WJ-3A Manual

ATTENTION

1. Please read this manual carefully before operation.

2. Operator shall be trained completely, to know configuration principles

and performance, and to learn how to maintain, troubleshoot, fix the
basic breakdowns as well.

3. Non-operator is prohibited to operate LHD without professional training.

4. Before operation, LHD shall be cleaned and without any problems and
leakages.

5. Inflammables and explosives are prohibited to transfer by LHD

6. Instruments and working area shall be kept cleaning.

7. When parked in steep grade applications, please use wooden wedge lock
tires.

8. Keep away as tires inflation.

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CHAPTER ⅠSUMMARY
1. SUMMARY
WJ-3A LHD is an underground loader, integrated with diesel engine, hydraulic powertrain,
articulated frames, tyres, etc.
WJ-3A LHD is for small-size (compact) operations that range from construction sites
(tunnels of railway, highway and water conservancy) to narrow-vein mining at extreme
altitudes. Its function is shoveling, transporting ores after explosion.
2. RECOMMENDED OPERATION CONDITIONS
The regular lubricants for engine and converter & transmission of WJ-3A loader are
recommended for use in mines of the normal ambient temperature. However, the
lubricants may thicken or thin in extreme cold or hot ambient temperature, it makes engine
startup hard and hydraulic transmission & pumps damaged. In any case, please refer to
DEUTZ engine Operation Manual and DANA Technical Service Bulletin.
3. REPRESENTATION OF MEANING OF THE MODEL
WJ-3A
W---LHD
J---Articulated frame
3---Bucket capacity（SAE Heaped）

STANDARD：
JB/T5500-2015 UNDERGROUND LHD
JB/T5501-2004 UNDERGROUND LHD TEST METHODS
JB/T8518-1997 UNDERGROUND LHD SAFETY REQUIREMENTS

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CHAPTER ⅡMAIN PARAMETER

2.1 MAIN CONFIGURATION
2.1.1 ENGINE
Manufacturer: DEUTZ AG
Model: BF6M1013EC
Power: 165kw/2300rmp
Cooling system: Water-cooled
Combustion chamber: whirl chamber，4-stroke
Exhaust system: purifier
2.1.2. TORQUE CONVERTER
Manufacturer: DANA
Model: C273
Type: single-stage, three element, hydraulic pump drive
2.1.3 TRANSMISSION
Manufacturer: DANA
Model: R32366
Type: power shift
Gear Shift: 3

2.1.4 AXLE
Manufacturer: DANA
Model: 16D2149
Type: front axle- fixed, rear axle-oscillation angle: ±8°
2.1.5 HYDRAULIC SYSTEM
Composition: service system, steering system, brake system, charging system
Description: main components are imported (bucket hydraulics pump, steering pump,
multi-directional valve, steering valve, charging valve, pedal valve, etc.)
2.1.6 TIRE
Model: 17.5 – 25-20TT L-5S

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2.1.7 OTHERS
Cylinders: self made, seal kits are made from NOK.
Blade: special wear-resistant alloy steel, Hardness≥500HB
2.1.8 BRAKE SYSTEM
Hydraulic brakes system for service operation, as well as parking/emergency. These
brakes are the Spring Applied, Hydraulically Released type, with fully enclosed, multiple
wet discs that are force-cooled at each wheel end.

2.2 MAIN TECHNICAL PARAMETER

Overall dimension (transportation): 8900×2175×2300 mm
Bucket capacity (Heaped SAE): 3m3
Rated Payload: 6t
Max. discharge height: 2100mm
Min. discharge distance: 900mm
Wheelbase: 3245mm
Departure angle: 16°
Min. clearance: 360mm
Max. gradeability：20°
Max. turning angle: ±38°
Rear axle oscillation degree: ±8°
Max. tractive effort: 128KN
Breakout force: 117KN
Boom lift time: 10s
Boom lower time: 4s
Bucket dump time: 8s
Overall weight: 19t
Speed:
1st gear: for. /rev. 0~4.7km/h
2nd gear: for. /rev. 0~9.4km/h
3rd gear: for. /rev. 0~18.4km/h

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Min. turning radius: 3720mm (inner) 6500mm (outer)

DIAGRAM ⅠDIMENSIONS

CHAPTER Ⅲ STRUCTURE AND OPERATION

3.1 ASSEMBLIES STRUCTURE
3.1.1 STEERING
It is hydraulic power pilot steering. Central articulation has two double-acting ф100
mm hydraulic cylinders with ±38° steering degree.
Turning radius: inner 3720mm, outer 6500 mm。
Main components:
Main valve
Steering pump
Pilot valve
Steering cylinder
Steering hydraulic system pressure setting: 16.0 Mpa (160bar)

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Anti-impact load valve pressure setting: 18.0 Mpa (180bar)

3.1.2 WORKING HYDRAULIC SYSTEM
Two ф160 mm lift cylinders.
One ф160 mm tilt cylinder.
Working system and steering system have tow pump. One is for lifting and tilting,
the other is for steering. When the steering system does not work, it is confluent with
working system, which increases the speed of lifting and tilting. Thus the productivity is
increased.
Main components:
Pump
Control valve
Multichannel conversion valve
Pilot return circuit pressure setting: 2.5 MPa (25bar)
Working hydraulic system pressure setting: 16.0 MPa (160 bar)
Anti-impact valve pressure setting: 18.0 MPa (180 bar)
Hydraulic tank capacity: about 300L
3.1.3 BRAKE HYDRAULIC SYSTEM
Service brake is closed multidisc wet brake, spring applied, hydraulic release, which
is safe and reliable. Parking brake and emergency brake are same as service brake,
controlled by the solenoid valve button in the cab.
Main components:
Pressure accumulator
Brake pedal
Brake
Charge valve
3.1.4 ELECTRICAL SYSTEM
Lights Headlight 70W
Taillight 70W
3.1.5 CANOPY EQUIPMENT

