3-1

MAINTENANCE

3-2
Never adopt check and repair methods which are not described in this manual.
Repair should be done on solid and plain road.

Preparation Before Repair

Following work should be carried out except some special cases.
• Let the working device close to the ground as shown in drawing
• All operating levers should be set at middle position.
• Pull up the stop brake lever to make brake in work.
• Put pad blocks before and after tyres.
• Lock the front and rear frames by safety lever.

Working Hours Meter:

Check readings on the meter every day to see if the maintenance time is up.
Changlin's spare parts:
Take specified spare parts in the spare parts list to make maintenance and change.

Changlin's Oil:
Adopt oil and lubricant recommended by Changlin (select oil and lubricant with suitable
viscosity according to ambient temperature).

Clean Washing Liquid:

Adopt window-washing liquid for automobile (do not let dirt come in).

Use Clean Oil and Lubricant:

Keep cleanness of oil tank and lubricant tank. Adopt clean oil and lubricant. Do not let oil and
lubricant attach impurities.
Keep cleanness of the machine:
Keeping machine cleanness can make troubles to be found easily. In addition, it should be

3-3
mentioned that grease nipple, ventilating plug and oil ruler should be clean without impurities.

Pay Attention to Oil and Water with High Temperature:

When the engine stops, it is dangerous to drain high temperature oil and coolant and to take out
oil strainer. It should be done when engine is cooled down. The suitable temperature to drain oil
is 20 - 40℃. If it is lower than this temperature, it should be heated up to the said range can drain
then be carried without.

Check Exhausted Oil and Oil Strainer:

After oil and oil strainer are replaced, check oil and the strainer to see if metal grains or other
impurities are existed. Should they are existed in big quantity, contact your Changlin's dealer.

Fuel Strainer:
If the fuel strainer is supplied, do not take it out when adding fuel.

Change of Oil:
Change oil on the place where there is less dust so as to prevent pollution.

Precautions:
When making maintenance, pay attention and observer all precautions.

Guides to Welding:
• Shut off the start switch of the engine.
• You cannot use a voltage over 200V continuously.
• The distance between welding area and the grounding cable should be within 1 m.
• Avoid the seal ring and bearings are between welding area and the grounding cable.
• Never weld steel pipe with fuel or machine oil.
• Draw off the plug of control cable of the speed variator:
Fireproof:
Use clean agent or light oil which is not flammable to clean parts. Do not approach sparkle or
smoke.

Sealing Surface:
When changing O ring or seal cushion, clean seal surface and change with new O ring or seal
cushion. When assembling, put them on correct position.

Check the Frame:

When working in rocky area, check the frame if damaged, check bolts and nuts if they are
loosened, cracked, worn out and damaged.

Attentions to Cleaning:
Never spray the heat radiator.

3-4
Do not allow to splash water upon any electrical devices

Check Before and After Work:

Before working on mud, rain field, snow land or sea bank, check tightness of screw plug and
valve. Clean the loader immediately after the work to avoid to be rusted.
Make more lubrication than usual If the working device is immersed in water, you should fill
lubricant every day.
As the working environment is bad, the maintenance period should be shortened, and lubricant
should be filled frequently.

In Much Dust Environment:

Following points should be noted if working under much dust environment:
• Check the dust indicating lamp of the air filter to see if it is blocked. Clean the air filter more
often.
• Often clean the core of the radiator in order to avoid blocked.
• Often clean and replace fuel strainer.
• Clean electrical devices, especially the start motor and generator to avoid dust to be gathered.

Avoid to Mixing Oils:

Never use mixed oil with different brands. If you have only one kind of oil, which is different
with what you are using, then replace it completely.

Use Changlin's spare parts.

When you replace or fill oil, do not use oi1 with different models.
Except in special case, normally oils can be used as following table:

ITEM TYPES OF LIQUIDS

Machine oil in Engine Mobil 1300 (SAE15W-40-CD)
Transmission Mobil 1300 (SAE15W-40-CD)
GL-5 (SAE80W-90)
Axles (front and rear)
(90EP)
Working Oil Tank GB11118.1-94 Bitter 22
Mineral oil or synthetic cold
hydrocarbon hydraulic oil In winter 32
(L-HM) In 46
summer
Pins and Axles GB/T5671-1995 universal lithium-base ZL-2H

3-5
 grease ZL-3H
SH/T0380-1992 compound lithium-base
grease
Bitter -35 -50
cold
Fuel GB252-1994
In winter -20 -10
Light diesel
In 0 10
summer
Heat Radiator Mobil Antifreeze Liquid

18.1 Generals of Oils, Fuel and Coolant

18.1.1 Oils

• Oils are always used in the engine and in all working devices. They are easily to be
deteriorated due to using conditions (high temperature and high pressure) are bad. It should
strictly follow the operation and maintenance manuals to apply oils. Even oils are clean they
should be still replaced regularly.
• Oils are like blood in human bodies, therefore you should take care to protect them not to be
invaded by impurities (water metal grains, dust etc).
Most troubles are caused by uncleanness of oils. Take great care not to let oils to be invaded by
impurities when replacing or filling oils.

• Never use oils with different brands and grades.

• Be sure Io fill oil as per stipulated amount.

Troubles can be caused if filling more or less oil.

• If oil in all working device are not clean, maybe water or air have come it. You can contact
with your Changlin's dealer.

• When replacing oil, relative oil strainer should be also replaced.

• It is suggested that make regular analysis upon oils to check working conditions. If you hope
so, you can contact with your Changlin's dealer so as to get relative maintenance.

18.1.2 Fuel
• The fuel pump is a precision device and it could not work normally if water or dirt is mixed
with fuel.
• Take great care not to let impurities to be mixed in when replacing or adding fuel.
• It should strictly follow the stipulations in operation and maintenance manual to use fuel.

3-6
 As oil is easily to be condensed under low temperature' (especially below-15℃), therefore it
is very important to change fuel depending on ambient temperature.
• In order to avoid wet air to be condensed into water and come into the fuel tank, if should be
filled up after completion of work every day.
• Drain sediment and water from the fuel tank before starting the engine and 10 minutes after
filling fuel.
• If fuel cannot be sucked up when starting the engine of just after replacement of the strainer, it
is necessary to remove air in pipeline.

18.1.3 Coolant
• As river water has a lot of calcium and other impurities, if it is used, water scale can block the
engine and the radiator so as to lower radiating function and cause high temperature of oil.
Do not use undrinkable water.
• When using antifreeze liquid, be care of precautions in operation and maintenance manual.
• When the loader is delivered, the coolant in it is Meifu Antifreeze Liquid or Suzhou Model
YX-Ⅲ-45℃ top grade antifreeze liquid for automobile.
This kind of antifreeze liquid is effective to prevent corrosion of the cooling system.
This kind of antifreeze liquid can be used for 2 years or 4000 hours continuously, and can also
be use din tropical area.
• The antifreeze liquid is inflammable, so let it never be close to fire.

The concentration of the antifreeze liquid to be used should be based on ambient temperature.
Detailed mixing method can be seen on "24.2.2 Clean Inside the Cooling System".

• If the engine is overheated, let the engine cool down before adding coolant.
• if the level of coolant in the engine is too lower, it can cause overheat and corrosion of the
cooling system.

