SEM 636D Wheel Loader Instruction Manual

636D Wheel Loader

Operation and Maintenance Manual SEM636D Wheel Loader
Caterpillar: Non-Confidential

Table of Contents
TABLE OF CONTENTS…………………………………………………………………………………………………. 2
SAFETY INFORMATION ……………………………………………………………………………………………. 6
SAFETY MESSAGES AND ATTACHED LOCATIONS ……………………………………………………………… 7 GENERAL PRECAUTIONS…………………………………………………………………………………………….. 7 OPERATING PRECAUTIONS ……………………………………………………………………………………….. 11 MAINTENANCE PRECAUTIONS ……………………………………………………………………………………. 18
TECHNICAL SPECIFICATIONS………………………………………………………………………………… 25
KEY TECHNICAL SPECIFICATIONS ……………………………………………………………………………….. 27 636D ARRANGEMENT DRAWING ………………………………………………………………………………… 29
OPERATION …………………………………………………………………………………………………………… 30
SWITCHES AND GAUGES ……………………………………………………………………………………. 31 ADDITIONAL ACCESSORIES ……………………………………………………………………………………….. 36 BREAKING-IN A NEW WHEEL LOADER ………………………………………………………………………….. 37 MACHINE OPERATION ………………………………………………………………………………………………. 38 PARKING AND STORAGE …………………………………………………………………………………………… 40 SPECIFIC OPERATIONS …………………………………………………………………………………………….. 41 TRANSPORTING………………………………………………………………………………………………………. 45
MAINTENANCE ………………………………………………………………………………………………………. 47
PERIODIC MAINTENANCE ………………………………………………………………………………………….. 48 MAINTENANCE SCHEDULE…………………………………………………………………………………………. 49 ENGINE…………………………………………………………………………………………………………………. 52 TRANSMISSION……………………………………………………………………………………………………….. 57 AXLE ……………………………………………………………………………………………………………………. 58 HYDRAULIC SYSTEM………………………………………………………………………………………………… 59 TIRES …………………………………………………………………………………………………………………… 61 BUCKET LIMITATION DEVICE ……………………………………………………………………………………… 61 PARKING BRAKE……………………………………………………………………………………………………… 61 PIN AND DRIVESHAFT ………………………………………………………………………………………………. 63 WELDING OPERATION………………………………………………………………………………………………. 66 BATTERY ………………………………………………………………………………………………………………. 66 FLUID SPECIFICATION ………………………………………………………………………………………………. 68
FAILURE CAUSES AND REPAIR……………………………………………………………………………… 70
ENGINE SYSTEM ……………………………………………………………………………………………………… 71 TRANSMISSION……………………………………………………………………………………………………….. 71 BRAKE SYSTEM………………………………………………………………………………………………………. 72 WORK TOOL AND HYDRAULIC SYSTEM ………………………………………………………………………… 73 STEERING SYSTEM………………………………………………………………………………………………….. 74 ELECTRIC SYSTEM ………………………………………………………………………………………………….. 76 AIR CONDITIONING SYSTEM ………………………………………………………………………………………. 76
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Foreword
This manual includes guidelines on how to use this Wheel Loader safely and effectively. This manual should be kept at hand and read periodically. If this manual is lost or becomes too dirty to be legible, you should buy a new one from your dealer. If you sell the machine, make sure this manual will be handed over to the new user.
This manual contains safety information, operation instructions, and lubrication and maintenance precautions. The information, specifications, and illustrations in this manual are based on information that was available at the time of publication. The specifications, torques, pressures, measurements & adjustments, illustrations, and other items may change at any time. These changes may affect the service that is given to the machine. Whenever a problem arises regarding the machine or the contents of this manual, please consult the manufacturer or dealers for the latest available information.
The safety section describes safety concerns that require your attention during operation, maintenance or repair. Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or protection measures. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. All related personnel must be acquainted with potential risks of accidents. Those persons should also have the necessary training, skills and tools to perform repair the failures. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this machine, until you have read and understood the operation, lubrication, and maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are neglected, injury or death may occur.
The operation section describes basic operation technique, and guides the operator through correct procedures of checking, starting, operating and stopping the machine. Therefore the operator should keep this manual at hand for continuous reading and studying.
The maintenance section is a guide to machine daily maintenance, and classified on the basis of maintenance intervals. This manual lists the maintenance interval on the basis of service hour meter reading. Calendar intervals (days, weeks, months) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Caterpillar (Qingzhou) Ltd. recommends that service should always be performed at the interval that occurs first. Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals schedule might be necessary. Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service or monthly, 50 service hours, or weekly, and every 10 service hours or daily. Caterpillar (Qingzhou) Ltd. cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by Caterpillar (Qingzhou) Ltd. is used; you should ensure that it is safe for yourself and others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.
Each wheel loader has its own design operating capacity. Additional attachments or modifications exceeding machine design capacity may adversely affect operation performance of the loader, which include the operation stability as well as brakes and steering units. Please contact your dealer for the latest information.
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Components
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Safety Information
Please read and become familiar with all of the safety information. Failure to do so may result in serious injury or death.
This “Safety Information” section also contains precautions regarding options and attachments.
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Safety Messages and Attached Locations
There are several specific safety messages on this machine. This section introduces the exact locations of those safety messages and description of related potential risks. Please become familiar with all safety messages. Make sure that all of the safety messages are legible, clean the safety messages or replace the safety messages if you cannot read the words or illustrations. When cleaning the safety messages, use a cloth and soapy water. Do not use solvent, gasoline to clean the safety messages. Replace any safety message that is damaged, missing or illegible after cleaning. If a safety message is attached to a part that has been replaced, install a new safety message on the replacement part.
No Entry
( No 1: located in the articulation area of frame)
Do not Walking Beneath Work Tools
(No 2: located on both sides of lift arms)
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Never Put Hands Close to Rotary Fan and Do not Get Too Close to the Machine
(No. 3 and 4: located at the rear end of engine hood)
General Precautions
Safety Rules
Only a trained and qualified person is authorized to operate and maintain the machine. Follow all safety rules, precautions and instructions while operating or performing maintenance on the machine. Do not operate the machine if you are sick, sleepy, after taking medicine, or after drinking alcohol. Operating in such cases will adversely affect your judgment and may lead to an accident. When working with another operator or a flag person on the job site, ensure that all persons understand all hand signals that are to be used. Follow all rules and regulations concerning safety.
Safety Devices
Make sure that all protective guards and all covers are secured in place on the machine. Repair immediately if damaged. Use safety devices properly, such as control levers lockout device and seat belt. Never remove any safety devices. Always keep them in good operating condition. Improper use of safety devices could result in serious injury or death.

Always Lock the Lockout Device When Leaving Operator’s Seat
Engage the parking brake by using the lever before leaving seat, otherwise the work tools may suddenly move by bumping control levers resulting in serious injury or damage. When leaving the loader, lower the work tools completely onto the ground, engage the parking brake lever into on position, stop the engine and use key to lock all devices, then carry the key with you. If the left window is closed, insure that it is rolled up tightly; if it is loose it could open. When locking up be sure that the seat is locked in place to prevent the glass from locking and the seat from moving when the operator enters the cab.
Clothing and Personal Protective Items
Do not wear loose clothing or jewelry and maintain short hair. These things can snag on controls or other parts of the equipment and cause serious injury or death. Do not wear oily clothing in order to avoid ignition. Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine. Always wear safety goggles, a hard hat and heavy gloves particularly if your job involves scattering metal chips or minute materials. Also, when driving pins with a hammer and when cleaning the air cleaner element with compressed air make sure that no one is around the machine. Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear face shield, protective clothing, and protective shoes. The maximum air pressure for cleaning purposes must be lower than 0.3Mpa. Check before using that all protective items will function properly.

Unauthorized Modification
Any modification made without authorization from Caterpillar (Qingzhou) Ltd. may result in hazards. Consult authorized distributor appointed by Caterpillar (Qingzhou) Ltd.before making any modification. Caterpillar (Qingzhou) Ltd.is not responsible for any injury or damage caused by any unauthorized modification.
Mounting and Dismounting
Before getting on or off the machine, check the handles and steps. If there is any oil, lubricants, or mud on them, wipe it off immediately. In addition, repair any damaged parts and tighten any loose bolts. Never jump on or off the machine. Never get on or off a moving machine. When getting on or off the machine, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handholds and steps to ensure that you support yourself. Never hold any control levers when getting on or off the machine. Do not get on the machine from the step at the rear of machine and never get off the machine from the tire beside cab. Do not get on or off the machine while carrying tools or other items. Use ropes to lift the required tools up to the operator station.
Fire Prevention
Fuels, lubricants in the engine, hydraulic oil in the hydraulic system, converter oil and gear oil in the transmission, brake oil in the braking system, and antifreeze in radiator system are all flammable by direct flame. Fuel is particularly flammable and hazardous. Therefore, be sure to pay attention to the following precautions: Keep the above-mentioned flammable fluids away from direct flame.

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When refilling, park machine in a ventilated area, and stop the engine. Do not smoke when refilling. Tighten caps of storage containers for all the above flammable fluids. Store flammable fluids in properly marked containers, and in a specified place as per categories. Do not allow unauthorized person to use. Store oily rags and any flammable materials in protective containers, and in a secured place. Do not weld on or flame cut lines that contain flammable fluids. Clean any such lines thoroughly with a nonflammable solvent prior to welding or flame cutting. Remove all flammable materials such as fuel, oil, and debris from the machine. Do not operate the machine near any flame or burning brush. This wheel loader is of general construction equipments. Therefore, do not operate under any flammable and explosive environment.

Asbestos Dust Hazard Prevention
Asbestos dust can be hazardous to your health if it is inhaled. Use the following guidelines when you handle any materials that contain asbestos: Never use compressed air for cleaning. Use water for cleaning so that the dust will be dissolved in the water. Areas that may have asbestos particles in the air are hazardous. Operate the machine in the same direction as the wind, whenever possible. Use an approved respirator if necessary.

Fire Extinguisher and First Aid Kit
Follow the precautions below in case of sinjuries or fire. Make sure that a fire extinguisher is available. Read the usage guide carefully and be familiar with the operation of the fire extinguisher. Make sure that a first aid kit is available at the job site. Check it regularly and add medical contents if necessary. Know what to do in the event of a fire or personal injury. Be sure you know the phone numbers of the people who should be contacted in case of an emergency, such as, doctors, first-aid centers, firehouses. Put up those numbers in a specified place, and make sure that all personnel know the numbers, location and the correct contact method.

Precautions When Operating Under High Temperature
Immediately after operations hydraulic oil, oil and water in the engine and radiator will be at high temperatures and under pressure. Attempting to remove the filler cap and radiator, to drain oil or water, or to replace the filters may lead to serious burns. Allow components to cool and follow the specified procedures. To prevent hot oil from spurting out, stop the engine first, and wait to allow oil to cool. Remove the filler cap slowly in order to relieve pressure. (When checking if the oil is cool enough, put your hand near the front face of the radiator of hydraulic oil and converter oil, and check the air temperature. Be careful not to touch the radiator.) When engine is hot, do not touch the relay

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with your hand to avoid being burned. Do not remove the engine oil temperature sensor, water temperature sensor, converter oil sensor and air conditioner water tube when the machine is hot, to avoid being burned.
Crushing Prevention and Cutting Prevention
Keep your hands, arms and all body parts clear of all moving parts such as, the area between the work tools and cylinders or the area between the machine and work tools. The clearance in the linkage area will change with the movement of the work tools. This may lead to serious accident or personal injury. If entrance between the machine and moving parts is necessary, always stop the engine, and then lock the work tools. Support the machine properly before you perform any work beneath the machine. Do not depend on the hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks. Unless otherwise stated, never make any adjustment when the machine is operating or the engine is running. Stay clear of all rotating and moving parts. Keep objects away from moving fan blades. The fan blade will throw or cut the tools or objects in between.
Precautions When Using ROPS (Rollover Protective Structure)
If ROPS is installed, do not operate the machine with the ROPS removed. The ROPS is installed to protect the operator if the loader should roll over. It is designed not only to support the tipping load, but also to dampen the impact. The ROPS meets international specifications and standards. Its strength may be reduced after rolling over or being damaged

by falling objects, and its protection function may be weakened. In such a case, contact your dealer for repair. Even if ROPS is installed, when operating the machine, the operator should wear the seat belt, and use other the safety devices to provide proper protection.
Precautions for Attachments
When installing and using an optional attachment, read the instruction manual for the attachment and the information related to attachments in this manual. Do not use attachments that are not authorized by Caterpillar (Qingzhou) Ltd. or your Caterpillar (Qingzhou) Ltd. distributor. Use of unauthorized attachments could create a safety concern and adversely affect the proper operation and service life of the machine. Caterpillar (Qingzhou) Ltd. is not responsible for any injuries, accidents, machine damages resulting from the use of unauthorized attachments.
Ventilation for Enclosed Areas
In an enclosed or poorly ventilated area, if it is necessary to start the engine, handle fuel, flush parts, or paint, immediately open the doors and windows to ensure that adequate ventilation is provided to prevent gas poisoning. If opening the doors and windows does not provide adequate ventilation, fans should be installed.
Lines, Tubes and Hoses
Do not bend high-pressure lines or strike high-pressure lines. Do not install any tubes or hoses that are bent or damaged. Always repair any loose or damaged tubes and hoses in fuel or oil circuits and hydraulic system because any leaks can cause fire. Consult your Caterpillar (Qingzhou) Ltd. distributor immediately for repair or replacement parts. Carefully check lines, tubes and hoses. Tighten all connections to the recommended torque. Always wear safety glasses and thick

