the full-hydraulic multifunctional mechanical loader shall have been lubricated, the grease lubricating parts shall not be lost or damaged. The liquid surface of hydraulic system oil storage tank, engine crankcase and the driving sprocket box shall have been filled to the appropriate height. Installation of all protective parts, cover and sleeve parts shall be firm and correct. Start the engine of mechanical loader, try to start the machine, and check all action control to be correct or not. The working of driving control lever shall be normal, there shall be no damage or binding. The neutral of driving control lever shall be adjusted correctly, the mechanical loader shall have no self motion at the neutral.

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