18.1.4 Lubricant Oil

• The lubricant oil can prevent deformation and noise at connecting place.
• The connecting parts (for example connector and coupling sleeve) not mentioned in
"Maintenance" Part should be treated at the time of overhaul. They do not need to fill
lubricant. If some parts are not flexible due to using for long time, please fill lubricant.
• When filling lubricant, wipe out overflowed lubricant. As lubricant mixed with sands and dirt
can speed up worn-out of connecting pieces, so great care should be taken to wipe them out if
found.

18.1.5 Storage of Oil and Fuel

• Prevent water, dirt and other impurities to be mixed in them.

3-7
• If oil in drum should be stored for a long time, it should be placed in such a way that the filling
port is at the side (to prevent wet air to come in).
If drum-packed oil is placed outdoor, waterproof hood or other protect measures should be
taken.

18.1.6 Strainer
• The strainer is a very important safety part. It can prevent impurities and sediments in fuel to
enter into important device and cause trouble.
Regularly replace all strainers. Detailed procedures can be seen on operation and maintenance
manual.
When working environment is bad, it is necessary to change strainers in a short period of time
based on features of oils and fuel (sulfur contained).
• Do not intend to use the strainer after it (filter screen) is cleaned. It should be replaced with
anew one.
• When replacing new strainer, check if the old one is blocked by metal particles. If so, please
contact with your Changlin's dealer.
• Do not unpack the strainer and its attachments until the time they are used.
• Be sure to use genuine Changlin's strainer and attachments.

18.2 Generals of Electrical System

• If electrical wires are wet or insulation is broken, the electrical system will leak electricity so
as to cause danger.

• Relative maintenance in relation to the electrical system: l) Check tightness of pulley belt of
the fan; 2) Check damage of the pulley belt; 3) Check the height of electrolyte in the storage
batteries.

• Do not remove any installed electrical parts.

• It is not allowed to increase any electrical parts except those stipulated by Changlin.

• Keep the electrical system dry when clean the whole machine of under rain.

• When working on the seaside, carefully clean the electrical system to avoid corrosion.

• The backup power supply should never be connected with fuses, start switch and storage
batteries.

3-8
Consumables such as core of strainer, cartridge of air filter, connecting scraper edge of bolts etc.
Should be replaced within the regular maintenance and worn-out period.

Correctly replace consumables under the principle to use the loader economically.

It should use Changlin’s attachments with superior quality (list of attachment is as follows).

3-9
 S/N CODE NAME SPECIFICATION UNIT QUANTITY REMARKS
1 GB235-76 O ring 8×1.9 piece 4
2 11×1.9 piece 17
3 14×2.4 piece 6
4 16×2.4 piece 2
5 20×2.4 piece 4
6 31×3.5 piece 4
7 32×3.1 piece 2
8 36×3.5 piece 1
9 38×3.5 piece 3
10 40×3.5 piece 2
11 41×3.5 piece 4
12 44×3.5 piece 5
13 48×3.5 piece 1
14 GB3452.1-93 O ring 30×3.55 piece 2

NAME UNIT QUANTITY SEE REMARKE IN DATAILS

Engine set 1 Engine list
attachment
Transmission set 1 ZF providing
filter
Reflector set 2

Select fuel, coolant and lubricant correctly.

Ambient Temperature Oil Amount

3-10
 -32 -4 14 32 50 68 86 104 122℉ Stipulated Adding
Type of
Device -30 -20 -10 0 10 20 30 40 50℃ Amount Amount
Medium
Bottom
Casing of SAE15W-40 19L 19L
Engine
Engine
Oil

Gearbox SAE15W-40 45L 45L

GB1111.1-94 Mineral Bitter cold 22

ZL50F

ZL60F

ZL50F

ZL60F
Hydraulic oil or synthetic
In winter 32
System hydrocarbon hydraulic
oil (L-HM) In summer 46 220L 250L 220L 250L

ZL50F GL-5(SAE80W-90)(90EP) 37L 37L

Axle ZL60H Gl-5(SAE80E-90)(90EP) Front Front
70L/rear 70L/rear
57L 57L

Brake Oil SAE 10W 2×1.5L 2×1.5L

GB/T5671-1995
In winter ZL-2H
universal lithium-
Lubricating
Pin Axle base grease - -
Grease In summer ZL-3H
SH/T0380-1992
compound lithium-
base grease
Fuel Tank Diesel GB252-1994 Bitter cold -35 -50
ZL50F

ZL60F

ZL50F

ZL60F

Light diesel In winter -20 -10

In summer 0 10 300L 350L 300L 350L

Cooling
Water Fill antifreeze liquid 20L -
System

Remarks:
When sulfur content in fuel is lower than 0.5%, it should be replaced in stipulated period of
maintenance in manual.
When sulfur content in fuel is higher than 0.5%, it should be replaced as per following table.

3-11
 Sulfur content in fuel Replace Period
0.5-1.0% 1/2 period of maintenance
higher than 1.0% 1/4 period of maintenance

• When ambient temperature is less than 0℃, it should be ensured that SAE 10W-30 and SAE
15W-40 are used even temperature in daytime is high than 10℃.
• The engine oil should be CF4 of API Grade. If CE and CD oils of API Grade are used, the
replace period should be reduced a half.

Total Volume: it means oil in all parts and pipelines.

Supplementary Volume: during the time to make maintenance and check, oil should be
Supplemented into the system.

SAE: Society of Automobile Engineering

API: American Petroleum Institute

3-12
21.1 Brief Introduction of Tools Used

Tools listed in the table are attached to the machine:

S/N Code Name Specifications Unit Quantity Remarks

1 GB1432-78 Minus head wooden handle 100×6mm piece 1

screwdriver
2 GB1432-78 Minus head wooden handle 150×10mm piece 1
screwdriver
3 GB1433-78 Crosshead wooden handle 100×5mm piece 1
screwdriver
4 GB6295.1-86 Pliers 180mm piece 1
5 GB4388-84 Fixed spanner (11 piece) 6～32mm piece 1
6 GB4388-84 Fixed spanner 50mm piece 1
7 GB4388-84 Double-head fixed spanner 5.5×7mm piece 1
8 GB4388-84 Double-head fixed spanner 32×36mm piece 1
9 GB4388-84 Double-head fixed spanner 41×46mm piece 1
10 GB4440-84 Adjustable wrench 300×36mm piece 1
11 GB5356-85 Socket wrench (7 piece) 3～17mm set 1
12 SG216-80 Round head hammer 0.66kg piece 1
13 WZ40.29.5.1 Hub socket wrench (27～36) set 1
14 Socket wrench (24 pieces) 10～32mm set 1
15 High pressure grease gun piece 1
16 Manometer for tyre 0～0.8Mpa piece 1
17 Angle jaw for retainer ring 175mm piece 1
18 Straight jaw for retainer 175mm piece 1
ring

If any tools in above list are damaged, you can purchase from your Changlin’s dealer.

