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Hyundai HL630VL Operator's Manual

Wheel loader
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  • Page 2 Attention Please Subject : Matters needing attention for maintenance and accessories 1. First welcome you to have used our product and thank you for great coordination in business. 2. In case the equipment is in faults, it should be maintained by our Company or the company appointed by our Company using standard parts.
  • Page 4 Topic: special explanation of fuel system operation and maintenance for loader In order to let Hyundai loader for you to create greater economic benefits, please read this article seriously. Fuel quality is the important factors of make the engine to obtain fine performance and prolong service life and realize low emission.
  • Page 6 Operation & Maintenance Manual Our Company has the right to continuously improve the products so as to promote the best products to the market as possible as we can. These improvements can be implemented at any time; however, we will not change the materials for the products being sold at that time. The consumers should particularly be reminded of that they should regularly contact with the Agent to ask for the newest information of the equipment.

  • Page 8: Table Of Contents

    Contents Safety ........................1-1 Advice for Operation of a HYUNDAI Wheel Loadar............. 1-1 Safety Labels........................ 1-5 Unauthorized Modifications ..................1-7 General Hazard Information ..................1-7 Before Starting Engine ....................1-16 Operation of Loader ....................1-20 Maintenance ....................... 1-26 Battery ........................1-34 Towing ........................
  • Page 9 Inspection,Maintenance and Adjustment .............4-1 Preparation and Setting of the Equipment Before Maintenance ........4-3 Recommended Lubricants Table ................. 4-4 Fluid Capacity....................... 4-5 Lubrication and Service Chart ..................4-6 Maintenance Interval ....................4-9 Electrical system ......................4-11 Bucket ........................4-13 Add Shim to Bucket ....................4-15 Tires ...........................

  • Page 10: Safety

    Safety ADVICE FOR OPERATION OF WHEEL LOADAR DANGER Unsafe use of the wheel loader could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
  • Page 11 In no event should you or others engage in prohibited uses or actions as described in this manual. Hyundai delivers machines that comply with all applicable regulations and standards of the country of which it has been sent. If this machine has been purchased in another country...
  • Page 12 SAFETY ALERT SYMBOL Be prepared-Get to Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you must be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
  • Page 13 SAFETY DECALS Fig 1 The safety decals are attached to the machine. In this Chapter, the locations and descriptions of these decals will be reviewed in the following section. Please become familiarized with all safety decals and their messages. Make sure that all the decals are in correct locations and legible. Clean or replace the safety deals if the decals are missing or damaged, or the texts and pictorials are not legible.
  • Page 14 1. Never stand under the moving arm. Sudden or accidental movement of boom may cause injury or death. Securely brace boom before working or walking under raised boom. Fig 2 2. Never stand under the bucket. Fig 3 3. Severe injury and death from crushing could occur in articulation position when machine turns.
  • Page 15 Keep Away C/W Standing here is strictly prohibited while the machine is moving. Otherwise, it will cause serious injury or death accidents. Fig 5 Hot Pressurized Fluid WARNING HOT PRESSURIZED FLUID CAN CAUSE SERIOUS BURNS • Do not loosen or open cap when hot. •...
  • Page 16 Rotating Parts - Fan WARNING CONTACT WITH ROTATING FAN CAN CAUSE DEATH OR SERIOUS INJURY • Keep away from fan and rotating parts. • Stop engine before servicing. Fig 9 9. Important Reminder about Hydraulic Oil Fig 10 10. Important Reminder about Air Tank. Fig 11 Safety 1-7...

  • Page 17: Unauthorized Modifications

    UNAUTHORIZED MODIFICATIONS In case of the safety accidents arising from any modification without authorization by Hyundai, the Owner shall bear the respon- sibilities. As a safety precaution, all OEM parts must be replaced with the correct authorized or genuine parts. If the fasteners, bolts or nuts are not regularly replaced with correct spare parts, it may cause these parts to exceed the safety limit of operation.
  • Page 18 Matters needing attention in cabin When entering the operator’s cabin, always remove all mud and oil from the soles of your shoes. If you operate the accelerator and brake pedals with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident.
  • Page 19 Clothing and Personal Protective Items Secure long hair, and avoid loose clothing and jewelry. These items have the tendency to catch on controls or protrude into parts and cause serious injury or death. Do not wear oily clothes. They are highly flammable. Full eye protection, a hard hat, safety shoes and gloves may be required at the work site.
  • Page 20 Fire Hazards for Fuel, Oil and Hydraulic If fuel, oil and anti-freeze fluid are put close to the fire source, it is easy to cause fire. In particular, the fuel may cause extreme danger. Pay strictly attention to the following conditions: Make sure the premises are well ventilated when the fuel, oil, anti-freeze-fluid and hydraulic oil are filled in.
  • Page 21 Coolant • During operation, the temperature of the engine coolant is higher and there is pressure in the engine. All piping lines connected to radiator or to engine have hot water or steam in them. The contact with them will cause severe burns. •...
  • Page 22 Fire extinguisher and first-aid kit In case of personal injury or fire happened, please operate as follows • Find the Fire extinguisher and carefully read the operation description on it to ensure that you can use it. It is recom- mended to use the multi-functional “A/B/C”...
  • Page 23 Prohibit reforming or changing any forms of protection structure by adding reinforcing devices (e.g., drilling hole, welding, re-in- stalling or re-installing fasteners etc.). The re-identification of the whole protective system is needed for the protective system which has suffered severe impact or damage. Re-installation, re-authentication, or replacement of system is needed if neces- sary.
  • Page 24 Battery • During operation, the battery can produce combustible gas- es which may cause explosion. • Do not smoke while checking the level of electrolyte of the battery. • The electrolyte is an acidic substance, and it will hurt the persons when it touches with skin or eyes.
  • Page 25 Tire That the fully inflated Tire may be exploded is due to the heating inside of the Tire. Generally, heating is caused from the welding or heating of rim, the external flames or the too frequency of braking. The explosion of Tire is much more powerful than air bleeding. It can make Tire, rim, and driving parts fly off over a distance of more than 500 meters.