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gloves, and use a piece of cardboard or a sheet of wood to check for oil leakage. Even a pinhole leak can penetrate your skin causing severe injury or death. If fluid is injected into your skin, you must immediately seek treatment from a doctor that is familiar with this type of injury.
Replace the parts if any of the following conditions are present:
1. Fittings are damaged or leaking. 2. Outer coverings are chafed or cut so that the steel wires are exposed. 3. Part of the hose is ballooning. 4. Hoses are obviously kinked or pressed. 5. Outer covers have embedded armoring. 6. End fittings are displaced. Make sure that all clamps, guards, and heat shields are installed correctly, to prevent vibration, rubbing against other parts, and excessive heat. When the connecting pipe of the air conditioning compressor is removed, direct flame is strictly prohibited, because poisonous gas could be produced, resulting in poisoning.
Operating Precautions
Turning on the Machine
Plan Your Operation Procedure
Before starting operations, thoroughly check the area for unusual conditions that could be dangerous. Examine the shape of the ground, the quality of the soil, the jobsite, and determine the optimum method of operation. Make sure the ground is firm and level before starting engine. When working at dusty worksites, the ground should be watered.
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When working on public roads, position a flagman and warning signs, such as “NO ENTRY” to ensure the safety of passing traffic and pedestrians. In places where there are buried objects, such as water pipes, gas pipes, or pipes for high voltage cables, contact the company in charge to confirm the position of the buried object, and be careful not to damage the object during operations. When working in water or when crossing sand banks, first check the condition of ground, the water depth and flow speed. Be sure not to exceed the permitted water depth. When working in water or on swampy ground, do not let the water come above the bottom of the axle housing. After finishing the operation, wash and check all lubricating points.
Before Starting Engine Checklist
Carry out the following checks before starting the engine at the beginning of the day’s work. Failure to carry out these checks may lead to serious injury or damage. Completely remove all the flammable materials accumulated in the engine compartment and around the battery. Check fuel, lubrication, and hydraulic systems for leaks, and have any leaks repaired. Remove any dirt from the mirrors, handrails, and steps. Return all fuel containers to their proper place. Remove all parts and tools from the operator’s compartment. The oscillation of walking and operating may get the tools fall off, then destroy the joy stick and switch, or make the joy stick starting again, it may lead to serious injury or damage. Clean your shoes before you get on the machine, and if there is dirt, clear immediately

in order to prevent dirt from accumulating on the accelerator pedal and break pedal, and to prevent pedal replacement Check the coolant level, fuel level, and oil level in the engine oil pan, clogging of the air cleaner, and damage to the electric wiring. Adjust the operator’s seat to a position where it is easy to carry out operations, and check for wear or damage to the seat belt and mounting equipment. Change the seat belt after three years. Check that the gauges work properly, and check that the control levers are at the PARK position. Remove all dirt from the surface of the window glass and lights to ensure good visibility. Adjust the side mirror to a position, which gives the best view from the operator’s seat, and clean the surface of the mirror. And clean the surface of the mirror. If the mirror glass is damaged, replace with a new part. Check that the front lamps and working lamps light up properly. If the results of the inspection show any abnormality, carry out the necessary repairs. Be sure a fire extinguisher is present and check the method of using it. Do not operate the machine near any fire or flame.
When Starting Engine
Walk around your machine and check for people and objects that might be in the way just before getting on. If a warning label, such as “DO NOT OPERATE”, has been attached to control lever, DO NOT start the engine. When starting the engine, sound the horn as an alert. Start and operate the machine only while sitting in the operator seat. Only the operator is allowed in the cab. Do not allow anyone to ride on the machine body. Start the engine in the cab; never start the machine by creating a short circuit of the electromotor, this may damage the electro circuit, and it is very dangerous. If there is a backup alarm, please check that it works properly.

After Starting Engine Check-list
Failure to carry out the checks properly after starting the engine will lead to delays in discovery of abnormalities. And, this may lead to serious injury or damage to the machine. When checking the area one must ensure that there are no obstacles and do not allow people to come near the operation area. Check the functionality of the gauges, work tools, and hydraulic system, brake system, travel system and lubricating system. Check for any abnormalities in the sound of the machine, vibration, heat, or smell; also check that there is no leakage of air, oil or fuel. If any abnormalities are found, carry out repairs immediately. If the machine is used when it is not in proper condition, it may lead to serious injury or damage to the machine. Before traveling or starting operations, check that safety bar is securely placed in the “unlocked” position.
Operation
Precautions When Starting Off
Before starting off, check again that there is no one in the surrounding area and that there are no obstacles. When starting off, sound the horn as an alert. Operate the machine only when seated in the operator’s seat. Always fasten the seat belt. (If equipped) Only the operator is allowed in the cab. Do not allow anyone ride on the machine body. If there is a backup alarm, please check that it works properly.
Precautions When Traveling
When traveling, never turn the key/start switch to the off position. It is dangerous if the engine stops when the machine is traveling because the steering becomes heavy. If the engine stops, apply the brake immediately to stop the machine. It is dangerous to look around when operating. Always concentrate on the work. It is dangerous to drive too fast, to start/stop suddenly, turn sharply, or zigzag. If you find an abnormality in the machine

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during operation (noise, vibration, smell, incorrect gauges, air leakage, oil leakage, etc.), move the machine immediately to safe place and look for the cause. Set the work tools to travel position. (Lift 30-40cm from level ground)
When traveling, do not operate the work tool control levers. If the work tool control levers have to be operated, stop the machine first and then operate the levers. Do not operate the steering wheel suddenly. The work tools may hit the ground surface causing the machine to lose its balance, or may damage the machine or other structures in the area. When traveling on rough ground, travel at low speed and avoid sudden changes in direction. Avoid traveling over obstacles as often as possible. If the machine has to travel over an obstacle, keep the work tools as close to the ground as possible and travel at low speed. When traveling or carrying out operations, always keep your distance from other machines or structures to avoid coming into contact with them. Never drive in water that is in excess of the permissible water depth. Do not let the water come above the bottom of the axle housing. When passing over bridges or structures on private land, check first that the structure is strong enough to support the mass of the machine. When traveling on public roads, check first with the relevant authorities and follow their instructions. Always obey the traffic regulations when traveling on public roads. This machine travels at lower speed than normal automobiles, so keep to the side of the road and be careful to leave the center of the road free for other vehicles. If you drive the machine at high speed continuously for a long time, the tires will overheat and the internal pressure will become abnormally high. This may result in the tires bursting. If a tire bursts, it produces an extremely large destructive force, and this may cause a serious injury or accident.
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If you are going to travel continuously, please consult your Caterpillar (Qingzhou) Ltd. agent.
Check When Changing Direction
To prevent serious injury or death, even that machine is equipped with a back up alarm and mirrors always do the following before moving the machine or the work tools: Sound the horn to warn people in the area. Check that there is no one near the machine. Be particularly careful to check behind the machine. This area cannot be seen clearly from the operator’s seat.
When operating in the areas that may be hazardous or have poor visibility, designate a person to direct worksite traffic. Ensure that no person can come within the direction of turning or direction of travel. When traveling at a high speed, never change direction.
Restricted Operation
To prevent the machine from turning over or the work tools from being damaged due to overload, always keep within the maximum load specified for the machine. Caterpillar (Qingzhou) Ltd. is not responsible for of any injuries, accidents or machine damage resulting from overload.
Traveling On Slopes
Be careful traveling on slopes can result in the machine tipping over or slipping to the side. When traveling on slopes, keep the bucket approximately 20-30cm (8-12in) above the ground. In case of emergency, quickly lower the bucket to the ground to help the machine to stop.

Do not turn on slopes or travel across slopes; always go down to a flat place to perform these operations. When traveling downhill, never shift gears or shift to neutral. Always shift to a low gear before starting to travel downhill. When traveling downhill, use the engines braking force and travel slowly. If necessary, use the brake pedal to reduce the speed. At high speeds, do not travel on grass, fallen leaves, or wet steel plates. Even slight slopes may cause the machine to slip to the side, so travel at low speed and make sure that the machine is always traveling directly up or down the slope. If the engine shuts off when traveling downhill, using the brake pedal and fully the apply the brakes. Lower the bucket to the ground, and then apply the parking brake to hold the machine in position. When traveling up or down hills with a loaded bucket, always travel with the bucket facing uphill (travel forward when going uphill and in reverse when going downhill). When traveling on a slope with a loaded bucket, if the machine travels with the bucket facing downhill, there is danger that the machine may tip over.
High-Voltage Cables
Do not let the machine touch electric cables; even getting close to high- voltage cables can cause electric shock. Always maintain the safe distance given below

between the machine and the electric cable.

Voltage V Min. safety

distance

Lower 100-200 2m

7ft

voltage 6,600

2m

7ft

Higher 22,000

3m

voltage 66,000

4m

10ft 14ft

154,000 5m

17ft

187,000 6m

20ft

275,000 7m

23ft

500,000 11m

36ft

To prevent accidents, always do as

follows:

1. On the jobsite where there is danger

that the machine may touch the electric

cables, consult the electric company

before starting operations to confirm that

the appropriate precautions are taken and

that the work abides to regulations.

2. Wear rubber shoes and gloves. Lay a

rubber sheet on top of the operator’s seat,

and be careful not to touch the chassis

with any exposed part of your body.

3. Use a signalman to give warning if the

machine approaches the electric cables.

4. If the work tools should touch the

electric cable, the operator should not

leave the operator’s compartment.

5. When carrying out operations near

high voltage cable, do not let anyone come

close to the machine.

6. Check with the electricity company

about the voltage of the cables before

starting operations.