3-13
21.2 Torque Table

Nominal Diameter of Bolt mm

Strength
Class of
Bolts

6 8 10 12 14 16 18 20
Tightening Torque Nm
4.6 4-5 10-12 20-25 36-45 55-70 90-110 120-150 170-210
5.6 5-7 12-15 25-32 45-55 70-90 110-140 150-190 210-270
6.8 7-9 17-23 33-45 58-78 93-124 145-193 199-264 282-376
8.8 9-12 22-30 45-59 78-104 124-165 193-257 264-354 376-502
10.9 13-16 30-36 65-78 110-130 180-210 280-330 380-450 540-650
12.9 16-21 38-51 75-100 131-175 131-175 326-434 448-597 635-847

Nominal Diameter of Bolt mm

Strength
Class of
Bolts

22 24 27 30 33 36 39
Tightening Torque Nm
4.6 230-190 300-377 450-530 540-680 670-880 900-1100 928-1237
5.6 290-350 370-450 550-700 680-850 825-1100 1120- 1160-
1400 1546
6.8 384-512 488-650 714-952 969-1293 1319- 1694- 1559-
1759 2259 2079
8.8 512-683 651-868 952-1269 1293- 1759- 2259- 2923-
1723 2345 3012 3898
10.9 740-880 940-1120 1400- 1700- 2471- 2800- 4111-
1650 2000 3298 3150 5481
12.9 864- 1098- 1606- 2181- 2968- 3812- 4933-
1152 1464 2142 2908 3958 5082 6577

3-14
In order to ensure the safety of the loader in application course, customer should persist in regular
maintenance. In addition, in order to further rise up the safety, customer should replace parts
listed in the table regularly, because these parts are so important in fields of safety and fireproof.

The materials of these parts will be deteriorated as time goes, or be easily worn out or corroded.
However these parts should be replaced regularly in spite of their application states. It is
necessary to ensure their application features.

If the replacement period does not expire but the abnormal running is found, they should be
replaced immediately.

If hose clip has any damage such as deformation or crack, they should be replaced together with
hoses. When replacing hose, O-ring, seal cushion or some other parts should be also replaced
together. Contact your Changlin’s dealer in order to replace key safety parts.

Key Safety Parts

S/N Key Part To be Replaced Regularly Quantity Time to be Replaced

1 Fuel Pipe (Oil Tank-Oil Spray Pump) 1
2 Fuel Return Pipe (Oil Spray Pump-Fuel Tank) 1
3 Fuel Outlet Pipe (between Nipples) 1
4 Oil Return Pipe for Turbocharger 5
5 Steering Pipe (Pump-amplifying valve) 1
Steering Pipe (amplifying valve-Steering Oil Every two years or
6 2 4000 hours
Cylinder)
7 Steering Pipe (amplifying valve-stop valve) 4 (whichever is first)
8 Steering Pipe (Steering Device-stop valve) 2
9 Steering Pipe (Steering Device-Hard Pipe) 2

3-15
 Cushion, Seal Piece and O Ring of Steering Oil
10 2
Cylinder
11 Brake Oil Pipe (Brake Valve-Front Brake) 2
12 Brake Oil Pipe (Brake Valve-Rear Brake) 1

3-16
3-17
23.1 Schedule Table of Maintenance

Maintenance Items Page

Maintenance of First 100 Hours (only after the first 100 hours)
Replace the strainer in the gearbox 3-19

Maintenance Items
Maintenance of First 250 Hours (only after the first 250 hours) 3-19
Replace the filter screen of the fuel strainer 3-19
Replace the cartridge of strainer of the working oil tank 3-19
Check clearance of air valve of the engine and make adjustment 3-19
Maintenance as Required
Check, clean or replace the cartridge of air filter 3-19
Clean the inside of the cooling system 3-21
Check oil level of the gearbox and fill oil 3-23
Check oil level inside the bridge and fill oil 3-24
Clean the aerator of the bridge casing 3-25
Clean the core of the radiator 3-25

3-18
Replace bolt-connected scraper edge (option) 3-26
Replace scraper teeth 3-27
Check the air conditioner 3-28
Clean the condenser of the air conditioner 3-29
Drain water from the oil-water separator 3-29
Check Before Start
Check height of coolant and fill water 3-29
Check level of fuel and fill fuel 3-30
Check oil level of the engine panel and fill oil 3-30
Check electrical circuit 3-31

Maintenance Items Page

Check stop brake 3-32
Check running brake 3-32
Check the siren and reverse running buzzer 3-32
Check lamps if clean and good 3-32
Check color and sound of exhausted air from the engine 3-32
Check working feature of meters 3-32
Check turning clearance of the steering wheel and working feature of steering device 3-32
Check the position of rearview mirror and if clean and good 3-32
Maintenance every 50 Hours
Check pneumatic pressure of tyres 3-33
Drain water and sediment from the fuel tank 3-33
Lubricate the spline of front middle driving shaft (1 places) 3-33
Maintenance Every 100 Hours
Check oil level in oil tank and fill oil 3-34
Clean element of the air filter at the air inlet of the air-conditioner 3-34

3-19
Lubricate the hinged pin at the rear bridge (3 places altogether) 3-35
Maintenance Every 250 Hours
Replace the engine oil and the screen of the oil filter 3-35
Check tightness of belt on the fan and the generator and make adjustment 3-36
Check if nuts are loosened at the hub and make tightening 3-37
Check tightness of the belt of the compressor of the air-conditioner 3-37
Check the height of electrolyte level of the storage batteries 3-38
Lubrication 3-38
• Hinged pin on scraper bowl (two places) 3-39
• Hinged pin on the connecting rod of the scraper bowl (two places) 3-39
• Hinged pin on the bowl-turning oil cylinder (two places) 3-39
• Hinged pin on the lifting oil tank (four places) 3-39

Maintenance Items Page

Maintenance Every 250 Hours (continued from the last page)
• Hinged place of the lifting arm (two places) 3-39
• Hinged pin on the connecting rod of the scraper bowl (one places) 3-39
• Hinged pin on the steering oil tank (four places) 3-39
Maintenance Every 500 Hours
Replace the filter screen of the fuel strainer 3-39
Replace the cartridge of the oil strainer of the gearbox 3-41
Maintenance Every 1000 Hours
Replace oil in of the gearbox and clean the strainer 3-42
Clean the aerator of the gearbox 3-43
Lubricating 3-44
• Hinged pin on the frame (one place) 3-44
• Front driving shaft (two places) 3-44

3-20
 • Support of the front driving shaft (one places) 3-44
• Middle driving shaft (two places) 3-44
• Rear driving shaft (two places) 3-44
Check fasteners of the turbocharger 3-45
Check clearance of rotor of the turbocharger 3-45
Maintenance Every 2000 Hours
Replace oil in working oil tank and elements of oil strainer 3-45
Replace the cartridge of the aerator of working oil tank 3-47
Replace oil in the bridge casing ★ 3-47
Check weariness of the brake disc 3-48
Check the generator and the start motor 3-48

★ It is stipulated maintenance to replace oil in the bridge casing every 2000 hours. If brake is so
frequent and noise occurs, it should be replaced in shorter time.

Maintenance Items Page

Check clearance of the air valve of the engine and make adjustment 3-48
Check the Vibration Dumper 3-48
Clean and check the turbocharger 3-48
Maintenance Every 4000 Hours
Check the cooling water pump 3-48

3-21
24.0 Maintenance of First 100 Hours
• Replace the strainer in the gearbox

24.1 Maintenance of First 250 Hours

After running for first 250 hours, the new vehicle should be maintained as follows:

• Replace the filter screen of the fuel strainer

• Replace the cartridge of strainer of the working oil tank
• Check clearance of air valve of the engine and make adjustment

Details of replace and maintenance can be seen on "Maintenance Every 500 Hours and

3-22
Maintenance Every 2000 Hours"

24.2 Maintenance as Required

24.2.1 Check, Clean or Replace the Cartridge of Air Filter

ATTENTION
• Never clean and replace the Cartridge of Air Filter when
the engine is running.
• When cleaning the cartridge with compressed air, wear
safety glasses or goggles to protect eyes.