  • Page 26: Before Starting Engine

    BEFORE STARTING ENGINE Matters needing attention on site Before starting, completely check the working area for the ab- normal conditions which may cause dangers. Check the terrain and ground surface on site, and identify the best and the safest operation method. Before operation, please make the ground hard and smooth as possible as you can.
  • Page 27 Please remember that the earth is very soft in this area after raining, explosion operation or earthquake. The soils piled up on the ground or by side of the channels are very soft which will be collapsed under the vibration of the ma- chine to cause the machine to tip over.
  • Page 28 Start the engine Walk around and check the loader before entering the cab. Check for oil leakage, loose, improper adjustment of compo- nents or the possible damage phenomenon of other equipment. In order to prevent the accidents, all cover plates and protective devices for the equipment shall be complete when operating the machine.
  • Page 29 Before operating loader If you do not correctly check after the engine is started up, then you may not timely find the abnormalities of the machine so that the personal injury or machine damage could occur. • Check the machine at a place without any obstacles, and do not let anybody to approach the machine while you are checking.

  • Page 30: Operation Of Loader

    OPERATION OF LOADER Matters needing attention on travelling Do not shut off the engine while the machine is travelling. The shutting off engine while the machine is travelling is dangerous. You cannot manipulate the steering wheel effectively. Do not operate the control handle of the attached device while the machine is travelling.
  • Page 31 Matters needing attention on travelling on slope Do not jump onto the incontrollable machine to shut it off, other- wise you will have the risk of serious injury. Travelling on the slope will cause the machine to tip-over or slip- ping.
  • Page 32 Matters needing attention on operating Be careful not to approach the edge of the cliff. If the machine is used for other operation, it will cause the oper- ation to fail. In order to ensure a good view, please obey the following items: •...
  • Page 33 Be careful for HV cables The touching of machinery with or the approaching of machin- ery to HV cables may cause serious injury or death. Prohibit the approaching of bucket to electric cables. The driver shall leave far away from the electric cables with as- sistance of observer and sign language when the driver’s sight line is not clear.
  • Page 34 Operation on slope Be especially careful for that travelling on the slope will cause the machine to sideslip or tip-over. The shovel must be 200-300mm over the ground while the machine is travelling on the slope. In an emergency, lower the bucket quickly down to the ground to assist the stop of the ma- chine.
  • Page 35 Parking the machine After the operation, avoid sudden switching-off or shutting-off. Park the loader on a hard plane, far away from traffic lines and high walls, cliffs, and edges of pools and drainage ditch. If the machine must be parked on the slope, it is necessary to stop up the Tires to prevent from moving, and lower the bucket and oth- er working devices down to ground or on the supporting bases.

  • Page 36: Maintenance

    MAINTENANCE Warning labels Warn of that others persons are performing the maintenance, and hang the warning sign on cab control device and other nec- essary places. Our company branch organizations provide control warning signs. Fig 28 P e r f o r m t h e c l e a n i n g w o r k b e f o r e maintenance Perform the cleaning work before inspection and maintenance to prevent the dust from entering the machine and ensure the...
  • Page 37 Proper tools Use tools which are proper for the operation. The use of dam- aged, low quality, unqualified or temporary tools may cause the personal injury. The scraps from chisel or hammer are very dan- gerous, and they will cause the persons to be blind. Fig 30 Operation of lighting devices The explosion-proof lighting devices should be used for check-...
  • Page 38 Avoid burns Stop the engine when checking the level of radiator to let the engine and radiator cool down. Slowly open the cover to release the pressure before opening the cover of the radiator. If the coolant in the recycling tank approaches the lower limit, add the coolant.
  • Page 39 Welding maintenance The welding operation should be performed at the specified place. The welding operation should be performed by quali- fied persons. The toxic gases and flames etc will be produced during welding, therefore, do not allow the unqualified persons to perform the welding operation.
  • Page 40 Matters needing attention for attachment moving, installation and storage Select the leader for the operation before starting removal and installation. Do not let any unauthorized persons to approach the machine or attachments. Put the attachments removed from the machine at the safety places to prevent from falling. The guard bars are set around the attachments and corresponding measures should be adopted to prevent unauthorized persons from enter- ing.
  • Page 41 Avoid being crushed or cut When performing maintenance,if you must operating the engine, ensure at least two persons must work together. One person is sitting on the driver seat to operate the control device and shut off the engine. Unless otherwise instructed by others, Do not adjust the ma- chine when the machine or the engine is running.
  • Page 42 Measures which should be taken when y o u f i n d t h e a b n o r m a l i t i e s d u r i n g inspection Please perform the maintenance if any abnormality is found during inspection.
  • Page 43 Scraps Contacting with used engine oil may cause threats to the health. Immediately rub off the engine oil from your hands, and wash away the remaining oil foot. The used engine oil is a pollutant to the environment, and it can be only disposed by using the approved recycling equipment.

  • Page 44: Battery

    BATTERY Prevention of battery risks The battery electrolytes contain sulphur acid, and battery can produce Hydrogen. Hydrogen is highly explosive. If disposing incorrectly, it will cause serious injury or fire. In order to prevent theses problems, please accomplish following items: Prohibit smoking or flame approaching the battery.
  • Page 45 Auxiliary starting or charging the engine battery The incorrect connection of battery cables may cause explosion or fire. Please obey the following items: • Switch off all electrical equipments before connecting to battery, including the electric switch for battery charger and auxiliary starting device.

  • Page 46: Towing

    TOWING Matters needing attention on towing If fault occurs during the selection or inspection of the traction string or during performance of traction, it will cause serious in- jury. Please obey the following items: • Use the methods introduced in Operation and Maintenance Manual.