Driving Precaution

Be careful not to get too close to the edge of cliffs. When marking embankments, landfills, or when dropping soil over a cliff, dump one pile and then use the next pile of soil to push the first pile. The load suddenly becomes lighter when the soil is pushed over a cliff or when the machine reaches the top of a slope. When this happens, there is danger that the travel speed will suddenly increase, so be sure to reduce the speed. When the bucket is fully loaded, never start, turn, or stop the machine suddenly. When handling unstable loads, such as

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round or cylindrical objects or piled sheets, if the work tool is raised high, there is danger that the load may fall on top of the operator’s compartment and cause serious injury or damage. When handling unstable loads, be careful not to raise the work tools too high or tip the bucket back too much. If the work tools is suddenly lowered or suddenly stopped, the reaction may cause the machine to tip over. Particularly when carrying a load, be sure to operate the work tools carefully. Do not use the bucket or lift arm for crane work. Do the following to ensure good visibility:
1. When operating in dark places, turn on the working lamps and front lamps, and install lighting at the jobsite if necessary. 2. Do not carry out operations in fog, snow, or heavy rain, or other conditions where the visibility is poor. Wait for the weather to clear so that visibility is sufficient to carry out work. Always do the following to prevent the work tools from hitting other objects 1. When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, be extremely careful not to let the bucket hit anything. 2. When loading dump trucks, check that there is no one in the area around the machine and be careful not to let the bucket hit the operator’s compartment of the dump truck. 3. To prevent accidents caused by hitting other objects, always operate the machine at a speed, which is safe for operation, particularly in confined spaces, indoors, and in places where there are other
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machines.
Using Brakes
Do not put your foot on the brake pedal unless necessary. Do not depress the brake pedal repeatedly unless necessary. When traveling downhill, use the engine as a brake, and never shift gear or place the transmission in neutral.
Operating on Snow
When working on snow or icy roads, even a slight slope may cause the machine to slip to the side, so always travel at low speed and avoid sudden starting, stopping, or turning. There is danger of slipping particularly on uphill or downhill slopes. With frozen road surfaces, the ground becomes soft when the temperature rises, so the travel conditions become unstable. In such cases be extremely careful when traveling. When there has been heavy snow, the road shoulder and objects placed beside the road will be buried in the snow and cannot be seen, so always carry out snow-removal operations carefully. When traveling on snow-covered roads, always add tire chains. When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and use the engine as a brake while applying the foot brake intermittently. If necessary, lower the bucket to the ground to stop the machine. The load varies greatly according to the characteristics of the snow, so adjust the load accordingly and be careful not to let the machine slip.
Working on Loose Ground
Do not operate the machine on soft ground because it will be difficult to get the machine out again. Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse under the mass or vibration of your machine, the machine could fall or tip over and this could result in serious injury or death. Remember that after heavy

rain, blasting, or earthquakes, the soil will be weak in these areas. If the soil on the ground or near the ditches is loose. It can collapse under the mass or vibration of your machine and cause your machine to tip over. Install the head guard (FOPS) when working in areas where there is danger of falling stones or rocks. Install the ROPS and wear the seat belt when working in areas where there is danger of falling rocks or of the machine turning over.
Parking the Machine
Park the machine on level ground and lower the work tools to the ground. Where there is no danger of falling rocks or landslides. Or of flooding if the land is low. If it is necessary to park the machine on a slope, set blocks under the wheels to prevent the machine from moving. Then, dig the work
tools into the ground. When parking on public roads, provide fences, signs, flags, or lights, and put up any other necessary signs to ensure that passing traffic can see the machine clearly. And park the machine so that the machine, flags, and fences do not obstruct traffic. When leaving the machine, lower the bucket completely to the ground, parking brake lever to the on position, stop the engine, and lock all the equipment. Always remove the key and take it with you.
Operating in Cold Areas
After completing operations, remove all

water, snow, or mud stuck to the wiring harness, connector, switches, or sensors, and cover these parts. If the water freezes, it will cause malfunctions of machine when it is next used, and this may lead to unexpected accidents. Carry out the pre-heat/deicing operation thoroughly. If the machine is not thoroughly warmed up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents. Operate the control levers to relieve the hydraulic pressure (raise to above the set pressure for the hydraulic circuit and release the oil to the hydraulic tank) to warm up the oil in the hydraulic circuit. This ensures good response from the machine and prevents malfunctions. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger that this will ignite the battery. When charging or starting the engine with a different power source, melt the battery electrolyte and check for leakage of battery electrolyte before starting.
Moving the Machine
Load and Unload the Machine
The potential danger factors always exist when loading and unloading the machine, so the workers should take care. The engine should be at low speed and the machine should run with a low speed. The machine should be loaded and unloaded in a hard flat ground. Keep safety distance from the roadside. Fix the shipping vehicle wheels all the time and put the seat pad under the access board. Use a ramp with enough intensity. Make sure the ramp is wide and long enough to provide a sloping ground for the loading and unloading. The angle between the sloping ground and the floor should not be larger than 15.º The distance of the ramp should be adaptable to the distance of the machine wheels. Make sure the ramp is fixed well and the

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height of the two sides should be the same. Make sure the surface of the tilted-plate is clean, no lube, oil, ice or loose material. Clear up the contamination on the machine tires. Do not turn the direction off the ramp. If necessary, the machine should move away from the ramp, adjust the machine direction and then run up on the ramp. After the wheel loader is loaded on the trailer, wedge the tire and tie and tighten the machine with a cord.
Delivery
When using the tow truck to deliver the machine, the operator should obey by the regulation for the weight, width, length and the national and regional laws. When confirming the delivery route, the operator should consider of the machine’s weight, height, width and length. When passing over bridges or structures on private land, check first that the structure is strong enough to support the mass of the machine. When the tow truck is running on the road, the delivery must meet the requirement of the related regulations and obey by them. When delivering the machine, the machine might be divided into several parts. So please contact the Caterpillar (Qingzhou) Ltd. dealer to conduct this work
Battery and Maintenance
Danger Precaution
The electrolyte of battery contains vitriol and the battery can produce the hydrogen. So the wrong battery treatment can cause the serious injury or fire. Therefore, do follow the following attentions. Never make the lightened cigarette or fire close to the battery. Wear the safe glasses or rubber gloves when you need to touch the battery during work. If the electrolyte of battery spatters onto the clothes or skin, please wash and clean with water immediately. The electrolyte of the battery spatters into one’s eyes, it may result in loss of sight. If the electrolyte spatters into the eyes, please clean the eyes with a lot of water to wash and see a
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doctor immediately. Attention: If electrolyte is swallowed inadvertently, drink large quantities of water, milk, beaten eggs or vegetable oil. Call a doctor immediately. Stop the engine before working with the engine. Avoid contacting with the metal that may cause a short circuit between positive terminal (+) and negative terminal (-). First connect the positive terminal (+) when assembling the battery. First disconnect the negative (-) terminal (on the side of ground cable) when disassembling the battery. First check which one is positive terminal (+) or negative terminal (-) when disassembling or assembling the battery. And tighten the nut. Wipe with the cloth when cleaning the top of the battery. Never use the gas, solvent, any other organic solvent or cleanser. Tighten the cover of battery. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger that this will ignite the battery. When charging or starting the engine with a different power source, melt the battery electrolyte and check for leakage of battery electrolyte before starting. Disassemble the battery from the machine before charging.
Jump-Starting the Battery
If the connection method of boosting cable is wrong, fire might be caused. Jump-start the machine according to the following method: Two operators are necessary when starting (one operator should sit down at the operator’s seat.) Do not allow the 2 machines to touch when starting another machine. Turn off the two starting switches of normal machine and failed machine when connecting the boosting cable. First connect positive (+) cable when setting boosting cable. First disconnect the ground cable or negative cable (-). The last ground cable should be connected to the engine cylinder of the failed machine. However, this may cause fire. So

maintain a safe distance from the battery when connecting. Pay attention not to allow the boosting cable clips touch with each other or let the clip touch to the machine when removing the boosting cable.
Battery Charging
If the battery is not correctly charged, it may have the possibility to explode. Therefore, charge the battery according to the correct procedure and following rules. Charge it under proper ventilation and remove the battery cover. This allows the hydrogen to diffuse and prevents explosion. The air from the battery might cause explosive. Do not have fire or spark near the battery and no smoking when charging. Set the voltage of charger to agree with one of charged battery. If there is something wrong with voltage, the charger will overheat and may catch fire, which might cause explosive. Connect the positive charging clip (+) to the battery the positive terminal (+) and tighten the two terminals. If the charging rate of battery is less than 1/10, charge it highly. Set the discrete value under the battery rated volume. If the charging current is too large, the electrolyte may leak or evaporate, which could cause fire or explosion.
Towing
Pulling the Machine
Improperly towing a machine that or by using an improper connection may result in damage or death, so please obey by the following regulations: Follow the towing instruction of the “O&MM”.

Wear leather gloves when using a steel wire line. When doing the work together with the other workers, make sure to use signals that everyone knows before starting the work. If the machine engine cannot start or there is a failure in the brake system, please contact the Caterpillar (Qingzhou) Ltd. dealer to repair the machine. It is very dangerous to pull a machine on an incline. The worker should select an area with a small gradient. If this does not exist, then select the area with the smallest possible gradient. If using the machine to tow another machine that has failed, the steel wire line must be strong enough to support the failed
machine’s weight. There should not be any broken braided wire, knots or reduced diameter on the steel wire line. Do not stride two feet to stand on the tow wire or the steel wire line. When connecting the machine that needs towed, do not stand between the machine being towed and the towing machine. To make sure the hook is in the correct position, the hook of the towed machine should be in line with the towing part of the machine,.
Maintenance Precautions
Before Maintenance
Attention: If maintenance that is not instructed in this “Operation and Maintenance Manual” is done, unexpected failure may arise. Please contact the dealers appointed by Shandong Machinery CO., Ltd for service.
Warning Label
If somebody starts the engine or shifts gears during fueling or maintenance, serious injury or death may arise. Glue the warning label on the shift levers in the cab to remind people that you are

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maintaining the machine. If necessary, put warning labels around the machine.
Clean Before Overhaul and Maintenance
Clean machines before overhaul and maintenance. This is to prevent dirt from falling into the machine and to make sure that the maintenance can be done safely. If the machine is dirty in the course of overhaul and maintenance, it is difficult to avoid dirt or mud going into eyes or slipping and getting injured. A few tips for cleaning wheel loaders:
1. Wear anti-slip shoes to avoid slipping on wet surface. 2. When cleaning wheel loaders with high-pressure water, wear safety clothing. This way, your eyes and skin can be protected from the impact of high-pressure. 3. Do not spray water directly onto the electrical components (e.g. sensors, wire connectors). If water get into electrical system, operation failure may arise.
Keep the Working Place Clean and Tidy
Do not leave any service tools at the working place. Wipe up grease and lubricant etc. to protect people from slipping. Clean and tidy working place to ensure safe maintenance If the working place is not tidy, danger such as slipping and tripping may arise.
Identify the Responsible Person for the Group
Identify the person responsible during maintenance and while loading/unloading the wheel loader. Everybody should follow his instruction. When working together, misunderstanding may lead to a serious accident.
Water Level in the Radiator
When checking water level in the radiator, stop the engine. After engine and radiator cools down, check the water level of radiator. Do not randomly open the radiator cover. If it is necessary to open the radiator cover, follow the below instructions:
1. Check the water level after water
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temperature in the radiator cools down. (When checking if the water temperature has gone down, put your hand near the engine or the front face of the radiator and check the air temperature. Be careful not to touch the engine or the radiator.) 2. When the water fill cover can be opened with a bare hand, unfasten the fill cover to release the inner pressure. If the top cover of the radiator needs to be open, do not open it until the water temperature cools down and the inner pressure is released.
Shut Down Engine Before Overhaul and Maintenance
In the course of overhaul and maintenance, park wheel loader on the flat ground where there is no danger of falling rocks or land slides. If it is a low terrain, there should be no danger of flooding. Then shut down engine. After engine stops, move the work tool control lever to the “lifting”, “lowering” and “rack back” positions a few times as to release the remaining inner pressure in the hydraulic systems. Lower the work tools to the ground. Pull up the brake lever to implement the
brake and then put the block under tires. Lock front and rear frame with lock bar. Be careful not to get hurt by moving components and parts.
Support of Work Tools
During check and maintenance when the bucket is lifted, support the lift arm so that it doesn’t fall.

Move the control lever to the “Center” position.
Proper Tools
Only use the proper tools. Injury may result from using damaged, low quality, flawed or interim replacement tools.
Periodic Replacement of Critical Parts and Components
Hoses in fuel system, hydraulic system and brake system and some other parts and components are the key to ensure safety, so they must be replaced periodically.
Specific skills are needed to replace these key parts and components. Please contact the appointed Caterpillar (Qingzhou) Ltd. dealer. These parts and component must be replaced with new ones no matter if they are failed or not. These parts can age gradually resulting in oil leakage or failure in the work tool system. And then serious accident may arise. Replace these parts and components right away if there is any issue, even of they are still within the usage period. Refer to the “Periodic Replacement of Critical Parts and Components” for the replacement of safety parts and components.
Illumination
Use the anti-explosive lighting equipment when checking the fuel, lubricant, and electrolyte of battery or window glass solvent. If such illumination equipment is not used, there is an explosive danger. If the application is dark without lightening equipment, injury may occur, so proper lightening equipment should be mounted. Though it is in the dark place, a lighter or flame should not be used for lightening, because there is possibility of fire. If the gas of the battery meets fire, explosion may occur. Follow the guide of Operation Maintenance Manual when using the machine to lighten.
Fire Prevention
The gas diffused from fuel or battery might be flammable. Follow the following attentions

when repairing or maintaining. The storage of fuel, lubricant and other combustible material should be far away from the flame. Use non-combustible material such as a solvent to wash the parts. Do not use diesel or gas because it is flammable. No smoking when repairing or maintaining equipment. Smoke in the appointed places. Use non-flammable lightening equipment when checking the fuel, lubricant or electrolyte of battery. Never use a lighter or match. Move the combustible material to the safe place when grinding or welding the frame. Have an extinguisher at the repair and maintenance place.
During Maintenance
Maintenance People
Only a qualified person can do maintenance and repair. Unauthorized personnel are not allowed to enter the work area. If necessary, designate a person to guard. Pay special attention, while grinding, welding, or using a sledgehammer,.
Attachment
Before we attach/detach an attachment or equipment, first designate an owner. A non-operator is not allowed to get close to machine or attachment. Detach the attachment to a safe place and make sure it will not fall down, Put a rail around the attachment, with the mark “do not enter’, to avoid people to get close.
Work Under the Machine
At the beginning of maintenance or before repair under the machine, put the machine and all attachments on solid flat ground. Secure the tire with a wedge. If the tire is supported only by equipment, it will be dangerous for people to work under the machine, never work under poor quality support.