Check
If the red piston of the dust monitor (1) appears, clean assembles of the filter.

Clean or Replace Outside Elements

1. Remove butterfly nuts ② and the cover ③, take out the
outer cartridge
2 Clean inside the air purifier
3. Flush with dry compressed air (max. 700 kPa (7 kg/cm2))
from the inside of the cartridge along the folded mark, and
flush the inside and the outside as well.
1) Once outside parts are cleaned, remove its seal piece
on it.
2) Replace the outer cartridge if it has cleaned 6 times or
used for over 1 year, and replace the inner cartridge as
well.

3) If the dust indicator flashes when the outer cartridge is

used after cleaned, then outer and inner cartridges
should be all replaced whatever the outer cartridge has
been cleaned 6 times or not.
4) Check if nuts of the inner cartridge are loose, and
tighten them if needed.
5) Replace the seal pad ⑤ of the butterfly nut ④ if

3-23
 broken.

Attention:
After the cartridge has been cleaned and dried, check with
lamp. If orifice or particles found, replace the cartridge.
When the cartridge is cleaned, do not let it touch other things.
Do not use the cartridge whose folding seam or seal piece or
pad has been damaged.

4. Mount clean cartridge.

Replace the Inner Cartridge

1. First take out the outer cartridge and then take out the inner
cartridge.
2. In order to prevent dust entering, cover the exit of the
outlet pipe by clean cloth or ribbon.
3. Clean inside the air purifier and take out the case, which is
installed in the second step when assembling.
4. Replace a new inner cartridge, and fix it with nuts. Never
clean and reuse it.
5. Mount the outer cartridge.

Spare parts are needed if following approaches are used.

Water
Clean inside with high pressure water (no higher than 294.2
kPa (3 kg/cm 2 )) from inside of the cartridge along the folded
mark, and then clean the outside and the inside as well.

Clean Agent
If removing oil, grease or carbon like on the elemen t, first
clean them with lukewarm clean agent with thin concentration,
then clean them on clean water and cool them dry.

Or you can use compressed air (no higher than 700 kPa (7 kg/cm2)) to blow from the inside to
the outside to reach fast dry.
Never heat the element.
Use lukewarm (about 40℃) instead of soap water can get better results.

24.2.2 Clean the Inside of the Cooling System

3-24
 ATTENTION
• When the engine stops running, cooling water is very hot
and can injury persons. So you can drain water only after
it is cooled down.
• As cleaning work is done when the engine is running, it is
quite dangerous to enter into the lower part of the machine
body as the loader could start in a sudden. Therefore When
the loader is working, never enter into the lower part of
the machine.
• When the loader is at working temperature, never take out
the cover on the inlet of the radiator because the boiling
water with pressure and steam could come out to injury
persons. Only when the engine is cooled down, and touch
the cover on the inlet to feel if it is cooled, then turn the

• When clean or replace cooling water, park the loader on the plain ground.
• Adopt the antifreeze agent with fixed brand. If it is impossible due to some reasons, please use
the antifreeze agent with ethylene and ethylene glycol.
• Be ensured that the replaced screen is made of stainless steel.
• Clean the cooling system as per following table, and replace cooling liquid and antirust agent.

Clean Cooling System Replace

Type of Coolant
and Replace Coolant Antirust Agent
Antifreeze agent with fixed Every year (in autumn) or
brand (used m four seasons) every 2000 hours
Every 1000 hours
Non-fixed brand of Every six months (in
or when cleaning
antifreeze agent with spring and autumn)
the inside of the
ethylene and ethylene glycol (removing preservative in
cooling system or
(used in winter) spring and adding
replacing coolant
preservative in autumn)
Antifreeze agent is not in Every 6 months or every
use 1000 hours

• Define the mixing ratio of preservative and water depending on the lowest temperature in
locality and the following table.
Actually, when defining the mixing ratio, it will be better if assuming the temperature i n
locality 10℃ below than normal.

3-25
 The Mixing Ratio between Water and Preservative

Lowest Ambient
℃ -13 -19 -23.5 -33.5 -40 -45
Temperature
Amount of
Antifreeze Agent Meifu 50 60 70 80 90 100
(volume in %) Antifreeze
Amount of Water Liquid
50 40 30 20 10 0
(volume in %)
Lowest Ambient
℃ -12 -17 -22 -28
Temperature
Value of Suzhou
1 1 1 1
Antifreeze Agent Model
Value of Water YX-III 1 0.75 0.5 0.25

ATTENTION
The antifreeze agent in inflammable do not let it approach
Fire.

• Take running water as cooling water. If water from river, well or other sources should be used,
contact with your Changlin's dealer.
• We suggest you to control mixing ratio according to the Concentration Table of the Antifreeze
Agent.

1. Turn the cover ② of the radiator slowly, then take it

down.

2. Prepare a container to fill cooling water, open the drain

valve ③ located at the lower left part of the radiator to
drain cooling water.

3. Close the drain valve after cooling water removed and add
new running water.

4. After water is filled in the radiator, start the engine to let it

at idling state.

3-26
 Open the water drain valve ③, the engine is at idling state,
add water continuously for 10 minutes.
When above work is carrying out, adjust speed of water
adding and draining to keep water full in the radiator.
When adding water, be care the hose of water adding does
not disconnect with the water inlet of the radiator.

5. After above work is finished, close the engine and open the water drain valve ③, drain all
water and close it again.

6. After completion of water draining, clean with cleaning agent. Details can be seen on
cleaning method and the description on cleaning agent.

7. After completion of cleaning, open the water drain valve ③, drain all cooling water and close
it tightly, then add clean running water.

8. When the height of water is closing to the water inlet, open the water drain valve③ to start
the engine at idling state to make cooling water to be circulated repeatedly until drained water
is clean.
When above work is carrying out, adjust speed of water adding and draining to keep water
full in the radiator.

9. When water is completely clean, close the engine and the water drain valve ③ as well.

10. Add cooling water until it is over filled.

11. In order to remove air from water, let the engine run at idling state for 5 minutes. During
this period, the cover of the radiator should be taken out.

12. After closing the engine for three minutes, add cooling water up to the water inlet, close the
cover and confirm it is tightened.

24.2.3 Check oil level of the gearbox and fill oil

ATTENTION
• When checking the height of oil, make stop brake working
and lock the front and rear frames by safety lever and pin.

• When the engine stops, oil temperature is high. You should

carry out following procedures only when oil temperature
is cooled down.

3-27
If oil in the gearbox has any abnormality or oil is mixed in
cooling water, carry out following procedures:
1. Start the engine at least for 5 minutes.
2. Open the cover of oil filling port (F), take out the mark
ruler (G) and wipe oil out by cloth.
3. Insert the oil mark ruler (G) into the filling port until the
bottom, then take it out.
4. Oil should be between the marks "H" and "L" on the oil
mark ruler (G). If oil level is lower than the mark "L", fill
oil from the oil filling port.
Referring to oil, see details in "20. Apply Fuel, Coolant
and Lubrication Oil Depending on Temperature of
Environment".
5. lf oil level is high than the mark "H", drain excess oil from the drain plug (P) and recheck the
oil level again.
6. If the height of the oil level is correct, insert the oil mark ruler in the inlet pipe and turn the
oil inlet cover tightly.

24.2.4 Cheek Oil Level Inside the Bridge and Fill Oil

ATTENTION
• When checking the height of oil, make stop brake working
and lock the front and rear frames by safety lever and pin.