  • Page 47: Shipping And Transportation

    The total height, total width and total weight should not exceed the related regulations. Please consult Hyundai or other agents for the solutions. In order to prevent the safety accidents from being occurred during the shipment of the machine, clear the ice and snow as well as other slippery materials on the dock and wagon.
  • Page 48 Lifting of loader 1. It is necessary to let the professionals with lifting knowledge be responsible for the command and operation. 2. You should calculate the crane’s maximum lifting weight and the sling’s bearing capacity to ensure the lifting safety. Meanwhile, the 4 hooks on the sling shall bear load evenly.
  • Page 49 Tow the fault machine This machine cannot be towed unless in the emergency. Towing is only used for towing this machine to a place where the overhaul can be performed, instead of transporting over a long distance. The towing distance for this machine should not exceed 10km, and the towing speed should not exceed 10km/h, otherwise the gearbox will be damaged for short supply of oil.
  • Page 50 Matters needing attention for towing 1. Be sure to release the parking braking. NOTE: You should use wedges to stop the wheels of the machine to prevent the machine from moving. If the machine wheel is not properly stopped by wedges, the machine will move.

  • Page 52: Operation Controls

    Operation Controls Description of each component position and each control switch, instrument and valve through drawings or photos. The meters on the dashboard are attached with indicators through which the operator monitors the operation of the machine and with which the faults are displayed. WARNING Warning lamp: If any warning lamp or several lamps on the console are lit up, immediately stop the operation and shut off...

  • Page 53: Component Locations

    COMPONENT LOCATIONS The following figure identifies the location of major machine components. 32.33 Fig 1 2-2 Operation Controls...
  • Page 54 Reference Reference Description Description Number Number Main Frame Cab Seat Engine & Gearbox Interior Engine Controls Fender Fuel Tank Stopper Hydraulic Oil Tank Counter Weight Driving Shaft Front additional device Driving Axle Bucket Tire Bucket teeth Bucket knifing edge Cooling Pipeline Harness;...

  • Page 55: Operator`s Area

    OPERATOR`S AREA Fig 2 Reference Reference Description Description Number Number Washing pot Steering wheel Adjusting handle for seat Brake pedal (Forwards, backwards, left- Electrical element box wards, rightwards) Seat Bucket manipulating handle A\C evaporator assembly Arm manipulating handle Control switch such as OFF Combo switch handle (Low/ VENT high beam, Horn, Steering...
  • Page 56 Shifting lever The shifting lever is located under the steering wheel.. (Fig. 3) Operate the shifting lever frontward or backward to get forward gear 1, forward gear 2, back gear, neutral position. Fig 3 Operation Controls 2-5...

  • Page 57: Manipulating Facility And Monitoring System

    MANIPULATING FACILITY AND MONITORING SYSTEM 1. The steering wheel rotation angle is not equal to the machine’s rotation angle. Continuously rotate the steering wheel to increase the rotation angle until to the required position. 2. The quicker the steering wheel rotates, the quicker the machine rotates.
  • Page 58 1. Auxiliary – the first position you meet when you insert the starter key and rotate it counterclockwise, and this gear position can be auto reset (i.e., the button will return to “OFF” position when you release your hand). This gear position is not available at present.
  • Page 59 Operation of pre-heater system The pre-heater system can be used in some regions and states where the cold weather may affect the starting ability of the engine. Please read the following specification carefully before operation Turn the starter switch to the position ‘ON’ Starter Switch (‘ON’) When the resistivity of the engine coolant sensor is less than 2700 ±...
  • Page 60 When the pre-heat time is up, the pre-heat indicator (DL) goes out (If the start switch is turned off during the pre-heat time, the controller will stop) and the pre-heat system then wait to start the engine for 30s. • During the waiting time (the pre-heat plug is in ON posi- tion),if you switch on the start switch (K2),the fuel supply valve is open and the pre-heat indicator will be lighted on...
  • Page 61 Schematic Fig 11 2-10 Operation Controls...
  • Page 62 Parking braking Parking braking switch (Hand brake) is located on the console on the left side of the cab. When it is pulled Up, the braking ap- plies. (Fig. 12) Fig 12 Service braking pedal Service braking pedal (foot brake) is located in front left of the cab floor.
  • Page 63 Do not selfishly change the shifting manipulating system when the shifting manipulating system of the vehicle is in fault ! If the fault cannot be removed, please contact with authorized maintenance station and after sales service company of Hyundai for the maintenance. 2-12 Operation Controls...
  • Page 64 Pilot manipulating handle (Standard configuration) Pilot manipulating handle is installed on the handle manipulating box on the right side of the driver seat. It is used for controlling the working device to perform the operation. The bucket manip- ulating handle with leftward and rightward manipulation is used to control the bucket’s movement and the arm manipulating handle with forward and backward manipulation is used to con- trol the arm’s movement.
  • Page 65 Arm floating device: If the manipulating handle is pulled backwards to the ex- treme rear position, the manipulating handle will be stuck by arm float holding magnet (in this case, the driver can release his hand, and the arm manipulating handle will not return back to the middle position), and at this time, the arm is in floating state.
  • Page 66 When the bucket manipulating handle is again pulled back- wards to the extreme left position, the manipulating handle will not be stuck by Bucket Receive holding magnet (it will return back to the middle position under the force of spring when you release your hand) because the Bucket Receive holding magnet is de-energized all the time due to the Limiting and Holding function of the bucket leveling limit...
  • Page 67 Pilot manipulating handle (Optional) Pilot manipulating handle is installed on the handle manipulat- ing box on the right side of the driver seat. It is used for con- trolling the working device to perform the operation. The inner side bucket manipulating handle is used to control the bucket’s movement and the outer side arm manipulating handle is used to control the arm’s movement.
  • Page 68 Arm floating device: If the arm manipulating handle is pushed forward to the extreme front position, the arm manipulating handle will be stuck by arm floating holding magnet (in this case, the driver can release his hand, and the arm manipulating han- dle will not return back to the middle position), and at this time, the arm is in floating state.
  • Page 69 Bucket leveling limit device When the bucket is in the unloading state, if the bucket manipulating handle is pulled backwards to the extreme rear position, the bucket manipulating handle will be stuck by Bucket Receive holding magnet and will be held at the extreme rear position (the bucket manipulating handle will not return back to the middle position even you release your hand), and the bucket will be rotated backwards all...