Seat

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Bucket control valve

Steering control valve
Accelerator pedal
Brake pedal valve
Controllers, switches, instruments and indicator lamps are all in the range of
easily accessible and easily seen by the operator.
Faulty components and parts should be repaired and maintained frequently.
Please often observe the pressure gauge and follow their index.
3.1.6 ADDITIONAL EQUIPMENTS

Fire extinguisher 2kg

3.2 CONTROL PRINCIPLE

3.2.1 CONTROL

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1. Steering handle 2. Shift lever 3. Direction lever 4. Brake pedal 5. Accelerator pedal
6. Bucket & boom joystick 7. Master switch
DIAGRAM Ⅱ CONTROL SYSTEM

3.2.1.1 STEERING HANDLE

The steering handle is designed ergonomically. The steering servo valve guides oil
directly to the main steering valve.
3.2.1.2 SHIFT LEVER
Movement of the lever is passed to the control valve of power shift system. The lever
near the driver is 1st gear; push the lever forward, the gear gradually become 2nd gear and
3rd gear.
3.2.1.3 DIRECTION LEVER
The direction lever near the drive is reverse position, push the lever forward, it
becomes neutral position and forward.
3.2.1.4 BRAKE PEDAL
When the brake pedal is put down, the spool is opened evenly. The return circuit
pressure of brake will vary depending on the size of angle which put down by the brake
pedal.
3.2.1.5 ACCELERATOR PEDAL
The accelerator pedal is one kind of oil pressure regulating valve controlled by right
foot. When the pedal is stepped on, oil flows into the cylinder connected with control rod
of engine injection pump. At this time, the pressure of this cylinder is increased, the
engine is sped up. The engine speed is proportional to the force exerted to the pedal.
3.2.1.6 BUCKET & BOOM JOYSTICK
The joystick controls the pilot oil into corresponding hydraulic valve of the bucket.

3.2.2 INSTRUMENT PANEL

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DIAGRAM Ⅲ INSTRUMENT PANEL

1. voltmeter 2. converter oil temperature 3. filter warning 4. water temp. & engine oil
warning 5. headlight switch 6. taillight switch 7. distinguish switch 8. distinguish switch
9. water level warning 10. brake warning 11. horn button 12. instrument light switch
13. preheat start 14. power indicator 15. preheat indicator 16. hand brake switch
17. water temperature gauge 18. engine oil pressure gauge 19. brake pressure gauge
20. tachometer & hourmeter 21. clutch pressure gauge

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3.2.2.1 VOLTMETER 1
Display the voltage of electrical system, the normal value is between 26V and 28V.
3.2.2.2 CONVERTER OIL TEMPERATURE 2
The pointer should be in the green region when the loader works normally.
3.2.2.3 FILTER WARNING 3
The indicator lamp of high pressure filter and return oil filter of hydraulic system.
When this lamp lights, it indicates one of the filters is clogged. Turn the distinguish
switch 8 at this time. If the lamp is still bright, then the high pressure filter is clogged;
otherwise, the return oil filter is clogged.
3.2.2.4 WATER TEMP. & ENGINE OIL WARNING 4
When the engine coolant temperature is high or engine oil pressure is low, this lamp
is bright. Turn the distinguish switch 7. If the lamp is still bright, it indicates that the
engine oil pressure is too low; otherwise, the engine coolant temperature is too high.
3.2.2.5 HEADLIGHT SWITCH 5
Control the headlight.
3.2.2.6 TAILLIGHT SWITCH 6
Control the taillight.
3.2.2.7 DISTINGUISH SWITCH 7
Please refer to 3.2.2.4.
3.2.2.8 DISTINGUISH SWITCH 8
Please refer to 3.2.2.3.
3.2.2.9 WATER LEVEL WARNING 9
When the coolant level is below the specified value, this lamp is bright.
3.2.2.10 BRAKE WARNING 10
When the brake system pressure is less than 10 Mpa, this lamp lights, showing the
brake system is malfunction.
3.2.2.11 HORN BUTTON 11
Press this button, the horn sounds.
3.2.2.12 INSTRUMENT LIGHT SWITCH 12

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Turn this switch, the instrument lights on the panel will be bright.
3.2.2.13 PREHEAT START 13
Insert the key (neutral position). Turn right the key to position 1. The system detects
automatically ambient temperature. When the temperature is below the specified value,
the preheat indicator lamp lights. The system preheats automatically. After preheating,
the indicator lamp goes out. Continue to turn the key to position 2, and then the engine is
started. Turn the key left, the engine is turned off.
3.2.2.14 POWER INDICATOR 14
When the alternator works normally, this indicator lamp is not bright. When the
alternator does not generate, this indicator lamp is bright.
3.2.2.15 PREHEAT INDICATOR 15
This indicator lamp lighting shows that ambient temperature is below specified value.
Please preheat before starting.
3.2.2.16 HAND BRAKE SWITCH 16
Push this button, the lamp is bright and the brake is implemented. Pull out the button,
the brake is released.
3.2.2.17 WATER TEMPERATURE GAUGE 17
This gauge shows temperature of coolant. The pointer should be within the green
area.
3.2.2.18 ENGINE OIL PRESSURE GAUGE 18
This gauge displays engine lubricating oil pressure. The value should not be less than
0.07 Mpa in normal operation.
3.2.2.19 BRAKE PRESSURE GAUGE 19
Display the brake system pressure. The normal pressure range is within 12.7-15.8
Mpa.
3.2.2.20 TACHOMETER & HOURMETER 20
It shows engine speed (usually between 600 rpm and 2300 rpm) and working hours.
3.2.2.21 CLUTCH PRESSURE GAUGE 21
This gauge indicates transmission clutch pressure, normal value is within 1.69-1.96
Mpa.

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3.2.3 CIRCUIT BREAKER

Circuit breakers are equipped on the rear frame.