• When the engine stops, oil temperature is high. You should

carry out following procedures only when oil temperature
is cooled down.
If oil in the bridge casing has any abnormality, car ry out
following procedures:
Check on the plain road (if the road is uneven, the measured
height of oil level is incorrect.

1. Close the engine and take out the measuring meter.

2. Wipe out oil on the oil level meter connected with the
measuring meter by wet cloth.
3. Set the oil level meter (G) at the place shown on the right
drawing.
4. If the oil height in between two lines on the oil meter, it is
correct. If it is less than the lower line, fill oil from the inlet

3-28
 port (F) of the bridge casing.

Referring to oil, see details in "20. Apply Fuel, Coolant and

Lubrication Oil Depending on Temperature of Environment".

5. If oil level is high than the higher line, drain excess oil
from the drain plug (P) and recheck the oil level again.

6. If the height of the oil level is correct, set the measuring

meter well.

Tighten torque: 132±39 Nm (13.5 ± 4 kgm)

24.2.5 Clean the Aerator of the Bridge Casing

ATTENTION
When cleaning, make stop brake working and lock the front
and rear frames by safety lever and pin.

Cleaning soil and dirt around the aerator by the brush.

When cleaning aerator, clean the aerator before and after the
bridge.

24.2.6 Clean the Core of the Radiator

If any soil or dirt is found on the radiator, carry our following

procedures:

1. Take out the bolts, open the protect grid on the tail of the
loader, and remove the plug of the tail lamp.

3-29
2. Clean soil and dust stuck on the radiator by compressed air. It is also possible to clean by
steam or water without pressure.

24.2.7 Replace Bolt-Connected Scraper Edge (Option)

ATTENTION
When adjusting or replacing scraper edge, any action of the
working device is very dangerous.
Set the working device at the fixed position and shut the
engine.

Change or replace the scraper edge when it is worn out but not reach the edge of the bowl.

1. Lift the scraper bowl to a suitable height. It is necessary to put pads underneath to avoid its
falling down.
Lift the scraper bowl to make its bottom to be horizontal.

2. Take down nuts and bolts ①, and take out the scraper edge.

3. Clean the connecting parts of the scraper edge ②.

4. Change the position of the scraper edge ②, and refit on the

scraper bowl. When mounting the scraper edge after
changing position, it should set on the place symmetrical to
the original position (the left scraper edge lies on the right
side and the right scraper edge lies on the left side).
If both edges of the scraper have been worn out, finish the
connecting surfaces before mounting.

5. Tightening all bolts and nuts to prevent clearance left between scraper bowl and edges.
The maximum torque of bolts and nuts: 745.3±107.9 Nm (76±11 kgm).

6. Retightening all bolts and nuts after working for several hours.

3-30
24.2.8 Replace the Scraper Teeth

ATTENTION
When replacing scraper teeth, any action of the working
device caused by error action is very dangerous.
Set the working device at the fixed position and shut the
engine.

After the scraper teeth are worn out, replace them as per
following procedures:

1. Lift the scraper bowl to a suitable height. It is necessary to

put pads underneath to avoid its falling down.
Lift the scraper bowl to make its bottom to be horizontal.

2. Take down bolts ① and nut ②, and then take out the
scraper teeth ③.

3. Clean the connecting parts of the scraper teeth ③.

4. Refit the new scraper teeth on the scraper bowl. Meanwhile, insert thin wooden piece to
remove clearance between the scraper teeth and the scraper bowl.
Continuously insert thin wooden piece until the thin wooden piece with the thickness of 0.5
mm couldn't be inserted. If connecting surfaces have been worn out, finish them before new
teeth are mounted.

5. In order to prevent clearance left between scraper teeth and the bowl, regularly tighten bolts
and nuts and knock tightly by the hammer.
The tightening torque of bolts: 902 ± 39 Nm (92 ± 4 kgm).

6. Retighten all bolts after the loader has worked for several hours.

3-31
24.2.9 Check the Air Conditioner

Check twice every year in spring and autumn separately.

Check the level of refrigerant.

ATTENTION
If liquid inside stuck on eyes or hands it will damage the sight
and make skin to be frozen, therefore do not loosen any parts
on the circuit of refrigerant.

Let the cooler of the air conditioner work 5 to 10 minutes, then touch the high pressure part and
low pressure part (or connectors of hose of high pressure and low pressure) by hand. Meanwhile,
check flowing of refrigerating bubbles (R134a) via the view glass in order to check density of
bubbles.
Please contact with Changlin's dealer for details of check.
The view glass is mounted on the energy accumulator on the side of condenser.

State of Cooler Normal Abnormal

Temperature of High pressure pipe is hot High pressure pipe is Almost no
high pressure and low pressure pipe is warm and low pressure temperature
pipe and low cold, the temperature pipe is cold, the difference between
pressure pipe difference is obvious temperature difference is high pressure pipe
not obvious and low pressure pipe

3-32
 View glass Transparent Air bubbles always exist, There is turbid
No bubbles if the engine sometimes they are substances flowing
increases or decreases transparent, sometimes
speed white bubbles appear

Connection Quite normal Some dirt in oil Some substances in

between pipes oil are very dirty
Normal state of Level of coolant is Some places have Almost all coolant is
the cooler normal without leakage. Contact with leaked, contact with
abnormality and can be repairing shop to make repairing shop
used check immediately

24.2.10 Clean the Condenser of the Air Conditioner

ATTENTION

Do not use high pressure water to flush the condenser,

otherwise it will be heated up to be damaged.

If there is mud or dirt on the condenser of the air conditioner, wash them out by water.
If water pressure is too high, the core will be deformed. Therefore when use high pressure water
to wash, it should keep a suitable distance.

Cleaning Method
1. Open the cover of the condenser on the right side of eh driving cab.
2. Remove bolts from the condenser.
3. Clean the condenser from the upper part of the condenser (by water).

24.2.11 Drain Water from the Oil-Water Separator

When the floating core reaches or surpasses the redline, drain water according to following
procedures.
1. Loosen the drain plug and the ventilating plug (if available) to drain gathered water until the
floating core reaches at the bottom.
2. Tighten the ventilating plug (if available) and the drain plug.
3. If exhausting air with the same style to drain water, see “24.7 Maintenance Every 50 Hours”

3-33
 of the screen of the fuel strainer.

24.3 Check Before Start

24.3.1 Check Height of Coolant and Fill Water

ATTENTION
Normally do not open the cover of the radiator. Let the engine
cool down before checking the height of level in water tank.

1. After completion of water adding, tighten the cover.

2. If the water tank is empty, check if there is something leak, then add water to the radiator.

24.3.2 Check Level of Fuel and Fill Fuel

ATTENTION
When adding fuel, never let fuel to be overfilled, otherwise it
can cause fire. So if overfill is found, wipe it out thoroughly.

Check the level of fuel through the oil mark ruler on the oil tank.

After that, add fuel from the oil adding port (F).

Referring to usage of fuel, see “20. Apply Fuel, Coolant and

Lubrication Oil Depending on Temperature of Environment”.

After fuel is filling up, turn the cover tightly.

Fuel amount: 300 L.

24.3.3 Check Oil Level of the Engine Panel and Fill Oil

First open the door on the side of the engine casing at the rear
part of the loader.

3-34
Then take out the oil ruler (G), and wipe oil out by cloth.