  • Page 70: Rocker Switch

    ROCKER SWITCH Fig 19 Combo rocker switch Rotating Beacon Light Switch (Optional) If unit is equipped with a rotating beacon warning light, push this switch to activate it. Fig 20 Rear Work Light Switch Rear lamp switch controls left and right lamps are turned “ON”...
  • Page 71 Hazard Warning Light Switch The hazard warning light is used when machine is stopped because of a malfunction or when an emergency occurs. When this switch is pressed, all directional indica- tor lights on front and back of machine will turn “ON” and “FLASH,”...
  • Page 72 The state of the front lamp switch in the picture is “OFF”, and both low beam and high beam are not available Figure 26 Only when you turn on the front lamp switch can you get the state you want——low beam high beam by operating the level noted in Fig 27 Figure 27 NOTE...

  • Page 73: Monitoring System

    MONITORING SYSTEM Most of monitoring instrument and meters and indicators are integrated in the Instrument Ass’y below the steering wheel. The Instrument include: totaling to 10 meters for tachometer, cooling water temperature, gearbox oil level, timer, braking air pressure, engine oil pressure, torque converter oil temperature, power supply voltage, speedometer, odometer;...
  • Page 74 1. Monitoring Instrument When the pointers of various monitoring instrument(ex- cept timepiece)are within green zones, this means that this monitoring item is now in the normal range, and the loader can normally work;; on the contrary, if the indicated positions are not within the green zones, you must confirm the states for this monitoring item and adopt corresponding measures to correct.
  • Page 75 3. Detailed descriptions for Monitoring instrument and Indicating lamp Fig 29 Gauges, Warning and Indicator Lights Reference Reference Description Description Number Number Tachometer TM warning light Fuel Gauge TM oil pressure warning light Engine oil pressure Gauge F/R selector indicator light Engine coolant Air cleaner clogger temperature Gauge...
  • Page 76 G1. Tachometer This meter displays engine speed in revolutions per minute. Fig 30 G2. Fuel Gauge This gauge displays amount of fuel in tank. “F” means the tank is “full”; “E” means the tank is “empty”. If the pointer comes close to “E” (red zone), add fuel as soon as possible.
  • Page 77 G4. Engine Coolant Temperature Gauge This gauge displays temperature of engine coolant. Note: When the pointer indicates red zone, it means the engine is overheated. Stop the operation, let the engine run at low rpm and wait for it to cool down. Do not stop engine.
  • Page 78 1. Left Turn and Hazard Warning Light This light blinks when left turn signal is turned “ON”. Both lights blink when warning lights are turned “ON”. Fig 37 2. Right Turn and Hazard Warning Light This light blinks when right turn signal is turned “ON”. Both lights blink when warning lights are turned “ON”.
  • Page 79 9. Water Separator Light This symbol indicates when the water is full in the fuel prefilter. When this symbol appears drain the water from the fuel prefilter as soon as possible. Fig 45 10. TM warning light NOT USED Fig 46 11.
  • Page 80 17. Brake air pressure warning light when the air pressure lower than normal value,the warning light turn on. Never operate or travel machine when this light is “ON” Note: or when alarm is sounding. Always investigate cause Fig 53 of the drop in brake air pressure, and repair problem before operating or traveling machine.

  • Page 81: Instrument Panel

    INSTRUMENT PANEL 1. Timepiece It is used to indicate the working time of the machine, in hours. The working scope of the timepiece is: 0 - 9999.99 hours. When the engine is started, the timing begins 2. Horn switch There are two horn switches in this machine: “A” at the center of steering wheel and “B”...

  • Page 82: A/C System

    A/C SYSTEM Refrigeration A. Close the heater water valve; (Fig. 65) B. After the engine working normal, turn the blowing rate switch to the proper position; C. Rotate the temperature control switch to the proper po- sition (Green indicator lit up), and the refrigeration sys- tem starts working and the cooled air begins to be sent out from the air outlet;...

  • Page 83: Stereo

    STEREO Audio system Audio system (optional): Audio system is located in the cab, including multimedia, speaker, and antenna. The multimedia speaker has many functions such as digital radio, USB / SD / MMC, MP3 / WMA, clock, adjustable volume. Configuration Digital radio, USB / SD / MMC, MP3 Player Radio The radio has both FM and AM.
  • Page 84 Fig 66 Reference Reference Description Description Number Number M3/RPT Store Channel/ POWER REPEAT MODE Select Mode/Set time M4/RDM Store Channel/ BAND Select Band/Save RANDOM Auto Searched Channel M5/-10 Store Channel/Next VOL+/VOL- 10 Songs TUNE+/TUNE- Auto Select M6/+10 Store Channel/Last Channel 10 Songs Last/Next song, Time set.
  • Page 85 Operation specification Operation A. M1, M2, M3, M4, M5, M6 are used to memorize the date of M1, FM2, FM3, AM1, AM2, AM3 respectively. Push the button for shorter than 2s, you can pick up the corresponding pre-saved channels. Push the button until more than 2s, you can store the cur- rent channel in corresponding internal storage.
  • Page 86 Operation for USB/SD/MMC A. M1/ II : Pause MP3 B. M2/STP : Stop playing Push M1/ II to play from the beginning. C. M3/RPT Repeat play the current songs. D. M4/RDM Play the current songs randomly. E. E. M5/-10 Move 10 songs down F.
  • Page 87 Wiper and scrubber This machine is equipped with wiper for front window. The con- trol switch is located handle-type combo-switch below the steer- ing wheel. Front wiper switch Front window wiper switch has three positions: STOP, LOW SPEED and HIGH SPEED. The wiper can automati- cally reset when the wiper in STOP state.
  • Page 88 Reversing auto alarm system Reversing alarm device is located by side of the lift cylinder of the engine cover (Fig.55). When you operate the gearshift han- dle to back the vehicle, the reversing alarm device will automati- cally hoot. Lifting device for engine hood The rising and dropping of the integrated engine hood of this machine is controlled by hand-operated cylinder and cylinder mechanism which is installed in the right battery box of the ma-...
  • Page 89 ADJUSTMENT OF DRIVER SEAT The driver seat equipped for this machine can be adjusted in aspects of soft and hard extent (i.e., height, front and rear direc- tion, backrest angle and headrest height) to adapt requirements from different drivers and different work situations. Adjustment of front and rear positions There is a handle in front sections of low left side of the driver seat.