3.3 WORKING PRINCIPLE

3.3.1 DRIVELINE SYSTEM

WJ-3A underground LHD is equipped with hydraulic shift transmission controlled by

torque converter and hydraulic.

DIAGRAM Ⅳ DRIVELINE SYSTEM

Hydraulic transmission is driven engine via torque converter. All the gears can be
driven forward and reverse. Output power of transmission enters the drive shafts of front
and rear axle differential. The differential drives planetary hub.
The torque converter consist of impeller (a), turbine (b) and reaction member(c)
which are driven by engine. The engine makes impeller rotate. The oil flow driven by
impeller impacts the turbine blades. Oil flow returns to the impeller through reaction
member. This liquid circle makes turbine rotate.
The oil in the transmission tank pumped by the converter pump goes into the
regulating valve through the filter. After that the oil flows into converter and cooler, then
into the transmission. Pressure oil goes into the direction matched by selected gear from
the control valve.

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DIAGRAM Ⅴ TORQUE CONVERTER

3.3.2 STEERING HYDRAULIC SYSTEM

18MPa
18MPa

16MPa

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DIAGRAM Ⅵ STEERING HYDRAULIC SCHEMATIC

(1) steering pump (2) steering main valve (3) pilot valve (4) steering cylinder
The steering pump (1) of converter pumps oil into the steering main valve (2)
controlled by pilot. In neutral, oil flows into the main working valve through the steering
valve, then returns to oil tank through mail working valve.
When the steering lever is turned to steering position, pilot pressure oil (25bar) flows
into main valve (2) from the pilot valve. Pilot pressure impels the spool opening high
pressure oil port, and makes high pressure oil into steering cylinder. The machine begins
to run.
The pilot system accumulator pressure is 2 Mpa.
The specified pressure of the main relief valve is 16Mpa. The specified overload
pressure is 18Mpa.
If the cab door is open, the LHD should not be steered.

3.3.3 WORKING HYDRAULIC SYSTEM

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DIAGRAM Ⅶ WORKING HYDRAULIC SCHEMATIC

(1) Working pump (2) pilot valve (3) main valve (4) lift cylinder (5) tilt cylinder

The Working pump (1) makes oil into the main working valve (3). The excessive oil
(when the steering system is not in use) from the steering hydraulic system flows into the
main working valve.
When move the bucket control valve, pilot pressure (25bar) goes into the main valve
from control valve and the spool is moved. High pressure oil (160 bar) flows into the lift
cylinder (4) or tilt cylinder (5) through the main valve (3) to make the bucket move.
Hydraulic oil flows back to the oil tank via the return filter.
The specified pressure of the main relief valve is 16Mpa. The specified overload
pressure is 18Mpa.

3.3.4 BRAKE HYDRAULIC SYSTEM

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DIAGRAM Ⅷ BRAKE HYDRAULIC SCHEMATIC

(1) brake pump (2) main relief valve (3) high pressure filter (4) charge valve
(5) accumulator (6) shutdown solenoid valve (7) sequence valve (8) brake
(9) brake pedal
Pressure oil flows into the charge valve (4) from the pilot system pump. System
pressure should be within normal working range (124~162 bar).
When the brake pedal is put down, hydraulic oil in the brake flows into the oil tank
through brake pedal (9), then the wheel brake works. When the brake pedal is released, oil
in the accumulator will push the springs of brake away, the LHD will begin to run.

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The emergency brake and parking brake are controlled by solenoid valve (6). Push
the solenoid valve button, the emergency brake is done. Release the button, emergency
brake is released.
The nitrogen pressure in the accumulator of brake system is 7.5 Mpa.
Notice: Never park the loader with the emergency brake! Never use parking
brake unless emergency.
If the system pressure drops suddenly or turn off the power, the parking brake will
automatically act. When release the brake (after the accumulator is charged), the
setting button on the control panel should be pushed.

CHAPTER Ⅳ ELECTRICAL SYSTEM

4.1 ELECTRIC SCHEMATIC DIAGRAM

DIAGRAM Ⅸ ELECTRIC SCHEMATIC DIAGRAM

4.2 ELECTRIC COMPONENTS LIST

ITEM SYMBOL DESCRIPTION QTY. REMARK

1 SB1 Preheat start switch 1

2 SB2 Brake button 1
3 SB3 Horn button 1

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4 Y1 Start relay 1
5 Y2 Parking solenoid valve 1
6 Y3 Enriched solenoid valve 1
7 Y4 Brake electromagnet 1
8 Y6 Low water level parking relay 1
9 V Voltmeter 1
10 S Power switch 1
11 GB Battery 2
12 HL1 Preheat indicator 1
13 HL2 Generating indicator 1
14 HL3 Parking brake indicator 1
15 HL4 Liquid level alarm lamp 1
Water temp. & oil pressure
16 HL5 1
alarm lamp
17 HL6 Brake pressure alarm lamp 1
18 HL7 Oil filter alarm lamp 1
19 HRS Glow plug 1
20 H1~4 Lights 4
21 SX1~2 Light switch 2
22 SX3~4 Distinguish switch 2
23 SX5 Instrument light switch 1
24 SP1 Oil pressure sensor 1
25 PT1 Water temp. sensor 1
26 PT2 Preheat sensor 1
27 K1 Level switch 1
28 K2 Water temp. alarm switch 1
29 K3 Oil pressure alarm switch 1
30 K4 Brake pressure alarm switch 1
31 K5 Return oil alarm switch 1
High pressure oil filter alarm
32 K6 1
switch
33 K7 Preheat relay 1
34 B Horn 2
35 PP Oil pressure gauge 1
36 PT Water temperature gauge 1

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37 PNH Hour meter & tachometer 1

38 Q Converter oil temp. gauge 1
39 QF1 Breaker 1
40 QF2~4 Breaker 3
41 QF5 Breaker 1
42 FU Fuse 1
43 M Starter motor 1
44 F Alternator 1
45 SQ Neutral switch 1
46 N6 Preheat relay 1