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Maintenance by Hanging the Frame
When the equipment or if the frame is hanging, use the lock bar to lock the front and rear frame, put the handlebar in the middle and wedge the equipment and frame. Move the control lever to the “Center” position. Use the blocks to stop the work tools and frame from moving. Before hanging, wedge the wheel on one side; put blocks under the machine when finished.
Work on Top of the Machine
When working on the top of the machine,
make sure the footing is clear and follow the rules to avoid falling.
1. Wipe up spilled lubricant oil or grease. 2. Work without tools around. 3. Watch your steps. Never jump from the machine. When climbing or down the machine, use the lift and handrail and keep three points of contact (two feet and one hand or two hands and one foot) Using protective equipment if necessary. At the top of the engine, the hood may be slippery and dangerous. Do not stand on it. The top of the tire may be slippery and dangerous. Do not stand on it. When cleaning the glass in the front of the cab, stand on the fender of front frame.
Do Not Drop Foreign Material in Machine
When repairing the window or oil tank, be careful not drop foreign objects (such bolts, nuts, twine or tools). These things may cause damage to the machine or cause other problems if dropped into the machine. If there are some foreign objects dropped inside, remove them immediately When repairing the machine, do not take
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unnecessary tools or parts. Maintenance when the Engine is Running To avoid getting hurt, do not do any maintenance when the engine is running. If it is necessary to do maintenance while the engine is running, abide by the following rules: One operator should sit in the operation chair and also prepare to shut off the engine when necessary. All the workers should keep contact with each other. When the working in a place close to the rotating parts, pay special attention to avoid being rolled up. Never allow any tools or any parts of body to touch the fan vane or fan belt. This is dangerous. When washing the inside of the radiator, prevent the equipment from turning. Also, pull the brake lever to implement braking. Do not touch any control levers. If you must touch them, first signal for other workers and warn them to go to a safety place.
Using a Hammer
When using a hammer, put on the safety glasses, safety helmet and other protection. Use copper stick as a mat between the hammer and the part, which is hit. When using the hammer to hit hard parts, such as pins or bearings, fragments may fly into ones eyes and result in harmful danger.
Welding Repair
Welding repair should only be done in a designated place and by qualified personnel. The gas emitted by welding can cause fire and electricity danger. Never allow and unqualified operator to enter. When welding abide by the following the rules: Break the battery connector to avoid explosion. Remove the painting in the welding post and dangerous gas generated. When welding on the hydraulic system, pipes, or any place close to them, they may produce combustible fumes and sparks. There is danger of fire; so electric welding should be avoided in these areas. If electric welding spark falls directly onto a rubber hose, electric wire or pressure pipes, the electric wire may be damaged and the

pipes may break suddenly,. In such cases the anti-fire blanket should be used to cover up. Wear a protective coat while carrying things before and after welding. Keep the welding ventilated. Clean up all flammable materials, and a fire extinguisher should be available.
Storage Battery Maintenance
While fixing electricity system or carrying on electric welding, discharge storage battery negative pole (-) or close the power supply totally, in order to prevent of electric current flow.
Finding the Problem
When finding a problem, it should be repaired immediately. Especially if it is in the braking system, steering system or other working equipment that will cause serious trouble. Please contact the Caterpillar (Qingzhou) Ltd. appointed dealer according to the failure type.
Rules for Adding Fuel or Lubricant Oil
Fuel, lubricant, hydraulic oil, antifreeze, brake fluid and window cleaner can all be caught by open flame. Abide by the following rules: Turn off the engine when adding fuel or lubricant. No smoking. Any of the fuel, lubricant, hydraulic oil, antifreeze, brake fluid and window cleaner that has overflowed should be wiped immediately. Tightly screw the cover of all the fuel, lubricant, hydraulic oil, antifreeze, brake fluid and window cleaner containers. The place where fuel, lubricant, hydraulic oil, antifreeze, brake fluid and window cleaner is added should be kept well ventilated.
High-Pressure Hose
A high-pressure hose leakage may hinder operation, cause personnel injury, or damage equipment. Stop working and contact your appointed Caterpillar (Qingzhou) Ltd. dealer. When replacing the high-pressure hose, the operator should be aware of the height. The instillation torque, should be according the

type and size of hose, so do not repair by yourself, contact your appointed Caterpillar (Qingzhou) Ltd. dealer.
Notes for High-Pressure Oil
When repairing or replacing, pipes in hydraulic systems, inspect system pressure (whether it has been released or not). If there is still pressure in pipes, it will cause serious injury or damage, so should follow the rules: Relevant detail about releasing pressure, see Hydraulic System Maintenance included in the Maintenance section of this manual. Do not continue work, check or replace before the pressure releases completely. Put on safety glasses and gloves. If the pipe leaks oil, the pipe and its surroundings will be wet, so check whether or not the steel pipe or hose has cracks or whether or not it has swelled up. If it is difficult to identify the location of leakage, please contact your appointed Caterpillar (Qingzhou) Ltd. dealer. Always wear safety glasses and thick gloves, and use a piece of cardboard or a sheet of wood to check for oil leakage. If shot by the high pressure oil spout, see a doctor immediately.
Check Under High Pressure
When the engine stops, the cooling water and oil for each part of the machine will be warm and highly pressurized. Opening the cover, removing the oil and water, or replace a filter, at this time all will cause burning or other harm. Wait for temperature to descend, and then operate according to operation maintenance manual. For other check items see Periodic Maintenance in the “Maintenance section of this manual for related contents.
Waste
To prevent pollution, obey the following procedure especially with environment where people and animal living. Do not release oil to the sewer or river etc. Put the waste oil in a container, do not pour

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onto the ground directly While handling harmful material, such as lubricant, fuel, and coolant, melting agent, filter, storage battery and other materials, obey relevant laws.
Repair and Check after Maintenance
Unexpected problems may occur if the proper checks and maintenance procedures are not performed. It may even damage the machine or cause injuries, and so pay attention to the following issue. Checking when the engine is off
1. Are all repair and maintenance parts checked? 2. Are repair and maintenance items correct? 3. Are there tools or parts dropped into the machine? It is dangerous if they are wedged into the linkage systems of the control levers? 4. Is the leaking water or oil repaired? Are the bolts screws down? Checking when engine running Pay attention to safety and the following items: 1. Do the repair and maintenance parts work normally? 2. Does the hydraulic system leak oil when the engine running, speeding up or adding load?
Tires
Handling of Tire
If a tire or a rim is handled in a wrong way, the tire may burst or may be damaged and the rim may be broken and scattered, which can cause serious injury or death. For the safety of maintenance workers, comply with the flowing proceedings. Since maintenance, disassembly, repair and assembly of the tires and rims require special equipment and skills, be sure to ask a tire repair shop to carry out the work. The specified tires must be used; inflate them to the specified pressure. The stated tires and pressure are in the “Tires” section in the Maintenance chapter. When inflating a tire, check that no one will enter the working area. And use an air chuck,
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which has a clip and can be fixed to the air valve. While inflating the tire, check the inflation pressure occasionally so that it will not rise too high. If the rim is not fitted normally, it may be burst or deflate while the tire is being inflated. To ensure safety, place a guard around the tire and do not work in front of the rim but work on the tread side of the tire. Abnormal drop of inflation pressure and abnormal fitting of the rim indicate trouble in the tire of rim. In this case, be sure to ask a tire repair shop to carry out repairs. Do not regulate the inflation pressure after working at high speeds or high loads. Explosions of air-inflated tires have resulted from heat- induced gas combustion inside the tires. Explosions can be caused by heat that is generated by welding, heating rim components, external fire, or excessive use of brakes.
The energy of tire explode are stronger than deflation. Explode can make tire rim and parts of transmission fly out more than 500 meter. It can arouse loss of property and personnel. It is recommended to fill tire with N2. If the tire has original air, it is suggested that nitrogen should be used to adjust the pressure. The nitrogen can be mixed with air. The tires inflated with nitrogen gas can prevent the tires from exploding because N2 is inflammable. The N2 can prevent from oxidation, aging of rubber and cauterization of rim parts.

Avoid excessive charging; this requires the appropriate equipment and personnel for instruction.
Storage of Tires
Tires should be stored in a depot. People must not enter to the depot unless allowed. If tires are stored outside, it should be have barrier around tires, and hold up the sign of “NO ENTRY”. Stand the tires on the ground and fixated them with a wedge so that they will not fall down when any unauthorized person touches them. If the tire is laid on the ground and one side is in contact with the surface, it will be staved and debased quality. Stand aside if the tires are fall down. Machines tires are very heavy and may cause injuries while attempting to control them.
Catalog and Change Cycle Parts Critical to Safety
To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out periodic maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts given in the table. These parts are closely connected to safety and fire prevention. With these parts, the material may change as time passed, or may easily wear or deteriorate. It is difficult to judge the condition of the parts simply by periodic maintenance. So regardless of the condition they should always be replaced after a fixed time has passed. This is necessary to ensure that they always maintain their function completely. However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately. If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the hoses. When replacing the hoses, always replace the O-ring, gaskets, and other such parts. Ask your Caterpillar (Qingzhou) Ltd. distributor to replace the parts critical to safety.
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Technical Specifications
The content of this chapter has significant impact toward correct use, maintenance and service of this machine.
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Application
This wheel loader is a large type of construction equipment mainly used to load bulk material. Primary operations include: digging, flattening, pushing material, loading, and dragging.
Working environment requirements
1. Height above sea level: 2000m 2. Environment temperature: 2040 3. Depth in water: 510mm This wheel loader is designed to work in ordinary construction applications, and is not fit to be used in flammable, explosive, or poison gas environments; or in environments with large amounts of airborne debris.
Forbidden operation
1. Overloading 2. Use as a lifting crane. 3. Overhead digging
Notes
The operation, maintenance and safe operation procedures written in the manual only apply when the machine is used as prescribed. If users don’t follow these procedure as described, Caterpillar (Qingzhou) Ltd. assumes no responsibility for accidents safety responsibility caused by users’ incorrect operation which will be taken on by users themselves.
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Key Technical Specifications

Performance Parameters

Rated Load Capacity Rated Bucket Capacity Bucket Lift Time when Full Loaded Three item time sum Maximum Travel Speed
Forward Gear I Forward Gear II Forward Gear III Forward Gear IV Reverse Gear I Reverse Gear II Maximum Traction Force Maximum Bucket Breakout Force Maximum Grade ability Minimum Turning Radius Outside Bucket

3 tons 1.66 m3 4.65sec 8.34 sec
7.8 km/h 14 km/h 24.9 km/h 39 km/h 9.7km/h 31 km/h 97 kN 113kN 26°
5869 mm

Dimension and Weight
Overall Length (bucket lying on the ground) Overall Width (outside bucket) Bucket Width Overall Height (to cab roof) Wheel base Operating Weight

7422 mm 2354 mm 2440±50 mm 3182mm 2740 mm 10047 kg

Engine
Commins Modelstage III Rated Power Rated Speed
Commins Modelstage II Rated Power Rated Speed
WDEC Model stage II Rated Power Rated Speed

QSB5.9 97 kW 2200 rpm
6BT5.9 92 kW 2200 rpm
DHB06G0095 92 kW 2200 rpm

Transmission
Torque Converter
Type Cooling Method

single three-element part Oil-cooled, pressurized circulation

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Transmission
Type Gear Shift Transmission pump pressure
Main drive and final drive reduction
Main drive type Final drive reduction type

power shift spur constant mesh four forward gears, two reverse gears
1.3-1.5Mpa
spiral bevel gear single-stage reduction spur cylinder gear planetary reduction