  • Page 90: Seat Belt

    SEAT BELT The driver seat of this machine is equipped with seat belt. The driver shall tie the seat belt when operating the machine. Check the wear and security of the seat belt before using it. Replace it if necessary. Adjust the length of the seat belt before using to ensure the seat belt can play the role of safety guarantee and have certain flexibility.
  • Page 91 ADJUSTMENT OF REAR-VIEW MIRROR There is one rear-view mirror each above, on the left and right side of the cab of this machine. Before operating this machine, you must adjust the field of view to ensure the driver has a good field of rear view.

  • Page 92: Operation

    Operation ADVICE FOR OPERATION OF NEW LOADER All loaders were checked and adjusted before delivery from the factory. However, during the initial running-in process, you should still obey the following procedures, otherwise the equipment could be damaged or its performance degraded. If perform the operation with full load before running-in period, it will produce adverse effect on the operation life and safety running, and cause accidents finally.
  • Page 93 Lubrication oil and filter element Change oil and renew filter element after working for first 50 hours. Change transmission oil after working for first 100 hours. Change the filter element in hydraulic oil line and renew filter element after working for first 250 hours. Change axle gear oil after working for first 100 hours.
  • Page 94 Perform the following operations after 8 hours of running-in period: Completely check bolt and nut of each component for the tightening. Especially you should check the following components one time: diesel engine cylinder head bolt, exhaust pipe bolt, and front/rear axle fixing bolts, rim nuts, propeller shaft connecting bolt, diesel engine fixing bolt, gearbox fixing bolt, front/rear frame hinged-type bolt.
  • Page 95 Adjustment of bucket limiting device This machine is equipped with bucket positioning system, and it has auto leveling and lifting limit function at any position. You can effectively improve the working efficiency by rationally using these functions. Adjustment of bucket auto leveling device Place the machine on a flat ground and the shifting ma- nipulating handle at the Neutral position.
  • Page 96 Adjust the lifting limit device for the arm WARNING Be careful for the personal safety when performing the adjustment of arm lifting height limit. Non-working persons shall not approach the machine, and nobody shall stand in the area near arm. Place the machine on a flat ground and the shifting ma- nipulating handle at the Neutral position.

  • Page 97: Operationg Manchine

    OPERATING MACHINE Before starting engine, check follows: 1. Check the engine coolant level. 2. Check the engine oil level. 3. Check hydraulic oil level. 4. Check the leakage tightness for each oil pipe, water pipe and each component. 5. Check battery connecting wires. If the connecting wires be- tween battery and cables are found loosened, tighten them timely.
  • Page 98 12. Slightly depress the throttle pedal, and rotate clockwise for another one increment to switch on diesel engine starter motor. The engine will be started to work within 10s. Now it is necessary to immediately release your hand to let the starting electric lock reset.
  • Page 99 Operation of driving loader Operate the manipulating handle and transfer the bucket backwards to the limit position; then raise the arm to the transportation position, i.e., the distance from the hinged point below the arm to the ground is about 500mm. Depress service brake pedal and meanwhile pull down the parking brake handle to release the parking braking.
  • Page 100 Check service braking performance of the vehicle. Drive the machine at gear Forward I or II on the flat ground. First release the throttle pedal and smoothly depress the service brake pedal, then the machine can obviously slow down and stop. Note : If you depress the service brake pedal, but feel that the machine cannot obviously slow down, please...
  • Page 101 The steering wheel cannot restore to original position after rotation, and the machine rotation angle is kept un- changed. Therefore, after the machine finishes the steer- ing, you should reversely rotate the steering wheel to eliminate the relative angle between front and rear frames of the machine and make the machine drive along the straight direction.
  • Page 102 Parking of machine Drive the machine to a flat field. Confirm that there is no risk of falling stones, landslip or flood. Apply service braking to stop the machine. Toggle the shifting manipulating handle to Neutral position. Push parking brake button to apply parking braking. Operate the manipulating handle of working device to low- er down the arm, and lay down bucket on the ground, then slightly press down the bucket.
  • Page 103 If the machine needs to be stored for a long time, operate according to the following requirements: Before storage Wash each part of the vehicle, dry and store in a dry ● warehouse. If the machine is only allowed to be stored in the open, it is necessary to park the machine on the con- crete road surface where the drain is easy, and use the canvas to cover.
  • Page 104 In the process of storage Start the vehicle once a month to operation each system, ● and fill lubrication grease to each movable axis pin, pro- peller shaft, thus lubricating each movable part. Mean- while, charge the battery also. Wipe off the grease on the piston rod of hydraulic cylin- ●...