CHAPTER Ⅴ MAINTENANCE INSTRUCTION

This manual is the important reference on the WJ-3A underground LHD safe, high
quality, efficient operation. The contents of this manual can help avoid potential hazard,
reduce the cost of maintenance and malfunction, increase reliability, longevity and
efficiency of this loader.
When the LHD is operated, this manual should be kept in the cab for easy access.
Everyone related to this LHD should read and use this manual and always abide by
national laws and regulations on preventing accidents and environmental protection, and
comply with norms of safety and technical operations. He also should comply with all
kinds of norms and requirements of user’s company including report and management.
Use objective: WJ-3A underground LHD is designed and built according to the latest
technology and safety rules. However, accidents and careless use can hurt the operators
and other personnel, or damage the machine or other property.

5.1 LHD USE CONDITION

（1）Accomplish its design purpose.
（2）Correct technical conditions.
（3）Clear understanding of safety and potential danger.
（4）Strict use and comply with requirements of this manual.

5.2 LHD USE ATTENTION

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（1）Make sure all the instrumentation and signal lamps in good condition.
（2）Keep all the safety and danger markers clear and legible, and implement in
strict accordance with them.
（3）Put the loader in neutral when the machine is free of any operations.
（4）Please park this LHD on the flat ground if possible.
（5）Wedge the wheel when the loader is parked on the slope.
（6）Idle the engine at least three minutes before stopping the loader.
（7）The gear combined with the transmission cannot stop the LHD because of the
torque converter, so please use parking brake.
（8）The engine should be turned off when shut off the main power switch.
（9）Make sure the tries are not slipped while loading.
（10）Do not let the front tries off the ground while loading.
（11）Do not drive the loader backward when the transmission is in the forward
gear as the loader working on the slope.
（12）Never leave the loader when the brake is not enabled.

5.3 SAFETY REGULATIONS

（1）Do not clean, refuel or adjust the loader when it is running.
（2）Passengers are not allowed to operate the loader.
（3）Do not get on or get off the loader with grasping the joystick and wheels.
（4）Please be properly seated while operating.
（5）Do not allow anyone enter the region of articulation. Make sure no one is in
the dangerous area before starting.
（6）Only the one who is qualified can operate the loader.
（7）Shut down the loader immediately when failure occurs, and set up obvious
warning signs. Eliminate the malfunction at once.
(8) The drive should undergo strict technical training. He must be familiar with
the structure principle and performance of this loader and familiar with relevant
rules and regulations. He can examine and eliminate simple failure and be skilled at
operating.

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(9) The operator should wear safety helmet, protective goggles and protective
shoes.
(10) Smoking is not allowed while refueling.
(11) Before entering the job site, the drive should check the stope roof and two
sides of rock wall. Please dispose of unsafe places.
(12) The pipes and cable on the roof and walls of the tunnel should be fixed.
There are no protruding rocks and drilling rods.
(13) The drive should clear up the rock debris on the tunnel road before working.
(14) The ore pass and temporary shaft along the LHD travelling road should have
safety measures and obvious signs.
(15) The job site lighting should be good.
5.3.1 MAIN DANGERS IN USE AND MAINTENANCE

Make sue that there is no unrelated persons in the work area while operating.
Crash danger. It can lead to severe injury or death. Make sue there is no unrelated
persons in the danger zone.
Burn danger. Be careful to the hot surface which may lead to burn. Do not touch hot
surfaces of the loader.
Boom movement danger. Ensure support the arm properly before maintain the
hydraulic system.
Pay attention to the balance of this loader. Do not exceed the specified tilt angle when
parking or driving this loader.
Extrusion danger, it can lead to severe injury. Please be careful when installing the
locking device.
Extrusion danger, it can lead to severe injury. Do not stay in the zone marked with this
sign.
High pressure oil jet danger. It can lead to severe injury. Make sure release pressure in
the hydraulic return circuit before opening covers or disconnecting.
5.3.2 CONDITIONS NOT ALLOWED TO WORK

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Operators without enough training.

There are unauthorized persons in work area.
Safety device is unavailable or does not work properly.
Loading explosive in the area.
Transport personnel with this loader.
Inadequate ventilation and water level is too high in the work
area.
Poor lighting in the job site.

5.3.3 FLAME PROOF

In case of fire, operator should evacuate quickly in order to reduce the risk of
injury by fire, heat, steam and explosion or other possible danger.

Please comply with local mandatory regulations when the fire occurs.

Fire extinguisher
Fire extinguisher is usually installed on the front frame. The specific position varies
with different equipments.

The instruction on the extinguisher should be read. Make

sure the pointer of the instrument is not in the red zone. If the
pointer is in the red zone, the extinguisher should be
maintained by the authorized center.

If the fire occurs:

1. Stop the loader safely.
2. Push the emergency stop button.
3. Cut off the master switch current.
4. Start the fire extinguishing system (optional). If using the hand held extinguisher,
please operate in accordance with below steps. And comply with local safety
regulations.

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5. Put the extinguisher upside a few times in order to make the extinguishing agent
mixed.
6. Put out the safety pin, and remove the jet pipe.
7. Stand firmly, seizing the jet pipe and make it aim at the fire point.

8. Press the handle, eject the extinguishing agent. Once the fire is out, stop ejecting so as
to save extinguishing agent to prevent resurgence.
9. The extinguisher should be refilled extinguishing agent by the authorized center after
using.
After fire extinguishing:
The waste heat of the fire may lead to refire after using out the extinguishing agent of
the fire extinguishing system.
After extinguishing fire, only after cleaning and maintenance the loader can be started.
Rinse the loader with plenty water as soon as possible after extinguishing fire, because the
dry extinguishing agent is corrosive especially to the cable. Check the fire extinguishing
system before resuming work and refill the extinguishing agent.