Insert the oil ruler (G) completely into the oil inlet pipe, and
take it out again.

The level of fuel should be between marks L and H on the oil

ruler (G). If the oil level is lower than the mark L, fill the
engine oil from the inlet (F).

Referring to usage of oil, see “20. Apply Fuel, Coolant and. Lubrication Oil Depending on
Temperature of Environment”.

If the oil level is higher than the mark H, drain excess oil from the oil drain plug (P) and recheck
the oil level again.

If the oil level is correct, cover the oil inlet and turn tightly, then close the door of the engine
casing.

Attention:
If the engine just worked, you should check the oil level at least 15 minutes after the engine goes
out.
If the loader is parking on the slope, you should let it on the plain ground first and make check
then.

24.3.4 Check Electrical Circuit

ATTENTION
• If the fuse in electrical circuit is often broken or cause short
circuit, find reasons and make repair.
• Inflammables (such as fallen leaves, branches and grass)
gathered around the storage batteries could cause fire, so
they should be clear out.
Check electrical circuit to see if there is broken fuse, if short circuit or broken circuit is existed.
Meanwhile, check if connections are loosened, If found, tighten it.

Following positions should be checked carefully:

• Storage batteries

3-35
• Start motor
• Generator

When making touring check or make check before start, check if there is flammables around the
storage batteries, and clear them out if found.

Referring to causes of trouble and their remedies, contact with your Changlin’s dealer.

24.3.5 Check Stop Brake

ATTENTION
Even the lever of the stop brake valve is pulled up, it is still
dangerous before the brake lamp lights. So the brake step
tread should be also stepped down.

Inspection Condition
• Pneumatic pressure of tyres: specified value
• Road surface: rough road surface with 1/5 slope (5○20’)
• Loader: working state

Inspection Method
1. Start the engine, make the loader run against the slope, let
the scraper be empty and run up on the slope.
2. Step down the brake tread to stop the loader, recover the
direction lever to the neutral position, then shut the engine.

3-36
3. Pull up the lever of the stop brake valve, release the brake
step tread slowly and check if the loader is still on the
original position.

24.3.6 Check the Stop Brake

Drive the loader on rough and dry cement road with the speed of 34 km/h, check if the distance
of brake sliding is less than 17 m.

Carefully check the brake system before driving the loader every day to see if leakage exists. Fill
up oil in the pond of the brake assistor. During the whole working period, the oil in the pond
should be at least kept above half the level and air should be exhausted from the brake hydraulic
part after oil is filled up.

24.3.7 Check the Siren and Reverse Running Buzzer

24.3.8 Check Lamps if Clean and Good

24.3.9 Check Color and Sound of Exhausted Air from the Engine

24.3.10 Check Working Features of Meters

24.3.11 Check Turning Clearance of the Steering Wheel and Working Feature of Steering
Device

24.3.12 Check the Position of the Rearview Mirror and if Clean and Good

24.4 Maintenance Every 50 Hours

24.4.1 Check Pneumatic pressure of Tyres

First of all check pneumatic pressure of tyres before working when tyres are cooled.
Pneumatic Pressure of Standard Tyres:
Standard Tyres 20.5-25-16PR (L3 rock):
Front Tyres: 343.2kPa (3.5kg/cm2)
Rear Tyres: 343.2kPa (3.5kg/cm2)

Large-Scale Tyres 23.5-25-16PR (L3 rock):

Front Tyres: 343.2kPa (3.5kg/cm2)
Rear Tyres: 304.0kPa (3.2kg/cm2)

Attention:
Suitable pneumatic pressure shall differ with different working conditions. See “12.8 Usage of

3-37
Tyres” in details.

24.4.2 Drain Water and Sediment from the Fuel Tank

Loosen the valve ① on the right side of the fuel tank to drain sediment, water and oil together.

24.4.3 Lubricate the Spline of Middle Driving Shaft (1 place)

ATTENTION
• Make the stop brake in effect and lock the front and back
frames by the safety lever and the pin.
• Set the working device in the fixed position and shut the
engine.

1. Use the grease gun to fill lubricant oil into the oil nipple as
shown on the drawing.

2. After lubricating, wipe out excessive useless lubricant oil.

24.5 Maintenance Every 100 Hours

The Maintenance Every 50 Hours should be carried out simultaneously.

24.4.1 Check Oil Level in the Hydraulic Oil Tank and Fill Oil

ATTENTION

3-38
 • When taking out the cover of the oil filling port, oil could
be sprayed out. Therefore you should shut the engine first,
and turn the cover slowly after oil temperature is cooled
down in order to release internal pressure, and take out the
cover at last.
• If filling excess oil beyong the mark, you should shut the
engine first, and drain excess oil from the oil drain plug
after hydraulic oil is cooled down.
1. Lower the scraper bowl down to close the ground, shut the engine or 5 minutes, then check
the view glass.

Attention:
Do not fill oil if oil level is above he mark, otherwise the hydraulic device will be damaged and
oil could be sprayer out.

2. If oil level is below the oil mark, open the check cover and fill oil from the filling port.
Referring to the usage of oil, see details in “20. Apply Fuel, Coolant and Lubrication Oil
Depending on Temperature of Environment”.

24.5.2 Clean Element of the Air Filter at the Air Inlet of the Air-Conditioner

ATTENTION
When using compressed air, wear safety goggles or other
necessary safety tools

After using air-conditioner, clean the air filter.

When cleaning elements of the air-conditioner, first shut the air-conditioner.

1. Flush with dry compressed air (max. 700 kPa (7 kg/cm 2)) from the inside of the cartridge
along the folded mark, and flush the inside and the outside as well.

24.5.3 Lubricate the Hinged Pin at the Rear Bridge (3 places Altogether)

ATTENTION

3-39
 • Make the stop brake at the brake state and lock the front
and back frames by the safety lever and the pin.
• Set the working device in the fixed position and shut the
engine.

1. Use the grease gun to fill lubricant oil into oil nipple as
shown on the drawing.

2. After lubricating, wipe out excessive useless lubricant oil.

24.6 Maintenance Every 250 Hours

The Maintenance Every 50 Hours and Every 100 Hours should be carried out simultaneously.

24.6.1 Replace the Engine Oil and the Screen of the Oil Filter

ATTENTION
When the engine just finished work, oil temperature is high,
so do not change oil immediately. Change oil when it is
cooled down.

Preparations:
• Volume of Oil Container: at least the container with volume of 28 liter
• Changed Oil Amount: 28 liter
• Wrench of the oil strainer

1. Open the door at the left side on the engine casing of the loader.

2. Open the oil filling port (F).

3. Place the oil container under the oil drain plug (p).

4. Loosen the oil drain plug (p) to drain oil.

5. Check drained oil. If more metal particles or impurities are

found, please contact with your Changlin’s dealer.

6. Mount the oil drain plug (P) well.

7. Open the door at the left side on the engine casing of the

3-40
 loader.

8. Use the wrench of the oil strainer to takeout the filtering

screen in counterclockwise direction.

Caution! If carry out such operation when the engine is just shut, a lot of oil will rush out.
Therefore do it after waiting 10 minutes.

9. Clean the support of the oil strainer. Fill engine oil into the
new screen, then coal engine oil (or thin layer of lubricant
oil) on the seal mouth of the new screen and screw, then
making installation.

10. When installing, put the sealing mouth on the support of

the oil strainer, and rotate 3/4 to 1 turn.