  • Page 105: Operation Of Loader

    OPERATION OF LOADER 1. Preparation before operation Before operation, first use this machine to level the working site, remove the protrusions, fill and level up the pits, shov- el the surface of wet ground, clear large and sharp stones on the site to prevent from scratching Tires. If you want to use this machine to load the materials onto or unload them from the truck or hopper, you should adjust the limit height of the arm limiting device to make the buck-...
  • Page 106 Depress the throttle pedal to make the bucket fully insert into the stock pile. When the machine could not advance further, the driver toggle backwards the bucket manipulating handle to move the bucket backwards and then push the bucket manipulating handle back to the middle position. At this time, the machine will continuously insert into the stock pile and repeat such insertion and retraction of the bucket until the bucket is full with materials.
  • Page 107 Exit from stock pile ● After the bucket is full with materials, the driver should operate the bucket manipulating handle to rotate the bucket backwards until the bucket’s stop dog touches backing plate, and then toggle the manipulating handle back to the middle position.
  • Page 108 WARNING Prohibit lifting the bucket to a higher position to conduct the transportation operation; otherwise it will cause the tip-over of the machine. Dumping ● ① Dumping the materials to truck or hopper When the loader with full materials is 15m away from the truck or hopper, you should release throttle pedal.
  • Page 109 During dumping, the impacting force of bucket limit stop and the arm shall not be too large, and the impacting times shall not be too many to avoid the damage to the machine. After completion of unloading, the driver shall toggle the bucket manipulating handle backwards to the limit rear position.
  • Page 110 Handling by pushing ● With bucket flatly close to the ground, put the shifting manipulating handle at Gear Forward I and depress the throttle pedal to push forward. During the pushing process, if some obstacles are found to hinder the advance of the vehicle, it is possible to slightly lift the arm to advance continuously.
  • Page 111 3. Operation method V-type operation method ● Loader is dead against stock pile, and the included angle between truck and loader driving direction is 60 º, and it stops at a place 12-15m away from the stock pile. When the loader is fully loaded, it will retreat directly back to the place 12-15m away from the stock pile.
  • Page 112 Operation in cold weather Matters needing attention in cold weather: If the ambient temperature is too low, the engine will be started difficultly and the radiator may be frozen. Therefore, you should obey the following instructions: When the environmental temperature is below 6 ℃, you should wait for about 8 or 10 minutes after you turn on the starting switch, and then start the engine.
  • Page 113 Matters needing attention for battery: When the ambient temperature is decreased, the ● battery capacity will also decrease. If the charge rate of the battery is low, the electrolytes may be frozen. Therefore, it is necessary to keep the rate as close to 100% as possible and perform the heat preservation as possible so that the engine can easily be started up the next day.
  • Page 114 OPERATION UNDER SPECIAL CONDITIONS Operation under extreme cold conditions If the machine is working in extremely cold weather, it is nec- essary to adopt protective measures to guarantee the normal operation. The following detailed inspection can ensure the ma- chine to work normally in cold temperature. Check whether the cooling system has used proper an- ti-freeze fluid under extreme low temperature.
  • Page 115 O p e r a t i o n u n d e r h i g h t e m p e r a t u r e conditions Operating the machine continuously under high temperature may cause overheat of the machine. Monitor the engine and gearbox temperature if necessary, and stop the machine to cool it down.
  • Page 116 B. Under the high temperature and wet weather, all parts of the machine will be corroded, and they will be more easily corroded in rainy season. The metal surface will be rusted and paint blistered, and other surfaces will have speckles. C.
  • Page 117 Operation under rainy weather Advice for operation under rainy weather is the similar to the un- der high temperature conditions. Coat lubrication oil onto all naked surfaces. Be especially careful, as early as possible, for the damaged or unpainted surfaces. Coat lubrication oil on the damaged paint surfac- es to prevent from being corroded.
  • Page 118 ON THE LAST PAGE OF OPER- ATION UNDER SPECIAL CONDI- TIONS,INSERT Working in Water After working in water,lubricate all lubrication points on front and rear frames which have been under water so water is removed. The water depth is an important factor to take into consiertation when the machine is working in swampy areas.Do not enter water whose depth exceeds the machine’s minimum ground clearance height or is high enough to wet the bottom of the axle...

  • Page 120: Inspection,Maintenance And Adjustment

    Inspection, Maintenance and Adjustment The maintenance and inspection of the equipment are necessary in order to keep the equipment working in normal conditions. The time interval, each system and components position and inspection method are listed as follows: The following items list the content and time interval Note: for the maintenance and inspection.
  • Page 121 Safety instructions In order to prevent some accidental operation during main- tenance, you must first identify the hydraulic system con- trol level be positioned in the middle and hang the Warning mark (warning sign). Confirm that the overflowed liquids are thoroughly cleared, especially those liquids around the engine.

  • Page 122: Preparation And Setting Of The Equipment Before Maintenance

    PREPARATION AND SETTING OF THE EQUIPMENT BEFORE MAINTENANCE Park the vehicle as the following requirements before perfor- mance of maintenance according to the regulations in this man- ual. Note: Some special maintenance requires the machinery has different parking mode. However, after completion of maintenance, the machine must be reset to the following positions.

  • Page 123: Recommended Lubricants Table

    RECOMMENDED LUBRICANTS TABLE Do not use un-recommended lubrication oil. Do not use unapproved products. Note: Refer to maintenance time interval table to make lubrication for the specified positions. Matters needing attention on lubrication • The oil must be cleaned and the diesel oil must be sed- imented for 72 hours;...
  • Page 124 See following table for oil varieties and brands Classification Name Application location Various rolling bearing, working device #3 molybdenum disulfide Lithium-based axis pin for rolling bearing, frame pin for Lubrication grease grease steering cylinder axis pin, propeller shaft spline of sub-frame pin, and water pump API :CD/CE/CF/SF/SG SAE15W40 Transmission oil...