Drive axle and wheel
Type Tire Tire air pressure (front axle) Tire air pressure (rear axle)

four-wheel drive 17.5-25
0.35Mpa 0.3Mpa

Braking System
service brake
Type

single circuit air-over-oil four-wheel caliper disc brake

Parking brake and emergency brake
Type System air pressure

manual mechanical type 0.784~0.824Mpa

Steering hydraulic system
Type System pressure Steering angle

Whole steering pump 14Mpa
37º both left and right

Work Tools Hydraulic System
Service pump type System pressure

gear pump 18Mpa

Electrical system
System voltage Bulb voltage
Diesel start

24V 24V 24V Electrical start

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636D Arrangement Drawing
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Operation
Please carefully read and understand the manual content before you use the machine in order to correctly operate the machine. Correct operation
has great significance for users to remain safe, have high working efficiency, and extend service life.
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SWITCHES AND GAUGES

Signal

Name
Water Temperatute
Temperature lamp of Gearbox oil

Function
Pointer showed in green area is normal,in red area is higher
When the temperature is higher ,the lamp is lighted

Work hour Clock

Show the machine work hour

Left Direction Lamp Caution machine to turn left

Right Direction Lamp Caution machine to turn right

Battery Charge Lamp
Engine oil Pressure Lamp
Gearbox Oil Pressure Lamp

When the lamp is on,the battery is charged
When the engine oil pressure is higher than 0.78Mpa or lower than 0.16Mpa, the lamp is lighted
Gearbox Oil Pressure Lamp is warining when the pressure is abnormal

When the brake air pressure is low and Brake Air pressure Lamp
higher than normal,the lamp is warning

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Signal

Name

Function

Dipped Headlight Lamp Dipped Headlight is on

Park Brake Lamp

When the park brake is open ,the lamp is lighted

Warmup Lamp

High Bream Lamp

High Bream is on

Water in Oil Warning Lamp
Water Temperature Lamp
Action Lamp

Request to drain out the water
When the water is higher than 104 degree and before the temperature drop to 104 degree. Show the brake pressure /gearbox pressure/battery chaging/ coolant temperature /oil pressure is abnormal

Engine

fault

Indicate the engine fault.

indicating lamp

Economic model

The Diversified power switch is at Economic model

Heavy load

The Diversified power switch is at Heavy load

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Service Brake Pedal
The service brake pedal is placed on the left forward side of operator’s seat. Step down on the service brake pedal and the wheel side brakes of both the front and rear axles will be engaged. At the same time, turn on the brake light switch so that the brake light shines. Loosen the service brake pedal and then free service brake. When braking system has failed immediately repair it to insure that the machine has sufficient brake ability.
Air Condition System Switch

2Turn the switch Clock wisely to cooling position. Cooling system begin to work, send cooling air from wind-gap Heating 1After engine started for a while, turn the wind switch to proper wind position 2 Turn the switch counterclockwise to Natural Wind position. Heating system begin to work, send warm air from wind-gap Natural Wind
This machine is equipped with an air system which can circulate inside and outside air wind. In Spring & Autumn cooling season .When you want use natural wind to adjust the cabs inside wind, turn the wind switch to proper wind position, and turn the switch to natural wind.
Switch valve

This machine’s air condition gets three functions: Cooling/ Heating/Natural Wind Air Condition Control Panel Air condition control panel is located on the left side of seat bottom bracket .Picture as below. Air flow switch: 1.Clockwise–Wind increase /Counterclockwise-Wind reduce 2. High/Middle/Low three grade wind 3. On OFF, wind close Switch get natural wind (O) Cooling gear (AC) Function and instruction as below: Cooling 1After engine started, turn the wind switch to proper wind position.
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Placed on the right plate of gauge panel. When normally working, the switch valve is turn to “OFF” position, brake won’t shutdown transmission power to insure operation ability. When working on gradient place, switch valve is turned to “ON” position; brake won’t shutdown transmission power to insure operation safety.
Parking brake button

Parking brake closes to implement brake when draw up; Parking brake is free to release braking when press down. The parking brake is also used to be emergency brake. When machine is working, if urgent, pull up parking brake button and then implement emergency brake. When parking brake system errors and air pressure in service brake loop is lower than 0.4Mpa, parking brake implements brake automatically. Wheel loader implements emergency parking to insure safety.
Pilot control lever

falls when pull 22 forward. The lift arm falls when you push 30 forward, the lift arm rises when you pull 30 backward.
The lift arm would be at the floating situation when you push the lift arm lever forward to the extreme position. When you pull the lift arm lever back to the middle position, the lift arm would be free from that situation.
When the lift arm falls, push the lift arm lever forward to the floating position, then the lift arm would fall due to gravity, meanwhile, the driver can do other operations by his right hand (like put the bucket flat), thus the operator can increase the work efficiency.
When you do the sticking and spading operation, push the lever to the floating position, and then the bucket can float with the ground, which can avoid the damage to the ground.
When you do the spading operation, make full use of the floating device of the lift arm and self-flatted device of the bucket, you can effectively reduce the work strength and make the operation more comfortable. Warning: No matter what the situation that the machine is in, make sure that there are no obstacles and people around, under or above the machine before you operate the lift arm and bucket. Or else it may damage the devices or hurt the people.
Accelerator Pedal

The device control levers are at the right side of the seat. They are used to control the working devices. The lever is used to control the bucket and lift arm. The levers are at the holding situation when they are at the neutral position, which is the middle position.
When the engine is working. The bucket tilt up when you push the 29 left, and the bucket tilt down when you push the 29 right ripper rises when pull 22 backword, ripper

The accelerator pedal is located at the front-right side of the seat. The engine is at the idle speed when the pedal is in the

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neutral position. The fuel supply and the power output of the diesel engine increase when the accelerator pedal is pressed down.
Speed Control Handle

The direction-speed control handle is under the steering wheel. You can control gear 1, gear 2, gear 3, gear 4, forward, reverse and the neutral position by moving the handle forward or backward.
Steering Wheel

You can control the forward, reverse and neutral position by moving the handle forward or backward.
Horn Switch
The horn switch is in the center of the steering wheel; the horn will sound when you press the horn switch.
Direction-Speed Control Handle
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The machine has articulation coaxial fluid amplified steering. The steering wheel is inside cab and connected to coaxial fluid amplified steering control unit. During regular operation, turn steering wheel clockwise and the machine will turn right; counter-clockwise and the machine will turn left. Features of coaxial fluid amplified steering: 1. The steering angle of steering wheel is not equal to that of machine, continuously turn the steering wheel until the steering angle of machine reaches the desired position. 2. The faster the steering wheel turns, the faster machine turns. 3. The steering wheel cannot return automatically, the steering angle of machine will not change. So when finishing steering, you should turn the steering wheel the opposite direction to keep machine running straight.
Lift cylinder lock
Push the pole to the icon witch the lock is open, the Lift cylinder will work Normal, and when push the pole to the icon witch the lock is close, and the lift cylinder will hold the state, and Can’t control by the Pilot control lever .

Warning! When the Arm is at the lift condition, if you need any operation (eg. maintenance or repair), must put this lock to the lock position. Otherwise will cause machine damage or personnel casualty!!

Additional Accessories
Lamps and Lanterns
The lamps and lanterns of the machine include: the front combined lamps (left and right), the rear combined lamps (left and right), the lamps in the cab, the anti-fog lamps (left and right), the rear lamps (left and right). The front combined lamps include: the front lamps, the front small lamps and the front steering lamps. The rear-combined lamps include the rear lamps, the rear small lamps and the rear steering lamps.
Seat Adjustment
The seat of the machine can be adjusted in four ways: the rigidity (stiffness), forward or backward direction, the angle of the backrest, and the height of the headrest. Allowing the seat to adapt to different operators and different working conditions. Forward or Backward: There is a handle at the left underside and foreside of the seat, the seat can move forward or backward when you pull the handle to the outside of the seat, during the movement, you would meet several designated positions. When you move the seat to the designated position and loosen the handle, the seat would be secured at that position. The seat of the machine can be moved forward 75mm or backward 75mm, and the seat can only be secured at the designated positions. Angle of the Backrest: There is a handle at the right underside of the seat, first turn the handle clockwise, then move the headrest forward or backward to a comfortable position and loosen the handle so the seat is fastened at that position. The backrest can be adjusted forward 90°(folded), and backward 28°. Rigidity of the Seat: There is a handle that is at the front-underside of the seat; it is used to adjust the rigidity of the seat, which can adapt to the operators with different weight. Turn the handle clockwise or anticlockwise in the vertical plane, when

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it reaches one side, turn the handle to the other side in the horizontal plane, and then turn the handle in the vertical plane. There is a weight indicator beside the handle, while you turn the handle, the numerical value of the indicator will change with the movement, it shows the current rigidity of the seat. The rigidity would adapt to the operators with the weight as the numerical value. The rigidity of the seat can be adjusted infinitely between the range of 50kg – 130kg; when the machine leaves factory it is set to 70kg.
Door Lock
The keys of the left and right door lock on the cab are the same. You cannot press the lock down when the door is locked. At this time, insert the key into the lock and turn 180°clockwise, then pull it out of the lock, hold the lock with you hand, press the lock with you thumb and draw the door outward at the same time, then you can open the door. When you want to lock the door, close the door firstly, and insert the key into the lock and turn 180° counterclockwise, then pull it out of the lock. Warning: When operating the machine, the operator must close the left and right doors for the safety requirement.
Rearview Mirror Adjustment
There are two rearview mirrors at the top of the cab, one is at the right side and the other is at the left side. Before operating the machine, the operator must adjust the rearview mirrors to make sure that the operator can see behind the machine. Loosen the bolt that connects the bracket of the rearview mirror and the cab, and turn the bracket, then you can adjust the position of the rearview mirror to the cab. Loosen the bolt that connect the bracket and the rearview mirror, and turn the rearview mirror, then you can adjust the elevation of the rearview mirror. Please tighten the bolt after the adjustment is complete.
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Breaking-in a New Wheel Loader
Proper Break-in is very important to prolong the life of the machine, to eliminate potential malfunctions, and to avoid fatal accidents. After purchasing the machine, the users need to operate and maintain the machine according to the rules of proper break-in described in this manual, and then the machine can be operated normally.
Break-in Rules:
1. The machine must be broken in before 100 hours of use. 2. Start the engine and let it run at speed for 5 min. 3. During break-in, forward gears I, II, III, IV, reverse gears I, II should be used conservatively. 4. Start the machine in idle speed, and speed it up gradually to the higher speed. Sudden start, speeding up, sharp steering and brake should be avoided except in emergency condition. 5. It will be better to load light things during break-in and to avoid abrupt operations. During break-in, the load should be less than the 70% of the rated load and the speed should be less than the 70% of the rated speed. 6. Pay attention to the lubricating state of loader, replace or add the lubricant or grease at set intervals. 7. Check frequently the temperatures of gearbox, torque converter, front and rear axles, hubs, brakes, and middle supporting axles and hydraulic oil, engine coolant, engine oil. Check out and fix the faults if there is overheating. 8. Check whether the bolts and nuts in each connecting part are loose.
After the first 8 running hours
1. Check bolts and nuts, especially the bolts of diesel engine cylinder head, exhaust pipe and front, rear axles, nuts for rims, connecting bolts of driving shafts and

fixing nuts of diesel engine, gear box, bolts at front and rear axle articulation. If needed tighten them. 2. Check whether the tightness of fan belt, engine belt and AC compressor belt is proper. 3. Check oil levels of the transmission, drive axle, and the diesel engine. 4. Check the sealing condition of the hydraulic and brake systems. 5. Check the connecting condition of every control lever and throttle parts. 6. Check the temperatures and connecting condition of every electric system, states of electric supply from generator, lamps, lightening and steering signals. Attention: When checking the oil level, comply with certain operation rules.
After the Break-in
1. Check the tightening conditions of bolts and nuts, especially the bolts of diesel engine cylinder head, exhaust pipe and front, rear axles, nuts for rims, connecting bolts of driving shafts and fixing nuts of diesel engine, gear box, bolts at front and rear axle articulation. 2. Check whether or not the tightness of fan belt, engine belt and AC compressor belt is proper. 3. Check the sealing condition of the hydraulic and brake systems. 4. Replace the hydraulic oil in gearbox, lubrication in drive axle. 5. Replace the filter for gearbox, engine oil, and replace the filter elements for fuel tank. 6. Clean the return filter elements in hydraulic tank. Attention: When replacing the transmission oil for, lubricant for drive axle and hydraulic oil for diesel engine, comply with the specified operation rules.
Machine Operation
Before Starting Engine
1. Check coolant level of engine. 2. Check oil level in engine oil pan.