11. After the screen is installed, fill engine oil from the oil strainer (F) up to the level between
marks H and L on the oil ruler.
Referring to usage of oil, see details in “20. Apply Fuel, Coolant and Lubrication Oil
Depending on Temperature of Environment”.

12. Start the engine and make it running at idling speed for a not too long time, then shut the
engine to check if the oil level is between marks H and L on the oil ruler. Details can be
seen on “24.3 Check before Start”.
Even the engine has not run for 250 hours but already for six months, oil and the screen
should be also changed.

Likewise, if the loader has not run for six months but already for 250 hours, oil and the
screen should be also changed as well.
Use CD oils of API Grade. If CC oil should be used, the time to change oil and the screen
should be shortened a half (125 hours).

24.6.2 Check Tightness of Belt on the Fan and the Generator and Make Adjustment

Check
Exert a force about 6 kg by finger on the middle of the belt on
the fan and the generator. The deformation of the belt in normal
direction is about 7.5 mm.

3-41
As the engine has a automatic belt tensioner A therefore no
need to make adjustment.

24.6.3 Check if Nuts are Loosened at the Hub and Make

Tightening

If nuts ① of the hub are loosened, they’ll speed up weariness

of tyres and cause accident to be happened.

1. Check if nuts are loosened. Tightening if needed.

When checking if nuts are loosened, you should check from tightening direction.
Tighten torque: 927 ± 103 Nm (94.5 ± 10.5 kgm)

2. If any bolts are damaged, all bolts on the wheel should be replaced.

24.6.4 Cheek Tightness of the Belt of the Compressor of the Air-Conditioner, and Make
Adjustment

Check
Exert a force about 10 kg by thumb on the middle of the belt on the compressor and the fan. The
deformation of the belt in normal direction is about 11 to 15 mm.

If the belt measurement meter is used, the pulling force kept with 36-54 kg is reasonable.

Check When V-Belt is Replaced

Exert a force about 10 kg by thumb on the middle of the belt on the compressor and the fan. The
deformation of the belt in normal direction is about 8 to 11.5 mm.

If the belt measurement meter is used, the pulling force kept

with 54 - 76 kg is reasonable.

Adjustment

Loosen nuts ① to move the compressor ② so as to adjust

the tension of the belt.

Check each pulley to see if damaged, if V-shaped grooves and

V-belt are worn out. Special care should be taken that V-belt
cannot touch the bottom of V-shaped groove.

When belt is completely loosened and couldn't be adjusted or

there is cutting trace or cracks on it, then replace belt.

3-42
When adjusting V-belt, you cannot use round pole instead of wrench to move the compressor

24.6.5 Check the Height of Electrolyte Level of the Storage Batteries

ATTENTION
• Never let sparkle to be closed to the storage batteries in
order to prevent explosion.
• The electrolyte is very dangerous to human body. If it is
stuck by eyes or skin, it should be flushed by a lot of
water and go to see doctor.

Make such a check before the loader starts to work.

1. Open the cover of the storage batteries box.

There are two storage batteries: equipped on both sides of
the tail part of the loader.
2. Remove the cover ①, check the height of the electrolyte if
it is at the specified height (10 to 12 mm from the bottom
of the box). If the level of the electrolyte is too lower, add
distilled water up to the specified height. If the electrolyte
is over-filled, add thin sulfur acid.
3. If any electrolyte tank ① is filled with distilled water, all other electrolyte tanks should be
also added With distilled water.
4. Clean the vent hole on the cover of the storage batteries, then turn the cover tightly.

Attention:
If fill distilled water in winter, you should fill before work in the morning in order to prevent
from condensation.

24.6.6 Lubrication

ATTENTION
• Make the stop brake in effect and lock the front and back
frames by the safety lever and the pin.
• Set the working device in the fixed position and shut the
engine.

1. Use the grease gun to fill lubricant oil into the oil nipple as shown on the drawing.

3-43
2. After lubricating, wipe out excessive useless lubricant oil.

1. Hinged pin on the scraper bowl (two places)

2. Hinged pin on the connecting rod of the scraper bowl (two places)
3. Hinged pin on the bowl-turning oil cylinder (two places)
4. Hinged pin on the lifting oil tank (four places)
5. Hinged place of the boom arm (two places)
6. Hinged pin on the rocking arm (one places)
7. Hinged pin on the steering oil tank (four places)

24.7 Maintenance Every 500 Hours

The Maintenance Every 50 Hours, 100 hours and 250 Hours should be carried out
simultaneously.

24.7.1 Replace the Filter Screen of the Fuel Strainer

ATTENTION

3-44
 • When the engine just finished work, the engine has higher
temperature. You can only replace the strainer when the
engine is cooled down.
• Never let sparkle to be closed to fuel.

Prepare the wrench and the container to fill fuel.

1. Open the door on the left casing of the loader.

2. Place the container under the filtering screen to receive drained fuel.

3. Use the wrench of the filter to turn the filtering screen in counterclockwise direction and take
it down.

4. Clean the filter support, fill clean fuel on the new filtering
screen, coat engine oil on its and install it on the support of
the filter.

5. When installing, tightening until screen and the sealing

surface of the support are combined completely, then
further rotate about 2/3 turn. If rotate too tight, the sealing
surface could be damaged to cause leakage of fuel
however if rotate too loose, fuel can also be leaked.
Therefore the tightness should be suitable.

6. After replacing the screen ①, loosen the air drain plug ②.

7. Draw out the connecting lever ③ from the oil filling pump, shake the pump up and down to
suck fuel until no air is exhausted from the drain plug.

8. After air is exhausted, tighten the ventilating plug and press into the connecting lever of the
oil filling pump and tighten it.

ATTENTION
When rocking the crankshaft of the engine, be ensured that it
is safe roundabout as the engine could be started.

9. After replacement of the filtering screen, turn the key in the start switch to the position
START. In the initial seconds there will be air bled, then the engine will be started. When the
engine is started, check if leakage exists in sealing part of the strainer. If so, check if the

3-45
 screen is tightened. Replace it if damaged or if impurities and dust on it, then repeat
procedures from 4. to 9. to install it.

24.7.2 Replace the Cartridge of the Oil Strainer of the Gearbox

• Prepare a container to receive oil.

1. Place the container under the oil strainer to receive drained oil.

2. Remove the oil drain plug on the bottom of the strainer casing to drain oil. After drained, turn
the oil plug tightly.

3. Hold the strainer casing to loosen the central bolt on the bottom, then take out the strainer
casing.

4. Take out the cartridge and clean the inside of the strainer casing.

5. Replace with new sealing pad and O ring. Before installing, coat clean engine oil on the
sealing pad and O ring.

6. Install the new cartridge into the strainer casing and turn the central bolt tightly.

Tighten torque: 76.5 ± 11.8 Nm (7.8 ± 1.2 kgm).

7. Start the engine and set it at the idling state without long time. Then check the height of oil to
see if it is suitable. Details can be seen on “24.2 Maintenance When Required”.

3-46
24.8 Maintenance Every 1000 Hours
The Maintenance Every 50 Hours, 100 Hours, 250 Hours and 500 Hours should be carried out
simultaneously.

24.8.1 Replace Oil in Gearbox

ATTENTION
When the loader just finished work, oil temperature is high.
Make maintenance only when the oil temperature is cooled
down.

The container to fill drained oil: at least 45 liter

Oil amount to be replaced: 45 liter

1. Place the container under the oil drain plug (p), then take
out the oil drain plug (P) to drain oil.
In order to prevent oil rushing out, you should loosen it
slowly then take out the oil drain plug (p).