  • Page 125: Fluid Capacity

    FLUID CAPACITY Component Capacity Oil pan ( incl. filter) Engine. Cooling system Fuel Tank 150L Hydraulic oil Tank Capacity 127L Gear Box Front Axle Driving Axle Rear Axle 4-6 Inspection, Maintenance and Adjustment...
  • Page 126 LUBRICATION OIL AND MAINTENANCE CHART Figure 4 Inspection, Maintenance and Adjustment 4-7...
  • Page 127 Maintenance period Service Interval（h） Items To Check Service 1000 2000 Front Joint Pin Grease Articulation Pin Grease Stabilizer pin Grease Steer Cylinder Grease Shaft Bearing Grease Engine Oil Engine Oil ● Engine Oil Filter Cartridge ● Fuel Pre-Filter Cartridge ● Fuel Filter Cartridge ●...

  • Page 128: Maintenance Interval

    MAINTENANCE INTERVALS 10 hours/routine maintenance 250 hours/monthly maintenance • V i s u a l l y c h e c k a r o u n d t h e m a c h i n e f o r •...
  • Page 129 1000hours/half-yearly maintenance • Replace Transmission oil and filter • Replace enging diesel oil filter • Inspect various temperature gauges and pressure gauges. • Check the tightening of engine exhaust pipe. • Check engine operation • Replace the oil return filter element, breather and pilot filter element of the hydraulic oil tank.

  • Page 130: Electrical System

    ELECTICAL SYSTEM Note: Strictly prohibit disassemble electric circuit and compo- nents. You should consult the agent to solve such prob- lems. Battery WARNING The electrolyte is the diluted Sulfuric acid which can quickly burn the skin and pierce in the clothes. Rinse immediately with water if the battery electrolyte spills over your body on your clothes for your careless operation.
  • Page 131 Check fluid level of battery The battery installed in this machined is the one without need- ing maintenance, and you need not add electrolyte into the battery. When the charge indicator is transparent, it indicates that the electrolyte is less, and the possible reason is leakage or the faults in charging system.

  • Page 132: Bucket

    BUCKET Replace O-ring seal for the bucket WARNING Wear safety helmet, gloves and goggles when you replace pins because metal objects may fly off. Check the O-ring seal for the bucket, and replace it if it is worn or damaged Fig 7 Move O-ring seal (1, Fig.8) onto bushing ( 2) , then ,re- move the bucket pin ( 3) and extract the bucket connecting...
  • Page 133 Remove old O-ring seal and install new O-ring seal (1, Fig. 10) onto bushing (2). Confirm that the O-ring seal on con- necting rod cover (4) and bucket bushing has been thor- oughly cleared. Align the bucket connecting rod cover and the bucket link pin hole, and install bucket pin (3, Fig.

  • Page 134: Add Shim To Bucket

    ADD SHIM TO BUCKET Install a new bucket If you want to install new bucket, you should measure the dimension of between internal lugs of the bucket and the dimension of bucket link width. Subtract one dimension from the other, and you will get the dimension of the shim you want to add on both sides.

  • Page 135: Tires

    TIRES The proper charging of the tire (2. Fig 12) is the important fac- tor to determine tire life and performance. If tire is inadequately charged (1. Fig 12), it will not support the equipment, and will be worn quickly; if tire is excessively charged (3. Fig 12), the fric- tion is less and it is easily to be pierced.
  • Page 136 Check Tires for damage WARNING Improper maintenance or replacement of Tires may cause explosion to cause serious injury or death. The maintenance and replacement of Tires may only be carried out by trained person who is properly equipped. For maintenance of Tires, please contact with the nearest Tires agent or Tires manufacturer.
  • Page 137 Replacement of tire WARNING If a wheel and tire must be removed from machine and replaced, or if a tire must be replaced on wheel, use only experienced and trained service personnel. A tire rim could be propelled off wheel and cause death or serious injury. See Figure 13.
  • Page 138 Remove the wheel nuts and tire assy from the hub (refer to Fig 17). Check the wearness of nut and replace the nut if necessary. Check all components for excessive wear, and replace them if necessary. Fig 17 When you tighten the wheel nuts, refer to the pattern shown in Fig.18.

  • Page 139: Inspection Of Bolt And Nut

    INSPECTION OF BOLT AND NUT Check all fasteners after working for 50 hours for the first time and every 250 hours from then on. If loose or loss is found, it is necessary to re-tighten or add new products. You must use torque wrench.

  • Page 140: Maintenance Under Special Conditions

    MAINTENANCE UNDER SPECIAL CONDITIONS Conditions Maintenance requirements Working in mud, water or rain 1. Walk around and check for the loose connector, obvious damage or leakage. 2. After working, clear the mud, rocks and sand on the machine. Check the welded parts for the cracks and components for the loose.

  • Page 141: Storage For A Long Term

    STORAGE FOR A LONG TIME Store the machine as shown in the following table if it will stop for more than one month Conditions Maintenance requirements 1. Flush the chassis and wheel drive assy using HP water gun. Check for the 1.

  • Page 142: Transportation

    Transportation Check federal, state and local laws and regulations regarding weight, width, and length of machine and load before making preparations for transporting on public roads or highways. The hauling vehicle, trailer, and load must comply with all applicable laws and regulations. Check the intended route for road width, overhead clearances, weight restrictions, and traffic control regulations.
  • Page 143 WARNING 1. Loading and unloading machine is dangerous. Be especially careful for running engine at low speed and driving at low speed. 2. The inclined plate must withstand the weight of the machine. If necessary, you can add the cushion block to increase the support force.
  • Page 144 LIFTING MANCHINE It is necessary to let the professionals with lifting knowl- edge be responsible for the command and operation. You should calculate the crane’s maximum lifting weight and the sling’s bearing capacity to ensure the lifting safety. Meanwhile, the 4 hooks on the sling shall bear load evenly. Accomplish the following preparation before lifting: •...
  • Page 145 TOWING FAULT MANCHINE This machine cannot be towed unless in the emergency. Tow- ing is only used for towing this machine to a place where the overhaul can be performed, instead of transporting over a long distance. The towing distance for this machine should not ex- ceed 10km, and the towing speed should not exceed 10km/h, otherwise the gearbox will be damaged for short supply of oil.
  • Page 146 Under normal conditions, the trailer shall be of a size as the machine. It is necessary to ensure the trailer shall have adequate braking capacity, weight and power to control the slope ascending of two machines and the travel distance etc..