3. Check the hydraulic oil level. 4. Check the sealing condition in the water pipe, oil pipe and other parts. 5. Check that there are no loose battery terminals, and tighten if necessary. 6. Check that the tire pressure is normal.
Starting Engine
1. Check that there are no people or obstacles in the surrounding area, and there are no servicemen under the loader. Except for operator in the cab, do not allow any person to stand anywhere on the machine or sit in the cab. 2. Turn on the battery switch. 3. Follow the safety instructions when stepping on and off the machine. 4. Adjust the side mirror to a position, which gives the best view from the operator’s seat, and approaches to the loader as near as possible. 5. Close the doors of cab. 6. Inspect the safety belt and tightly secure it. 7. Confirm the machine is in the neutral gear position; if not, please move the lever to the neutral gear position. 8. Check whether the control lever is on the middle position. If not, please pull it to the middle position. 9. Check whether the fan switch of air-conditioning system is in ” natural fan” and the changeover switch on “OFF”, if not, please turn it to the correct position. 10. Insert the key and turn it once clockwise to power up the entire vehicle. Sound the horn, which means that the machine will start and other personnel cannot approach this machine. 11. Check the fuel level in tank. 12. Press accelerator pedal slightly, and continue to revolve the key clockwise to the next position to turn on the engine and start the motor. In the normal condition it can start in 10 seconds. When the machine is starting, you should release your hand and let the starting electric lock return. Attention: Do not hold the key continuously for more than 15 seconds.

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You should release the start switch immediately if the machine cannot start. Wait more than 30 seconds to start again. This is resulted from the characteristics of the starter and the battery, if the engine does not start after three consecutive times, check out the reason. After removing the trouble, wait at least three minutes to start the engine. 13. After starting the machine, it should remain in idle speed (750 20r/min) to warm the machine, after the engine cooling water temperature up to 55°C, the engine oil temperature up to 45°C, allow the machine work in capacity load. 14. Listen attentively whether or not the engine works normally in the low speed, and whether or not the gearbox brings the abnormal sound. 15. Inspect whether or not all gauges are normal and whether or not each lighting attachment, indicating lamp, horn, wiper, and brake light can work normally. Attention: Especially pay attention to the indicated value of the engine oil pressure, it should not be lower than 0.1MPa (in idle speed condition). If it is lower than this value, you should stop and inspect whether or not there are troubles with the engine. 16. During winter, you should preheat the hydraulic oil. Pull the bucket control level back and maintain for 4 – 5 minutes, at the same time step on the accelerator pedal. This will cause the plate of bucket to stop against the lift arm and cause hydraulic oil overflow. This will make the oil temperature rise more quickly. 17. Inspect whether the service brake, and the parking brake systems work normally. 18. If there are no obstacles around the machine, you should slowly rotate the steering, observe whether there are movements in right or left orientation.
Before Traveling
1. Operate the pilot valve control level, pull bucket control level back to rack-back position, and lift the lift arm to the carrying
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position, namely the distance between the bottom of bucket and ground is about 30-40cm.
2. Press the service brake pedal, and push the parking brake lever down at the same time to release parking brake. Loosen the parking brake pedal slowly; observe whether or not the loader can move. Warning: If the machine can move, please press the service brake pedal immediately and press the parking brake pedal to apply the brake. Then, inspect whether the gearshift control system has troubles. If the machine is on the slope, first use wedge blocks under the wheels, this prevents the machine from moving, then inspect the machine. 3. Change the gearshift control lever to forward I gear or the reverse gear, and suitably press the throttle pedal to confirm that the loader moves forward or backward respectively. 4. Drive the loader to an open and flat site, if the steering inspection has not been carried out because of narrow site in the previous stage. Rotate the steering wheel now, inspect whether or not the machine can change direction freely. 5. Check the quality of the service pedal. In an open and flat place, drive the machine forward in gear 1 or gear 2, first release the accelerator pedal, then gently press down the service brake pedal, the machine should immediately decelerate and stop. Attention: If the machine does not immediately decelerate after pressing down the service brake pedal, please pull the parking brake lever immediately to implement emergency brake. At the same time, operate the pilot valve control level to drop the lift arm to the lowest position. Turn the bucket forward to make the bucket

teeth or bucket cutting edge insert or sit on the ground, forcing the machine to stop to ensure security. 6. Inspect the union situation of every gearshift. Drive the machine to an open and flat area; integrate every gear separately to inspect the situation of shift gears.
Machine Steering Operation
When there appears to be curved road in front of the machine, you must properly steer the machine, please comply with the local traffic laws to carry on the operation. Before turning, push the turning signals to the relevant position. Move lever to bottom left to turn left and up and right to turn right, this notifies a person near the loader that the loader is going to operate steering. Then rotate the steering wheel for steering. This loader use articulated joint coaxial fluid amplified power steering. The rotation angle of the steering wheel and loader turning are not equal, rotate the steering wheel continually and enlarge the turning angle of the loader. The quicker you rotate the steering wheel, the quicker loader will turn. The steering wheel cannot return automatically, the steering angle of machine will not change. So, turn the steering wheel back after turning it in order to correct the relative angle of front and rear frame drive so the machine is in the linear direction. After steering, move the turning signal to the middle position, so the steering light and steering indicating light will go off. To operate steering at high speed, you should release the throttle pedal firstly and use service brake; when necessary to lower the service brake, operate steering to ensure the safety. Warning: Operating steering on slope is forbidden; you should drive the loader to the level ground for steering.
Braking
First, release the throttle pedal when braking, and then press the brake pedal stably for braking. Warning: When the

machine is operated at high speed, sudden complete braking is not permitted except in urgent situations. This may result in an accident or damage to the machine.
Parking and Storage
Select Location
1. Park the machine in flat place, without falling stones, loose dirt of flooding. 2. Stop the machine with the brake. 3. Put the gearshift control lever to the neutral position. 4. Put the hand brake lever to park’ position. 5. To operate pilot valve control lever, put the lift arm down to the ground and lower the bucket. 6. To cool down every part evenly, keep the engine running for 5min after parked. 7. Turn the power key toOFF’ position, turnoff the engine, switch off the machine power, pull out the key. 8. Put every switch to neutral or OFF’ position. 9. Lock the doors, and then step down using the ladders. 10. If the machine will be stopped for a long time (overnight, for an example), open the right charged battery cover and put the power switch toOFF’. 11. In winter, if there is no antifreeze in the machine, open each water valve in the engine, drain all the antifreeze in the cooling system and evaporate the air conditioning system to prevent frozen parts of the machine. 12. Lock everything and take the keys with you. Attention: Keep the machine on the plane ground. Use chock near the tire to stop the machine if the machine is located on a slope.
If the machine will be stopped for a long time, it should be located complying with the rules as follows:
Before Long-Term Storage
Clean all parts of the machine dry it

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and put it in a dry garage. If it only can be put in open air, it should be put on concrete road and covered with a canvas. Fill the fuel tank and lubricate the moving pins, acting axels, and change the hydraulic oil. Put the gearshift control lever to the neutral position. Place the hand brake lever in the break’ position. Put the bucket down to the ground, put the pilot valve control lever to the neutral position. Put every switch to neutral orOFF’ position and lock every door. Apply a thin film of grease to hydraulic cylinder exposure part. Take out the battery from the machine. If the temperature is lower than 0Cº , add antifreeze to the engine, make sure that the antifreeze can reach the engine parts and evaporate air conditioner. Or drain the water in the cooling system so the water in the air condition will also evaporate. Fix the front and rear with blocks or structure fixtures.
During Storage
Once a month start the machine, run every system, lubricate every moving pin, moving axle, and charge the batteries. Before starting the machine, clean up the grease on the rod of the hydraulic cylinders. Apply a thin film of grease again after the operation. Apply a thin film of rust preventive oil to every rusty part. Attention: If applying the rust preventive oil indoors, open the door and window to vent the poisoned air.
After Storage
When ending the long-term storage, do the following work: Change the lubrication in the engine, gearbox, driving axle and the hydraulic oil and antifreeze. Lubricate all the moving pins and
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transmission shafts. Before starting the machine, clean up the grease on the rod of the hydraulic cylinders.
Specific Operations
Preparing before work
First, Clear and level the working site. Remove any rock or things that may cut the tires. If use this loader to dump for truck or carriage, base on the height of truck and carriage to adjust the limit height for bucket dumping safety, avoid to impact from material to trunk because the dump height is too high.
General Shoveling
General dumping is used to shovel the loose material. Shift the gear to forward II speed, drive the loader to loose material and face the material with the middle of bucket. The operator handle the steering wheel by left hand and operate the lever of pilot valve arm operating to down the arm to 30cm from ground. Lower the arm when the distance is about 1000mm between the loader and material, create bucket contact with ground and change from forward II to forward I gear. Attention: When the bucket contacts the ground, make sure to avoid making large press on the surface, which will lead to unnecessary forward resistance. It should not have an angle between the front frame and the rear frame.
Press the throttle pedal, so that the bucket full inserts material pile; when the machine cannot move forward, move the control

lever of bucket pilot valve backward (to turn the bucket backward), then push the bucket lever to midpoint, the machine will continue forward to insert the material pile, repeat the operation of inserting and rotating the bucket until the bucket is filled with material.
Combine Shoveling
Combine shoveling applies to shoveling the harder or more viscous material. The operation before the bucket is inserted in the material is the same as general shoveling. Move the buckets pilot valve lever backward after the bucket is inserted into the material, then push the lever to midpoint to make the bucket turn upward, therefore the bucket inserted a long way forward. After that, the operator moves the pilot valve lever backward, then move it to midpoint again to make the bucket backward rotation so that bucket could continue forward. Repeatedly insert, bring up the bucket, insert and rotate the bucket until the bucket is filled with material.
Withdraw from Material Pile
Operator operates the pilot valve control lever of the bucket after the bucket is filled with material, rotate the bucket backward until the block on the bucket collision with arm, and then push the bucket control lever to the midpoint. At this point, the largest back tilt angle of bucket is obtained. Raise the bucket to a certain height; make sure the bucket avoids the material pile when the machine reverses. While the operator handles the steering wheel using the right hand, pull the gearshift control lever to the reverse position to allow the loader to reverse. After the machine backs away from the material pile, the operator lowers the control arm lever to lower the arm 30-40cm from the ground.
Material Transporting
In the following cases, material can be transported The road is too soft and cannot be

done by using a truck. There is not a clear and level the working site and cannot be done by using a truck. Transporting by truck is not economic al when the distance is less than 500 meters.
Keep the bottom of bucket at the transporting location (30- 40cm from the ground), and the bucket turning back to the stop location (the stop plate touching the lift arm) in the transporting process, so that the material transporting process is smooth and safe, and the material is not easily scattered. Transporting speed is determined by the transporting distance and road condition, when machine pass a pothole or the protuberance, the worker should release the accelerator pedal, if necessary may use “point braking” by reducing the speed, and passing the roadblock slowly, this reduces the impact to machine and scattering.
Warning: Lifting the bucket to a higher location to transporting material is forbidden. This may cause the machine to turn over.
Unloading Material
Unload to Truck and Hopper
Release the accelerator pedal while the wheel loader with full material is 15 meters away from the truck or the hopper, if necessary use the brake to decrease the speed, and approach the truck or the hopper slowly. At the same time the operator operates the control lever back to the last location, the lever will be magnetized by the electromagnet, and the

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operator can release the control lever, which will not return to middle location. In this course, operator should drive the machine carefully, watching the circumstance of the bucket being close to the truck or the hopper, and turn back the operation handle at any moment. the bucket should not collide with the truck or hopper.
When the bucket is just on the top of the truck or the hopper, operator should step on the brake pedal to stop the machine and push ahead the bucket control lever to tip the bucket forward. Put the material in the truck or hopper, at this time operator should watch the bucket working process carefully, the bucket and the edge of the truck or hopper should not make the collide. If material is very viscous, the bucket control lever should be operated forward and backward several times in order to make the collision between bucket stop plate and lift arm time and time, and release the material with the bucket down and sticking into the material. Unloading material should begin from the front of the pile if the length of the truck is twice or more for the width of the bucket. Notice: When unloading, the collision force between bucket stop plate and lift arm should not too large, and collision times should be low to prevent to damage machine.
When machine finished unloading, the operator should turn the bucket rotating control lever back to last location until it
stops contact with lift arm, then move the lever to the middle location. After that, the operator moves the shifting lever to
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reverse location, then release the brake pedal to make the machine leave from the truck or hopper. When machine leaves the truck or hopper, the operator should drive the machine carefully, watching the process bucket leaving the truck or hopper, not to collide between bucket and truck or hopper. After the bucket pulls away from the truck or hopper completely, the operator can let the lift arm down when driving, and prepare next work cycle.
Unloading at Low Location
When transporting material among fields, sometimes unloading material is done at low locations or locations lower than ground level. At this time, after unloading, bucket back should first turn to the horizontal position, and then lift the arm. Otherwise you cannot lift the arm because of the interference of the work tools linkage structure.
Carrying
When bucket is touching ground at even level, put the gearshift control lever in forward I gear, step on accelerator pedal to make the machine go forward, if finding some obstacle in process, can go on carrying with lifting the arm a little, the lift arm control lever should be in the position between downside and upside when operating the lift arm up and down, it should not be turned to either upside or downside position, to ensure the carrying work.
Scraping Work
Lift the arm, and turn the bucket forward until the cutting edge is touching ground, the angle between cutting edge and ground should remain about 40 degrees, for a hard road, lift control lever, it should be put into the floating position, and it should be put the middle position for soft material road, gearshift lever should be turned backward shift, step on accelerator pedal, to make machine backward, scrape ground by cutting edge.