2. After oil is drained, place the oil drain plug (p) well.

Tighten torque: 68.6 ± 9.8 Nm (7.0 ± 1.0 kgm).

3. Place the container under the strainer of the gearbox.

4. Take out the oil drain plug of the strainer of the gearbox to drain oil, then turn the oil drain
plug tightly.

Tighten torque:107.9 ± 14.7 Nm (11 ± 1.5 kgm).

3-47
5. Fill the engine oil with specified amount into F from the
strainer.

Referring to usage of oil, see details in “20 Apply Fuel.

Coolant and Lubrication Oil Depending on Temperature of
Environment”.

6. After oil is filled, check if it is up to specified amount.

Details can be seen on “24.2 Maintenance when
Required”.

7. Check from the gearbox and the strainer to see if there is leakage.

24.8.2 Clean the Aerator of the Gearbox

Clean mud and dirt around the aerator then take out the ventilating plug, add clean cleaning liquid
to wash the aerator.

When taking out the aerator, be care not let dust and impurities enter into from the ventilating
hole.

24.8.3 Lubrication

ATTENTION

3-48
 • Make the stop brake in effect and lock the front and back
frames by the safety lever and the pin.
• Set the working device in the fixed position and shut the
engine.

1. Use the grease gun to fill lubricant oil into the oil nipple as shown on the drawing.
2. After lubricating, wipe out excessive useless lubricant oil.

1. Hinged axles on the frame (two places)

2. Front driving shaft (two places)

3. Middle Support of the front driving shaft (one places)

4. Middle driving shaft (two places)

3-49
5. Rear driving shaft (two places)

24.8.4 Check Fasteners of the Turbocharger

Referring to check in this field, you can contact with your Changlin’s dealer.

24.8.5 Check Clearance of Rotor of the Turbocharger

Referring to check in this field, you can contact with your changlin’s dealer.

24.9 Maintenance Every 2000 Hours

The Maintenance Every 50 Hours, 100 hours, 250 Hours, 500 Hours and 1000 Hours should be
carried out simultaneously.

24.9.1 Replace Oil in Working Oil Tank and Elements of Oil Strainer

ATTENTION
When the loader just finished work, oil temperature is very
high. Oil replace should be waited until oil is cooled down.
When opening the cover of oil inlet port, you should turn it
slowly to release pressure inside the box, then take it down.

3-50
Preparation:
• Volume of the container to fill drained oil: 220 liter
• Oil amount to be filled: 220 liter

1. Place the scraper bowl horizontally on the ground, to let the

loader stop brake and shut the engine.

2. Remove the screw ① and the cover ②.

3. Open the cover ③ of the oil filling port.

4. Place the container to be filled with oil under the oil drain
plug ④.

5. Remove the oil drain plug to drain oil.

6. After draining oil, install the oil drain plug and turn the
cover tightly.

7. Loosen the two tightening bolts on the cover of the strainer on the top of oil tank, and
remove the cover.

8. Take out elements such as cartridges etc.

9. First check inside the strainer casing to see if impurities exist, then clean it.

10. Replace with the new cartridge and mount the elements in order. If O-ring on the cover has
been damaged and deteriorated, remove the new one.

11. Install bolts on the cover, press the cover and tighten all bolts evenly.

12. Fill specified amount of oil from the oil filling port, then install the cover.
Referring to the usage of oil, see details in “20. Apply Fuel, Coolant and Lubrication Oil
Depending on Temperature of Environment”.

13. Check the level of hydraulic oil to see if it is within specified height. Details can be seen in
“24.5 Maintenance Every 100 Hours”.

3-51
14. Start the engine and let it at idling state, make oil cylinders of steering, scraper bowl and
lifting boom working for 4 to 5 reciprocations. It should be noted that do not let the oil
cylinder run to its end of stroke (about 100 mm far from the end of the stroke).
Attention: If the engine runs directly at high speed or the oil cylinder run to its end, the gas
in the cylinder can damage the cushion of the piston.

15. Then operate the oil cylinders of steering, scraper bowl and lifting boom to its end of the
stroke for 4 to 5 reciprocations.

16. Check the level of hydraulic oil and fill oil to the specified height. Details can be seen on
“24.5 Maintenance Every 100 Hours”.

17. Then rise up the speed of the engine and repeat steps 15, exhaust air until all air is
exhausted.

18. Check the level of hydraulic oil to see if it is at the specified height. Details can be seen on
“24.5 Maintenance Every 100 Hours”.

19. Check fixing parts on the cover of the oil strainer to see if oil is leaking.

24.9.2 Replace the Cartridge of the Aerator of Working Oil Tank

ATTENTION
When the loader just finished work, oil temperature is very
high. Oil replace should be waited until oil is cooled down.
When opening the cover of oil inlet port, you should turn it
slowly to release pressure inside the box, then take it down.

1. Take out the oil filling cover.

2. Take out the clip ring of the aerator and open the cover of the aerator.
3. Replace with the new cartridge of the aerator and install the cover.
4. Turn the oil filling cover tightly.

24.9.3 Replace Oil in the Bridge Casing

3-52
 ATTENTION

When the loader just finished work, oil temperature is very

high. Following operations should be done only after oil
temperature is cooled down.

Preparation:
• Volume of the container to fill drained oil: at least 74 liter
• Oil amount to be replaced: 37 liter (for front and rear bridges each)

1. Place the container under the oil drain plug (P).

2. Open the oil filling plug on both front and rear bridges,
then open the oil drain plug (P) to drain oil.
3. After oil is drained, clean the oil drain plug (P) and install
it.
4. Fill oil from the oil filling plug to the specified height.
Referring to the usage of oil, see details in “20. Apply
Fuel, Coolant and lubrication Oil Depending on
Temperature of Environment”.
5. After oil if filled, check the level if it is within the
specified height. Details can be seen on “24.2
Maintenance When Required”.

Attention:
If brake is used frequently, the replacement period of oil in the bridge casing should be shortened.

24.9.4 Check Weariness of the Brake Disc

Contact with Changlin’s dealer to make repair upon the brake disc.

24.9.5 Check the Generator And the Start Motor

Electrical brush could be worn out and no lubricant oil in bearings, so you should contact with
Changlin’s dealer to make repair.
If the engine is found to start frequently, make check every 1000 hours.

24.9.6 Check Clearance of the Air Valve of the Engine and Make Adjustment
It should have special tools to take out these parts and make adjustment, therefore contact with
your Changlin’s dealer and ask for maintenance in this field.

24.9.7 Check the Vibration Dumper

Check the outer surface of rubber to see if crack or peeling exists.

3-53
If crack or peeling is found, you can contact with your Changlin’s dealer to replace this part.

24.9.8 Clean and Check the Turbocharger

If the blades of the turbocharger have stuck carbon or oily soil, it can reduce features of the
turbocharger and damage it, so you should contact with your Changlin’s dealer.

24.10 Maintenance Every 4000 Hours

The Maintenance Every 50 Hours, 100 Hours, 250 Hours, 500 Hours, 1000 Hours and 2000
Hours should be carried out simultaneously.

24.10.1 Check the Cooling Water Pump

Check if there is abnormalities such as pulley swinging, lubricant and water leakage, block of
holes (air, oil and water exhausting) etc. If so, contact with your Changlin’s dealer to make
removal, maintenance and replacement.

3-54