  • Page 147: Transportation Dimension

    TRANSPORTATION DIMENSION Fig 5 Basic dimension Sign Description Dimensions Transportation length 6,900mm Transportation width 2,830mm Cab height 3,280mm Ground clearance 340mm Space between front and rear Tires 2,506mm 5-6 Transportation...
  • Page 148 Troubles Shooting TRANSMISSION Characteristics of faults Cause Remedy Shifting pressure low for each Oil level too low in gearbox oil pool Add oil to the specified oil level position Leakage in main oil way Check main oil way Gearbox oil filter blocked Clean or replace variant pump Variant pump ineffective Replace working pump...
  • Page 149 BRAKING SYSTEM Characteristics of faults Cause Remedy F o o t b r a k i n g f o r c e n o t Air in braking hydraulic pipeline Exhaust air from the pipeline adequate Oil leakage in clamp Replace seals on the clamp Check tightness of air compressor, Brake air pressure low...

  • Page 150: Hydraulic System For Working Device

    HYDRAULIC SYSTEM FOR WORKING DEVICE Characteristics of faults Cause Remedy Arm lifting force or bucket Wear or damage of cylinder oil seal Replace oil seal digging up force inadequate Distribution valve excessively worn. Disassemble, check and repair Fit clearance between valve stem to make the clearance meet and valve body exceeds the specified requirements on specified value , or...

  • Page 151: Steering Hydraulic System

    STEERING HYDRAULIC SYSTEM Characteristics of faults Cause Remedy Hard to make steering Increase the oil temperature , then Oil temperature too low start working Load sensing oil way blocked Clean it Adjust overflow valve block pressure Pressure of steering pump low according to the regulations Partial bolts for metering motor of full hydraulic steering gear tightened too...

  • Page 152: Electrical System

    ELECTICAL SYSTEM Characteristics of faults Cause Remedy Generator not working, or Wipe using clean cloth dipping with output low voltage Commutator oil stained or worn gasoline, or grind using #00 emery cloth Check external magnetic field , and Remanence coil open circuit check exciting circuit using light bulb Perform magnetizing or replace with Remanence disappeared...
  • Page 153 Characteristics of faults Cause Remedy Engine could not start or start Battery damaged or its capacity Replace with new battery or charge difficultly inadequate the old battery Electric lock damaged Replace electric lock Electric circuit contact badly or short- Check and repair circuited Check the coil for perfection , the Starter motor electromagnetic switch...

  • Page 154: Specification

    Specification SPECIFICATION Item Size Bucket capacity 1.7m Rated load 3000kg Lifting time(full load) ≤5.3s Cycle time ≤9.9s Forward IV 36km/h Forward III 25km/h Forward II 14km/h Highest speed at each gear Forward II 8km/h Reverse I 9km/h Reverse II 27km/h Maximum traction force 97.5±5kN Maximum digging up force...
  • Page 155 Item Specification Type WP06 Diesel engine Rated power 92kW Rated rotation speed 2200r/min Maximum torque 500N.m/1300-1500r/min Engine Fuel consumption at rated working conditions(rig-test) ≤215g/kw.h Fuel oil #40 light diesel oil Fan diameter (exhaust) 600mm Type Dual turbine H y d r a u l i c t o r q u e Torque ratio 3.25 converter...
  • Page 156 Item Specification Type Articulation frame, full hydraulic system Steering cylinders — I.D. × stroke 2-φ80×376mm Steering pump CBGJ3100(shared with working system) Steering system System pressure 14MPa Discharge 100ml/r Steering angle 40º each on left and right Boom cylinders -I.D. 2-φ125×710mm Bucket cylinders -I.D.

  • Page 157: Working Range And Dimensions

    WORKING RANGE AND DIMENSIONS Fig 1 Intergral dimension Sign Description Dimensions Transportation length 6,900mm Transportation width 2,506mm Cab height 3,280mm Ground clearance 340mm Space between Front and RearTires 2,830mm 7-4 Specification...

  • Page 158: Approximate Weight Of Workload Materials

    APPROXIMATE WEIGHT OF WORKLOAD MATERIALS The data below describes weight of a cubic meter (cubic yard) of many types of workload materials. MEDIUM WEIGHT OR HIGH WEIGHT OR LOW WEIGHT OR DENSITY DENSITY DENSITY Material 1,600 kg/m 2,000 kg/m 1,100 kg/m (2,700 lb/yd ), OR LESS (3,370 lb/yd...
  • Page 159 MEDIUM WEIGHT OR HIGH WEIGHT OR LOW WEIGHT OR DENSITY DENSITY DENSITY Material 1,600 kg/m 2,000 kg/m 1,100 kg/m (2,700 lb/yd ), OR LESS (3,370 lb/yd ), OR LESS (1,850 lb/yd ), OR LESS 1,762kg/m Earth, WET, muddy ------- ------- (2,970 lb/yd Gypsum, calcined, (heated, 961kg/m...

  • Page 160: Environment Protection

    Environment protection When you perform the maintenance of the equipment and the disassembling of any pipeline, connector or other associated parts, you should use the special containers to collect coolants, oil liquids, fuel, electrolytes or other materials which may cause environment pollution.

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