Towing
Can transport 20 tons by towing. The method is as follows: Link to this machine’s draught pin securely. Be sure to have good performance in the brake system. Lay the bucket in transporting position. Operating slowly when start and stop the machine be careful to brake before decelerating. Notice: When braking, should brake for the tow truck firstly, and break this machine.
Efficient Loading/Unloading
V style Operation Method
As the following picture, wheel loader faces the material pile, the truck stops when the angle is 60 degrees from WL’s driving direction and 12~15 meters away the pile. After WL loads full material, go directly back 12~15 meters away mass, turn around and drive to truck while lifting the bucket. After unloading, turn back to previous place, and do next operation.
Right Angle Loading
WL is faced to material mass, after shoveling material, drive along linear direction. And drive the dump truck between WL and material mass. This method needs little time and shortens the work cycle time effectively.

Operation in cold weather
If temperature is too low, the engine will be difficult to start, and the radiator may be frozen, so you should do the following: All components should use low viscous fuel, hydraulic oil, lubricating oil; Antifreeze should be put into the cooling water. Specifications of the fuel should follow the “fluid specifications” of the Operation and Maintenance Manual. Notes of using antifreeze: do not mix the different type antifreeze together.
Attention: Keep antifreeze away from fire,
no smoking when adding the antifreeze. Notes of using the battery. When outside temperature descends, the capacity of the storage battery will be reduced. If there is a low charge rate, the electrolyte may freeze, you should keep the charge rate near 100% as often as possible, and keep it warm as often as possible so engine could be easily start the next day. In extremely cold areas, you should use an anti-cold storage battery.
After Daily Work
To ensure the machine easily starts avoid silt, water and freezing snow. If these are encountered you should do the following: 1. Thoroughly clean the silt, water and snow. To avoid damaging the seal performance because of silt, water and snow leaking into the seals and freezing. 2. Stop the machine on a dry and solid ground. If this is not possible, stop it on boards. Using boards can prevent the machine from being frozen to the ground.

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3. In low temperature, as the parking time is longer the battery storage capacity will decrease, so the battery should be covered or move to a warmer place, and mounted on the second day.
After Cold Season
As the season changes and turns warm, do the following: All components should use mid-viscosity fuel, hydraulic oil, lubricating oil. Specifications of the fuel should follow the “fluid specifications” of the Operation and Maintenance Manual. If you do not use permanent antifreeze, you must drain all of the fluid in radiator system, clean up the radiator, and change to new cooling fluid.
Transporting
Before transport, the channel height, width and the allowable carrying capacity along the route should be checked. When the machine is placed on the transport truck, the total height, total width and total weight cannot exceed the related rules. If there are problems of being too tall or too wide, please consult the Caterpillar (Qingzhou) Ltd. or its dealer to find a solution. In order to prevent the accidents during transport, clean up any snow, ice or other material on dock or truck before transport. Attention: While transporting, please follow the national and local regulations regarding transport height, width, length and weight.
Hauling on a Trailer
Follow this procedure: 1. Before shipping, lay blocks under the machine’s wheels. 2. When the truck is driving, do not make steering operations. If it is necessary, return the vehicle to flat ground and then follow through with the turning operation. 3. After parking the machine, use the frame bumper to fix the front and rear frame. 4. Lay the bucket with its flat side down in the transport truck, and put it in the neutral
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position. Warning: Incorrect shipping may cause vehicle damage and may lead personal injury or casualty.
Urgent Towing
This vehicle cannot be towed except for in urgent conditions. Towing is only used so that the vehicle being towed can get to place to perform check and repair. Towing is not used to move long distances. This vehicle’s towing distance is limited to 10 kilometers and the towing speed is limited to 10 kilometers per hour. If these limitations are exceeded, the transmission will be damaged because of insufficient oil. If the vehicle must be moved in a long distance, a special trailer should be used. Warning: Incorrect towing of the troubled vehicle may lead to personal injury or casualty. Towing a vehicle on bad road may cause further damage. If there is something wrong with the brakes, and the vehicle cannot brake during the towing process, the operator should be especially careful. Notices in the Towing Process This vehicle’s parking brake system is a spring brake and is pressure air released. Any malfunction caused by air system failure, brake air chamber leakage or air storage failure may cause the vehicle to become immobile. At this time the pin connecting the brake air chamber and brake detent rod should be taken off so that the brake is forced to release. Attention: Before releasing the parking brake, the wheels of the vehicle should be under laid with blocks to prevent vehicle from moving. If the blocks are not positioned well, the vehicle may move. The blocks should not be removed until beginning towing. People should not stand on the towed vehicle unless operator can control the direction and / or detent. Before towing you must confirm that the towrope or tow rod is in good condition and has enough strength to pull vehicle.

The strength of the towrope or tow rod must be at least 1.5 times the gross weight of the towed vehicle; this will allow it to pull the vehicle from the mud or a slope. Keep the towrope at an angle, the angle between dragrope and forefront location should not be more than 30 degrees. Vehicles moving too fast may make the towrope or tow rod to break or crack. Moving vehicle slowly and smoothly will result in effective work. When towing, all people should be far away from both sides of the towrope. This will to prevent injury if the towrope were to break.

Generally, the trailer should be the same size as the towed vehicle. Confirm the trailer has enough brake capability, weight and power to control and move two vehicles up a slope. In order to have enough control or brake capability when a towing a vehicle down slope, there should be a bigger trailer or other machine behind it to prevent rolling when out of control. The operator must steer along with the towrope direction so that the towed vehicle direction can be controlled.

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Maintenance
During uses this machine, please perform the maintenance according to the maintenance interval schedule and procedure specified in this manual. Good maintenance is helpful to extend the machine service life
and the safeguard operational security
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Periodic Maintenance
The service hour meter determines the maintenance intervals or calendar intervals (daily, weekly, monthly, etc.). Maintenance procedures are stated in this manual. Caterpillar (Qingzhou) Ltd. requested maintenance should be done either by the service hour meter or the time interval, whichever occurs first. Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals schedule might be necessary.
Other than daily maintenance schedules, four periodic maintenance points should be considered: PM250: every 250 service hours, PM500: every 500 service hours, PM1000: every 1000 service hours, and PM2000: every 2000 service hours
During maintenance, daily maintenance and initial maintenance of related components should be strictly performed. Then, perform respective periodic maintenance according to specific service hour.
Notes: The engine info of this section is only applied to Weichai engine configuration, for Cummins engine’ maintenance and troubleshooting&parts information, please refer to the supplied Cummins Operation And Maintenance Manual

Fluid fill volume

Hydraulic oil

15 7L

Crankcase

18L (oil gauge graduation as actual refueling volume)

Transmission system

45L(oil gauge graduation as actual refueling volume)

Front axle (main drive and final drive reducer)

10L (oil gauge graduation as actual refueling volume)

Rear axle (main drive and final drive reducer)

10L (oil gauge graduation as actual refueling volume)

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Maintenance Schedule

Maintenance items

Daily

PM250

Check engine oil level

Check coolant level

Check hydraulic oil level

Check fuel level, Drain the water and the

sediment from the fuel pre-filter

Check the operation of the lights and

gauges

Check tire pressure and wear

Check transmission oil level

Check the lubrication at all lubrication

points, apply grease to them according to

the Machine Lubricating Figure attached

on the machine

Check oil level of the brake booster

Check transmission control system, make

adjustment if necessary

Check and tight the retaining nuts of the

steering wheel

Walk around and visually inspect all the

systems weather there are abnormal or

leakage

Visually inspect engine fan and drive belt

Apply grease to every driveshaft according

to the Machine Lubricating Figure attached

on the machine

Tight all driveshaft connecting bolts

Check the clearance between the parking

brake shoe and brake drum at the first 50

Initial Check

service hours, make adjustment if

necessary

Check the tightening torque of rims

connecting bolts at the first 50 service

Initial Check

hours

Initially replace the engine oil and oil filter

Initial

(the first 50 service hours)

Replacement

Initially replace the powertrain filter and the oil for the transmission, torque converter and radiator

Initial Replacement

Initially replace the hydraulic tank return

Initial

element (upper element on the oil tank)

Replacement

Initially replace pilot hydraulic system oil

Initial

filter element

Replacement

PM500

Clean

PM1000

PM2000

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Maintenance items Keep the battery post clean and apply Vaseline on it to prevent acid fog from corrosion Change engine oil and oil filter Clean engine cylinder head Clean radiator fins Clean filling screen of the fuel tank Clean filling screen of the engine oil tank Check the tightening torque of the engine and transmission mounting bolts Check work tool, front and rear frames, stress welding seams, and retaining bolts for cracks or loose Check the oil level of front and rear axle Check the engine air inlet system Check the engine drive belt, air conditioning compressor belt for tension and damage Check the operating capacity of service brake and parking brake Change engine oil and oil filter Change fuel pre-filter Check the retaining bolts of frame hinge pin for loose Check oil level of the brake booster Tighten connecting bolts between frame and front, rear axle Clean the screen of the air booster breather Change fuel filter Change oil tank breather element Change air filter element Adjust engine valve lash Check the bearings of the engine tension pulley and the fan shaft bearing case Fasten all the retaining bolts of the battery, clean the top of the battery Clean fuel tank Clean transmission, torque converter breather Replace the oil for the transmission, torque converter and radiator Replace transmission suction screen and return screen

Daily

PM250

PM500

PM1000

PM2000

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Maintenance items

Daily

PM250

PM500

PM1000

PM2000

Replace the hydraulic tank return element (upper element on the oil tank)

Replace the lubricating oil of the axles

Initially replace pilot hydraulic system oil filter element

Check the engine shock absorber

Check the operation of service brake system lines and parking brake system. If
necessary, remove and inspect the abrasion of disc, and replace brake lines

Check the flexibility of steering system,
replace steering lines if necessary

Check the generator, starting motor,
cleanup the turbocharger

Clean the seals and springs of brake

booster, replace the brake oil, check the

sensitivity of each brake

Check the sealing of distribution valve and

power cylinder by measuring the cylinder

natural subsidence

Change oil tank breather (filling screen)

Change fuel tank breather (filling screen)

Change coolant and coolant filter, Clean cooling system Replace the coolant every
two years if the service hours do not occur first

Replace hydraulic oil, clean hydraulic tank
and check the suction pipe

Warning: Please use the spare parts approved by Caterpillar (Qingzhou) Ltd. or

Caterpillar (Qingzhou) Ltd. dealer. The use unauthorized spare parts, may cause

security problems and reduce the service life of machine.

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Engine
Engine Coolant
The proper maintenance of engine cooling system is very important. Overheating, overcooling, pitting, cavitations, cylinder head cracks, stuck piston and plugged radiator, are common problems of the cooling system, these problems will not only reduce the work efficiency of the engine, but also can cause the engine damage.
Antifreeze Fluid
The main function of antifreeze fluid is to decrease the condensation and increase the boiling point of the coolant. The antifreeze fluid is also needed when operating the machine under the normal temperature, because it can increase the boiling point of the coolant, the additive included in the antifreeze fluid can also reduce the framework corrosion and cracks.