Warning: Operators should read carefully the above safety rules and comply
with them before using this loader.

5.4 EXAMINATION BEFORE STARTUP

（1）Make sure no one is injured in the starting.
（2）Coolant level.
（3）Engine, transmission, hydraulic oil.
（4）All lubrication points.
（5）Make use the secure connection is removed.
（6）Make visual inspection. Check if there is oil leakage, loose hose or worn and other
parts need maintenance. If defective parts are found, ask for the maintenance
personnel to maintain it.

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(7) Check the operation mechanism, steering system, braking system if they are
flexible, safe and reliable. The hidden danger is not allowed strictly. The speed
lever should be in the neutral position.
(8) Check the bolts and nuts of every part, especially the transmission, engine, drive
shaft, axle, tire, base plate of the lift bracket, the cradle of axle, the support plate
of axles, if loose or broken, please fasten or replace them if necessary.
(9) Check the belts of fan and alternator.
(10) Check the hydraulic hoses, wires, etc. make sure they are not against the engine or
the drive shaft, fixed firmly.
(11) Check the tire pressure; inflate them to the specific valve if they are less than it. It
is prohibited to let the loader work with the tires pressure less than the specific
value.
(12) Check the air cleaner and sealing of the intake pipe.
(13) Check the limit block.

5.5 IN CAB AND STARTUP

(1) Close the power switch.
(2) Please turn the main switch to ON position.
(3) Check the parking brake lever if it is in the forward position.
(4) If the engine is cold, please preheat it about one minute until the glow plug is
ignited. If the temperature is very low, preheat the engine 2 minutes.
(5) Put the start switch on the start position and accelerate the loader to 1/2 throttle
until the engine is ignited. Turn the switch to O position when the engine is ignited.
Release the accelerator when the loader is running smoothly. If the engine is not
ignited, please turn the switch to the preheat position a short while and restart it.
One start takes no more than 20 seconds.

Attention!
The loader is usually used in the mine, so the engine, transmission and hydraulic
system are filled with oil suitable to normal condition use. However, the oil may thicken in

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low temperature, which makes the startup difficult and damage the torque convert and
pump. Therefore avoid temporary stop in frost climate. It the loader is used in extremely
cold or hot conditions, please refer to DEUTZ manual.

5.6 OPERATION AFTER STARTUP

(1) After starting, do not turn the key to the power-off position.
(2) Release the accelerator pedal once started until stable running at idle. After starting
the cold engine, do not allow excessive acceleration. Do not run the loader until the
oil pressure and engine cylinder head temperature reaching the standard value.
(3) After starting, the key is on the “ON” position. Each instrument has current.
Tachometer and hourmeter can be read and the oil pressure gauge and oil
temperature indicates.

5.7 CHECKING AFTER STARTUP

5.7.1 CHECK THE INSTRUMENTS AND INDICATORS

1. Engine coolant temperature, it should be below 100℃.

2. Engine oil pressure, the minimum pressure should be at least 0.07 Mpa after heating
the engine.
3. Alternator charge voltage is about 26-28V.
4. The transmission oil pressure should be between 1.69 Mpa (16.9 bar) and 1.96 Mpa
(19.6 bar).
5.7.2 CHECK BRAKE PRESSURE GAUGE

1. The brake gauge shows front and rear braking release pressure.
2. The brake system pressure should be between 127 bar and 158 bar. When the
pressure drops too low, the warning lamp will light.
5.7.3 CHECK ALL THE JOYSTICKS IF THEY WORK.

Check lifting arm, damping bucket, rolling back bucket and lowing the arm at engine
speed 1000-1500 rpm.
Make the loader steer from left to right.
5.7.4 CHECK THE STEERING SYSTEM

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5.7.5 CHECK SERVICE BRAKE AND PARKING BRAKE

Check the leakage.

Test the braking function.
Shift 2nd gear and implement braking. The brake should make the loader remain
immobile at engine speed 2300 rpm and 2nd gear.

5.8 RUNNING SET

1. Make the engine run at 1000-1500 rpm until the low pressure warning lamp is out.
2. Let the engine run at low speed.
3. Select the direction and gear. Push the shift lever forward if you want the loader go
forward, push back it if you want the loader go reverse. Low gear and neutral gear
are nearest from the driver, and the high speed gear is far off the drive.
4. Push the release button of the brake on the panel to release the parking brake.
5. Step the accelerator pedal evenly, and the loader starts to move.
6. When changing the gear, release the accelerator pedal and change the gear at the
same time. When you want to change the drive direction, make the loader stop
completely. Smooth shifting and direction changing can protect the driveline
system from damage by additional stress.
7. Always start the loader in low gear. Change the next higher gear if the conditions
permitted.
8. Do not make the loader glide in neutral.
9. Never shift the gear on the slope to prevent the loader from slipping.
10. Use the transmission to slow down the loader as you can as possible which can
reduce the wearing of the service brake.
11. Do not keep the loader in low gear unless it is required to run in low speed.
12. Make sure the transmission shift lever can be pulled in place.
13. At any time, change the gear from one to another. However, when you change to
the higher gear, release the accelerator pedal instantaneously. When you change to
the low gear, accelerate the loader slightly.
14. If the transmission is overheating, place it to neutral position and make the engine

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run at the median speed until the temperature drops to the permitted range
indicated by the transmission temperature gauge.
15. Advice: to change the direction in motion, you should put it in neutral. Change the
travel direction after stop the loader stably. Otherwise it will cause damage to the
driveline system such as gear, clutch friction plate, drive shaft and axle shaft.

5.9 LOADING OPERATION

LOADING:
Flatting the operation area improves the loader efficiency. The operation area should
be as wide as possible. Load the ore material from outside to center.
If following the correct loading process, the operators and the loader will form a
efficient work group.
Do not make full load operation before the converter temperature increases
(transmission oil temperature +40 oC).
Lower the arm close to the material pile. Put the bucket edge as close to the ground as
you can before inserting it into the material pile.
Start the loader with 1st gear. Straighten the front and rear frames before inserting it
into the material pile. Put the accelerator pedal to the end when shoveling material.
In order to avoid wheel slipping, raise the boom and bucket a little. That will make the
front tires flatter; therefore the contact surface between tire and ground is increased.
If the forward motion and disconnecting jointed correctly, the bucket can be filled
once and the tires do not slip.
If the resistance of the material pile is big, the speed of output shaft of the converter
will quickly reduce to zero. At this moment, the engine power is output completely,
however the wheels do not move at all.
Do not stall the converter more than 30 seconds one time, because all the power of the
engine will transfer heat. The stalling of converter will occur easily at high gears.

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Do not put the bucket edge too low. That would make the front tires off the ground, so
that the rear wheels become the single driving source.

Do not let the rear wheels off the ground, which will add unnecessary stress onto the
front axles.

When the bucket is inserted into the pile completely, open the bucket control valve
fully to place the bucket in transport position. The above operation should be done quickly,
so that the back of bucket is fully filled.
TRANSPORTATION
Put the arm on the bracket combined with reverse gear. Run the loader with correct
gear all the time. To operate the loader with the gear which can control the speed and has

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no excessive use of brake at declivity. As usual rules, when run the loader on the downhill,
please select same gear as on the uphill. Tap back the bucket in order to empty the bucket,
reverse the loader and put the arm of bucket to the lowest position.
DISCHARGE
Roll back the bucket to the transport position and go to the unloading point. Relax the
bucket as possible as you can. The load must be supported by the frame and brake block
instead of cylinder. No matter operate the loader on uphill or on downhill, the bucket
points to the downhill. That can help stopping the loader in case of emergency.
Drive the loader to unloading place, lift the arm to necessary height and aim at the
receiving container. Operate the tilt lever, put the bucket down and discharge the material.
When the arm is lifted when unloading, please avoid the loader turning.
Release the accelerator pedal when unloading the material. Put the brake pedal down
and put the transmission in neutral.
Make the engine run at the high speed, lift the arm and bucket if necessary, then dump
the bucket.

Tap back the bucket in order to empty the bucket, reverse the loader and put the arm of
bucket to the lowest position.
Attentions:
1. Try to put the bucket lower when operating, so the vision is good and the stability is

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good as well.
2. It is prohibited to let the front wheels off the ground when the bucket is inserted into
the material pile. When you find the front wheels off the ground, lift the bucket to get
good contact between tires and ground in order to get enough insertion force.
3. Try to keep the loader in low gear when driving it on the slope in order to reduce the
speed. Use the brake only when it is necessary to avoid pulse brake.
4. Lift the bucket to the height as long as the materials can be dumped when unloading.
Always pay attention to avoid the bucket touching the tunnel roof.
5. Keep the ground flat as far as possible after loading/unloading.
6. Usually make the engine run at full speed when shoveling or loading. Slow down
the engine just in order to prevent the tires slippage.
7. Do not make the loader with catalytic converter idle run for a long time, because
long time idle running will cause obstruction of catalyst and reduce the purifying effect.

5.10 GRADIENT
Driving on the slope.
Turnover danger. It can lead to severe injury or death. Do not exceed the
allowable maximum slope degree.
On the slippery road such as on the snow or on the slick stone, the safety driving
gradient is much smaller than that on the road with good ground grip.
Please be careful and slow when the loader is close to the unloading place with lifting
the bucket.
When the bucket is lifted, especially when the loader is turning, avoid sudden
movement of the arm up or down.

5.11 BRAKING
Sudden stop may cause injury to personnel. Please always pay attention to the
instruments and indicator lamps, and
operate the loader in accordance with
the instruments and indication signals.
The brake pedal (1) position in the

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cab is shown in the picture. The pedal is controlled by foot to stop the loader. Push the
pedal by foot to implement braking and the loader will stop.

Withdraw the foot, the brake is released and the loader will move. The more down you
push the pedal, the bigger the brake force will be and the faster the loader will stop.
Never drive the loader with foot putting on the brake pedal. That will cause the
hydraulic system overheating and early wearing or lead to brake failure. Put the foot
on the footrest when the brake is not needed.
Attention!
The parking brake/emergency brake will be implemented automatically in the
following cases.
The current is cut off.
The emergency brake button is used.

5.12 STOP & TURN OFF THE ENGINE

1. Do not park the loader in the place where there is traffic jam.
2. Park the loader on the flat ground. If not, turn the loader and make the bucket face
the downhill direction leaning on the wall (please see the picture).

3. Put the transmission in neutral and release the brake. If the loader does not move,
then the loader is parked safely.
4. Put the arm to the lowest position and the bucket edge against the ground.
5. Use the parking brake button, the indicator lamp flashes.
6. Let the engine run at 1000-1500 rpm at least 3 minutes. Push the stop button until
the engine stops.

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7. Turn the power switch on the instruments panel to off position. Turn off the master
switch.
Warning!
Do not turn off the power switch when the engine is running.
Do not park the loader on the slope only with the brake. Shift joystick position
has no any effect on the brake ability.
Never park the loader on the slope only with the brake.
Do not leave the loader unattended if the brake is not implemented and the engine is
not turned off.

5.13 TOWING
Do not start the loader by towing. If the loader needs to be towed, please perform it in
accordance with the following procedures.
1. Towing the loader may damage the drive shafts and torque converter, so the front
and rear drive shafts should be disconnected as shown in the picture.

2. If the braking system pressure is too low, the parking brake will be automatically
implemented and the indicator lamp lights. At this time, pump the hydraulic oil by hand
pump and open the brake. The pressure does not exceed 11 Mpa (110 bar), otherwise it
will damage the brake oil seal.
3. Disconnect the steering cylinder hose to release pressure of the steering hydraulic
system.