The antifreeze fluid Caterpillar (Qingzhou) Ltd. recommends are listed as follows:

Changcheng

Lowest ambient

Antifreeze Fluid

Temperature C Model

50

YF-3

45

YF-2A

40

YF-2B

35

YF-2

25

YF-1

When replacing antifreeze fluid, use

premium antifreeze liquid and fill according

to its use guide. Attention: Antifreeze fluid

is highly flammable, do not use near an

open flame.

Checking the Coolant Level

The water radiator is located on the rear of the machine. Wait until the temperature of the engine coolant drops to below 50°C, then remove the water radiator filler cap slowly in order to relieve pressure. Any contact

with hot coolant or with steam can cause severe burns. Check the coolant level. The coolant should be located between the high-level mark and low-level mark of the radiator tank. Fill coolant to the high level mark if the coolant is below the low level mark. Check the sealing of the water radiator filler cap; change the filler cap if it is damaged.
Fasten the radiator filler cap. If filling coolant is needed every day, please check engine-cooling system for leaks. If there is a leakage, follow through with the necessary repair, then fill antifreeze fluid to corresponding level.
Fill the Coolant
Prior to filling the coolant of a new engine, or an engine with a clean cooling system, choose the anti-freeze fluid density of the coolant basing on the lowest local temperature (10°C below the lowest local temperature is even better), calculate the anti-freeze fluid quantity by volume of the total engine cooling system, the total cooling system volume of this machine is 30 liters. Attention: Make sure not to use water as a coolant, this will caused corrosion damage. If water is used as coolant, the warranty to the cooling system is void. Attention: Do not fill coolant then the engine is at a high temperature, this could cause engine body damage. Wait until the engine temperature is below 50C, and then continue. Fill the Coolant as Follows: 1. Turn on the power negative switch;

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insert the key into the ignition and turn clockwise to 1 gear position, turn on the machine power; toggle the transfer switch of the air-conditioning system to the warm position. 2. Manually turn the engine water inlet pipe valve to the ON position (when in the ON position, valve handle and the pipe are in the same direction). 3. Open the radiator filler cap, fill the coolant slowly, until the coolant level is at the high level mark of the radiator tank, and maintain the level for ten minutes. Attention: When filling the coolant, the air must be vented from the lines of the engine cooling system. 4. Keep the radiator filler cap open, start engine, run engine for 5 minutes at low idle speed, then another 5 minutes at high idle speed, and enable the coolant temperature to go above 85 °C. 5. Check the coolant level again. If necessary, continue to fill coolant to the high water level mark of the surge tank. 6. Check the sealing of the water radiator filler cap and change the filler cap if it is damaged. Attention: If the coolant leakage is caused by the user, for any subsequent losses resulting from decreases in anti-freeze fluid density, Caterpillar (Qingzhou) Ltd. will not take any responsibility.
Clean Cooling System
Every 2,000 service hours or two years (whichever occurs first), completely replace the coolant and clean cooling system. Before this, if the coolant becomes contaminated, the engine overheats or there are some bubbles in the radiator, clean the cooling system. Use the following steps to clean cooling system: 1. Turn the power to the negative switch; insert the key into start switch and turn clockwise to 1 gear position, turn on the machine power; toggle the transfer switch of the air-conditioning system to the warm position. 2. Turn the manual valve of the engine
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water inlet pipe to the ON position (when in the ON position, valve handle and the pipe are in the same direction). 3. Start engine, run the engine for 5 minutes at idle speed, then stop engine. Turn the start switch to the first gear position again, turn on the machine power; toggle the transfer switch of the air-conditioning system to the warm position, make sure the electromagnetism water valve in open position. 4. Wait until the temperature of the engine coolant drops to below 50°C, then remove the radiator filler cap slowly in order to relieve pressure. 5. Open the drain valve under the radiator and the drain valve of engine lubricating oil cooler, drain the coolant to a container. 6. After draining the coolant, close the drain valve under the radiator and drain valve of engine lubricating oil cooler. 7. Check all water pipes and the clamps of the cooling system for damages, make replacement if necessary. Check the radiator for leaks, damage and dirt, clean and repair if necessary. 8. Fill the engine cooling system with cleaning fluid, which is mixed by the water and the sodium carbonate, the proportion of mixture is in every 23 liters of water add 0.5 liters sodium carbonate. The fluid level should be at the engine normal fluid level, and remain stable after ten minutes. Attention: When filling the cleaning fluid, the air must be vented from the lines of the engine cooling system. During the entire cooling system cleaning process, the engine is running with the radiator filler cap open. 9. Keep the radiator filler cap open, start engine, when coolant temperature increases to more than 80C, run the engine for another 5 minutes. 10. Stop the engine and drain cleaning fluid. 11. Fill the engine cooling system with clean water to the normal level, and keep for ten minutes. Keep the water radiator

filler cap open, start engine, when coolant temperature increases to more than 80C, run the engine for another 5 minutes. 12. Stop the engine, drain out the water. If the water being drained is still dirty, the cooling system must be cleaned until the water is clean. Warning: The engine coolant is poisonous, do not drink, please handle it according to the local relevant laws and regulations.
Clean Radiator Fins
Perform following clean procedure if there is any mud or dirt stuck to the radiator. 1. Remove the bolts, take off the rear grill from the rear of the machine. At the same time, remove the connector of the rear work lamp. 2. Clean the dirt and leaves off o the radiator fins with compressed air. Steam or water may be used instead of compressed air.
3. At the same time, check the rubber hoses. If the hoses are found to have cracks or to be hardened by ageing, they should be replaced with a new one. Also, tighten the loose hose clamps.
Engine Air Filter
If the diesel engine generates black smoke or power decreases, the air filter may be plugged and need maintenance. Use the following procedure: 1. Stop the engine and open the engine hood. Attention: To avoid engine damage, never service the air filter when the engine is running. 2. Remove the outer cover of the air filter. 3. Remove the nut on the top of the primary filter element and take out the

primary filter element. 4. Clean the inside of the air filter body. 5. Clean the primary filter element with compressed air (less than 300 kPa), direct the airflow from the inside of the filter element and along its folds. Attention: When cleaning the primary filter element, do not hit it or beat it against anything, this may damage the engine.
6. After cleaning up the primary filter element, perform a lamp inspection. If the eyelet or particle is found on it, or if the gasket or the seal are damaged, replace it with a new primary filter element. 7. Install a clean primary filter element into the air filter housing; keep the primary filter element end seals in uniform contact. Tighten the nut on the top of the primary filter element by hand, do not use tools in order to avoid damages the primary filter element. 8. Clean and install air filter cover, keep air filter gasket and air filter housing uniform contact.
9. After cleaning primary filter element, start the engine, if the engine generates black smoke or power decreases again, replace the secondary filter element with a new one. The primary filter element must be changed after being cleaned 6 times. It

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should be changed every year regardless of how many times it has been cleaned. Change the secondary filter element when changing the primary filter element.
Change Air Filter Secondary Element
When changing the primary filter element also change the secondary filter element. Stop the engine and then open the engine hood. 1. Remove the outer cover of the air filter. 2. Remove the primary filter element. 3. Remove the nut on the top of the secondary filter element and take out the secondary filter element. 4. Clean the inside of the air filter body. 5. Install a new secondary filter element; the seal ring on the end must have uniform contact. Tighten the mounting nut of the secondary filter element by hand. Do not use tools. 6. Install a new primary filter element and the outer cover of the air filter. Tighten the nut on the top of the primary filter element by hand. Do not use tools. Attention: Always replace the secondary filter element. Never attempt to reuse the secondary filter element by cleaning the element.
Diesel Fuel Use and Maintenance
Diesel fuel tank
The diesel fuel tank on this machine is located on the rear of the cab. Its volume is 150 liters. Open the engine hood; you can see the filler of the diesel fuel tank. Take off the filler cap, and then fill diesel fuel. When filling diesel fuel, please do not to take out the filler screen. The filler screen and the diesel fuel tank should be cleaned regularly; the diesel fuel tank may be cleaned according to following method: 1. Remove the flange on the bottom of the diesel fuel tank, 2. Clean the internal surface of diesel fuel tank, loosen the drain plug under the diesel fuel tank, and drain the fuel 3. Repeatedly flush, until the drained fuel
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is clean.
Drain the Sediment and Water in Diesel Fuel
The fuel pump and injection pump nozzle are precision instruments, and if the diesel fuel contains water or dirt, it will not work properly and will wear quickly. You should drain the sediment and water in diesel fuel. The method is as follows: 1. When conditions permit, diesel fuel should be left drained for 24 hours before filling the diesel fuel tank. 2. Before filling fuel, open the drain plug on the bottom of the diesel fuel tank. Drain the sediment and water from the diesel fuel tank every week. 3. In order to vent the saturated air, fill the diesel fuel tank after completing the day’s work. 4. In order to precipitate the sediment and water to the bottom of the diesel fuel tank, 5 to 10 minutes after filling fuel restart the engine. 5. Loosen the drain plug under the diesel fuel pre-filter and diesel fuel primary filter. Drain out the sediment and water after completing the day’s work. Attention: Never wait to fill fuel until the fuel of the tank has run out, this will make the engine stop, and the diesel fuel contains lots of water and sediment, can impact engine proper work.
The Sulfur Quantity in the Diesel Fuel
The sulfur percentage in the diesel fuel affects the engine oil selection and replacement intervals. In the combustion process, the sulfur makes a chemical reaction and generates the sulfuric acid and the sulfurous acid; these acids can corrode the metal surface. So you must select diesel fuel contain less sulfur. Some chemical additives in the lubricating oil include alkali compound, the alkali compound can neutralize the acid. So the oil change intervals should be adjusted by the sulfur quantity in the diesel fuel:

1. If the content of sulfur in the diesel fuel is lower than 0.5%, replace the engine oil according to the intervals specified in Periodic Maintenance section of this manual. 2. If the content of sulfur in the diesel fuel is 0.5%~1%, replace the engine oil according to the half of the intervals specified in Periodic Maintenance section of this manual. 3. If the content of sulfur in the diesel fuel is more than 1.5%, replace the engine oil according to the 1/4 of the intervals specified in the Periodic Maintenance section of this manual.
Replace the Diesel Fuel Filter and Pre-Filter
1. First, clean the peripheral region and the mounting base. 2. Remove the filter with the belt wrench from the mounting base. 3. Remove the gasket on the threaded adapter of the mounting base. Clean up the seal surface of the mounting base with the non- textile fiber cloth.
4. Attach a new gasket to the adapter of the pre-filter mounting base; coat engine oil on the filter seal surface; fill the clean fuel into the filter. 5. Fasten filter on the mounting base by hand, after it contacts the mounting base, turn by an additional 1/2 ~3/4. In order to avoid damaging the filter, do not use the mechanical method to fasten.

Engine Oil Maintenance
Check Engine Oil Level
1. Move the machine to flat ground, stop the engine, and pull up the parking brake lever. 2. After stopping the engine, wait for ten minutes; let the engine oil completely flow back to the engine oil pan. 3. Open the engine hood, the oil dipstick is located on the center of the right side of the engine, the oil filler is located on the front upper of the engine. 4. Draw out the oil dipstick, wipe it with clean cloth, reinsert the engine oil dipstick to the end, draw out again and check, the oil level should between the “L” scale and “H” scale. 5. If the oil level is under the “L” scale, add engine oil; if the oil level is above the “H” scale, loosen the drain plug, drain some oil. Attention: Too much or not enough oil may damage the engine.
Change Engine Oil
When the specified oil change interval occurs, replace the engine oil. Park the machine on level ground, start the engine and wait until the water temperature is at 60°C, then stop the engine. Pull up the parking brake, remove the drain plug on the bottom of the engine oil pan, drain the oil into a container and replace oil filter. Fasten the plug; fill the clean engine oil until the oil level reaches the “H” scale on the dipstick. Run the engine at idle speed, check the oil filter and drain plug for leaks. Stop the engine, wait for about 10 minutes, and let the oil fully drain into the engine oil pan. Check the engine oil level once more, if the oil is insufficient, fill oil to the oil dipstick “H” scale. Attention: Within 15 seconds after engine starts, the engine oil pressure gauge should have the reading. If there is no reading, stop the engine immediately in order to avoid damaging engine, check engine oil level for correct position.

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