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Releasing the steering system pressure may cause the loader turning
(especially on the slope). Be careful to release the pressure in order to avoid
danger to other personnel or equipments.
4. The towing vehicle should be same heavy as the WJ-3A loader or heavier. Use rigid
towing rod with warning sign. Tow the loader as slowly as possible.
5. When install the drive shafts, the both ends universal union couplers should be
along the same line.
Attention!
1. Never attempt to start the loader by towing.
2. Please be extremely careful to tow the loader.
3. Tow the loader as slowly and carefully as possible.
4. After towing, wedge the four wheels to implement braking.

5.14 TRANSPORTATION
Before putting the loader on the transport vehicle, move the bucket to the handling
position. Do not exceed specified gradient.
When load the loader on the transport vehicle or unload off it, it is necessary to use
gradient springboard. The loading work must be always done on the level ground.
On the gradient springboard, keep the loader balance with bucket motion.
Drive the loader onto the flatbed trailer through the gradient springboard slowly and
carefully.
Lower the bucket and put the frame lockpin before shipment.
Tie up the loader in the flatbed trailer with rope or chain of high intensity so as to the
loader does not move during the transportation.

5.15 STORAGE CONDITIONS

Environment:
Storage temperature should be +0 ~ +35℃. Please prevent the loader from sunlight
and rain.
The air humidity should be below 90%.
Preparatory work:

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The loader should be thoroughly washed (using high pressure washer or steam) after
usage or ocean shipment to storage.

Grease all the grease fittings.

If the loader is stored for a long time, the accumulator should be released. Recharge it
before use again.
Daub the piston rod with antirust oil.
Replace all lubricants and liquids.
Check the air filter of the engine and maintain it if necessary.
Protect the electric devices with anticorrosive agent to prevent from poor contact.
Disconnect the battery wire.
Daub the following parts with antirust oil.
- Terminal board.
- Battery terminal
- The connectors on the covers of solenoid valves, pressure switch and so on. Fill
grease to the covers.

CHAPTER Ⅵ ROUTINE MAINTENANCE

WJ-3A underground LHD is designed for difficult and tough working conditions
underground. In order to ensure the loader work economically without malfunction, the
periodic maintenance is very important. If the maintenance plan is implemented, the
possible failure could be found easily and repaired before the problems becoming serious.
That will keep low maintenance cost and does not reduce the production efficiency.

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The following content gives the different maintenance points and intervals of WJ-3A
loader.

6.1 SAFETY PRECAUTIONS

6.1.1 GENERAL SAFETY PRECAUTIONS DURING OPERATION

We suggest that the records of repairing and replacing parts be kept. Maintaining the
loader in accordance with correct intervals can improve productivity, reliability, economy
and security.
The maintenance work may cause danger if it is done with carelessness. So everyone
involved in the maintenance work should know the possible danger and use safe work
methods. Please read the manufacturer’s manual before any maintenance or repair and
work in accordance with the requirements of manual.
The maintenance personnel shall not wear long and fluffy hair, fat clothes, and shall
not wear jewelry including ring, which may have the risk of injury. The personnel should
wear work clothes or other compulsive protection things.
Do not make any modification, rebuild to the loader effecting the security including
adjusting safety devices and a variety of valves and weldment of the frame. Please consult
with the supplier or manufacturer if your want to do these tasks.
Spare parts should meet the technical specification of the manufacturer. Only using the
genuine parts can meet the standards.
Personnel should know the location and use method of the fire extinguisher.
Special workshop equipment is absolutely necessary in order to ensure high quality of
maintenance.
Only the personnel with formal training can maintain or repair the loader. The
maintenance on electric devices should be carried out by electrician under plenty
knowledge and experience; the maintenance of hydraulic devices by mechanic.
6.1.2 GENERAL REPAIR WORK

Define clearly the responsibility of the maintenance and repair personnel.

Do not do any work which is not required.
The maintenance work area must be ample.
Inform the loader user when the maintenance or other special work is done.

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Make sure the component or parts cannot move accidently.

Turn off the master switch.
Remove the start key.
Put a warning icon like Danger! Don not start! on the master switch. This icon can be
removed only by the one who fully knew the situation.
Appropriate and safe ladder or platform is prepared for maintenance work if necessary.
Do not use any equipment as ladder. Use safety device to prevent from falling if the
maintenance work is done on the high position or dangerous positions.
Platform, ladder, knob, fence and other similar components should be kept clean and
free of grease, snow and ice to prevent accidents.
Use correct tools to do the maintenance work always.
Make sure the loader is parked on level ground and does not move before beginning
the maintenance work.
Pay particular attention to the exhaust pipe system and exhaust purification system.
Make sure adequate ventilation.
The jack can be used only on the level and solid ground.
Always make sure the other side wheel is wedged before using the jack. Support the
wheel or underlay it to make sure the loader does not move to prevent the jack from
slipping.
Disinflate the tire before unscrewing the nuts/bolts of the wheel. The unscrewed parts
of rim may lead to serious injury to the personnel in case of forgetting discharging the air
of tire.
Do not attempt to repair the parts of wheel by brazing and welding. Replace the parts
with same size, model and brand ones.
Do not transport the inflated spare tire with the removable rim. The inflation pressure
is OK which can fix the rim parts on the proper position. Inflate the tire to the normal
pressure only when the nuts/bolts are imposed appropriated torque so as to the tire and rim
are tied up.
Use safety bracket, safety cage or other protective devices when you inflate, install or
remove the tires.

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Do not stand in front of the tire and rim when the tires are inflated. Use the lengthened
hose to inflate the tire so that you can stand on one side.
Use correct lifting equipments and technology when the heavy components are
replaced.
After the preventive maintenance and repair work, screw down the loose fasteners.
Reassembly all the safety devices which are disassembled immediately after maintenance
work. All the safety systems should be tested before the loader reentering the normal
work.
Pay attention to safety and environmental protection when the materials and parts are
processed.
6.1.3 MAINTENANCE SAFETY PRECAUTIONS

1. Any work to the loader such as operation, maintenance and repair should be completed
by trained personnel.
2. Operation of electrical equipments of the loader should be performed in accordance
with electrical specifications by the electrical engineer or under supervision of the
electrical engineer.
3. The hydraulic system maintenance should be performed only by the personnel who
know how to work and is experienced.
4. Limit any way of operation may cause danger.
5. Measure the operation area. The loader can work only in safe and operational condition.
6. Comply with the procedure of start and stop according with this manual.
7. Make sure the loader is protected to prevent accidental starting.
8. Do not stay or work under the lifted bucket if it is not supported safely.
9. Keep all the armrests and pedals clean and free of dirt.
10. Reinstall all the safety devices which are disassembled immediately after maintenance
work.
11. Please obey the relative safety regulations when the oil, grease and other chemical
materials is used.

6.2 IMPORTANCE OF MAINTENANCE

6.2.1 ROUTINE MAINTENANCE

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WJ-3A loader is designed for carrying ore under difficult conditions underground. In
order to ensure trouble free and economic operation, the maintenance in accordance with
plans is very important. It is easy to find out the potential problems and repair it in time
with fully implementing the routine maintenance, so as not to result in further serious
malfunction. That will reduce the maintenance cost and minimize the effect on the
production.
6.2.2 MAINTENANCE OF HYDRAULIC SYSTEM

Maintenance, repair or installation of hydraulic equipment should be performed by

experienced expert of hydraulic system.
Do not attempt to do the repair work which you are not good at.
Never do any repairs to the hydraulic circuit when the hydraulic system has pressure.
The engine should be stopped when the hose unions are tightened or repaired.
Do not test the leak points by hand. The high pressure oil emitted from the leakage
point may penetrate the skin. High pressure oil spay can also cause fire.
Avoid skin contract with oil directly. Wear goggles to prevent oil from splashing into
the eyes.
Do not work under the devices or components only supported hydraulically. The
devices or components which need maintenance or repair should be supported separately.
Do not remove the lift cylinder or its valve if the arm is not supported correctly and the
hydraulic system pressure is not discharged.
Hose connection, length and type should meet the requirements of technical
specification. Please use the genuine hoses and connectors or recommended parts by the
manufacturer when you replace or repair them. Make sure the hose and connector rated
pressure is same as working pressure.
Any change or remodeling should be approved by the factory.
6.2.3 MAINTENANCE OF ELECTRICAL SYSTEM

Maintenance of electrical equipments or components should be performed only by

qualified electrician.
Comply always with local electrical technology and electrical safety regulations.
Only the original electric parts can be used.

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Please stop the loader immediately if the power supply has failure.
Turn off the electricity when inspection, maintenance or repair of parts or devices is
performed. Make sure the disconnected parts have no current. Then lock the main switch
and has correct grounding.
Do not touch the terminals of battery and alternator or wires when the engine is
running. It may shock and result in personnel injury due to improper shielding of the
electric parts.
Check regularly the electrical devices. Please repair immediately when the loose
connection or insulation damage or other failures are found.
Please pay attention to high voltage parts. Capacitors may still be filled with charge
although the power is turned off. Discharge the capacitors with grounding rod.
Consult the Electrical Department of XINGYE before doing any change to the
electric devices and get the written approval in order not to change normal operation
of this loader.
6.2.4 MAINTENANCE OF BATTERY

Please wear goggles, gloves and working clothes when the maintenance of battery
is done.
Always disconnect the negative (-) first, then positive (+). First connect the positive
(+), and then connect the negative (-) when connection is performed.
It may cause personnel injury by reverse polarity due to sudden discharging of
electrolyte from the vent or internal hydrogen explosion.
To prevent the spark when connecting the battery charge, first disconnect the power
supply wire of the charger or turn off the charger switch, and then connect the charge wire
with the terminal of battery. Open the batter cover a little in order to make the gas escape
when charge it.
The battery acid can burn the skin and the clothes. It may lead to blindness if the acid
splashed into the eye. Please rinse the skin by water immediately if the acid splashed on it.
Immediately rinse the eye by plenty of water if it is splashed into eye and go to the doctor
as soon as possible.
Please keep in mind that the lead acid battery can bring out oxygen and hydrogen and

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 WJ-3A Manual

form high explosive mixture. Little spark or open flame can cause explosion.
Keep the hydrolyte level at enough height and check it regularly to prevent explosion.
If necessary, please add the distilled water. The distilled water should be added before
starting use. Do not add distilled water immediately after use. The gas space will be small
if the hydrolyte remains enough high.
Check the hydrolyte level with flashlight. Open flame is absolutely prohibited.
Do not test the electric devices with touching the terminals of the battery.
6.2.5 WELDING

Determine the material of the welded parts before welding and choose appropriate
welding methods and welding rods. Contact Service Department of XINGYE if necessary.
Do not repair the steering devices by welding.
Welding should be performed by qualified welder.
Turn off the main switch before welding. Besides, disconnect the remote control
device (optional).
If the welding must be performed near any control module, disconnect the connection
of this module.
The grounding wire of the welding machine should be connected as close to the
welding point as possible.
The ground wire cannot be connected this way that the current could go through the
bearing, universal coupling, seal surface, joystick. Clear a large enough area of paint when
you weld in the area with paint so as not to bring flue gas.
Ventilate adequately, or use welding fumes extractor.
Wear protective mask or other individual protective tools.
Make precautionary measures to prevent fire.
6.2.6 MAINTENANCE OF EVERY WORK TEAM

Check the tire and wheel nuts---drive shafts

Check connection---central hinge pin
---oscillation axle
---steering cylinder pin
Check the warning and indicator lamps

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Check all the hoses appearance

Check the main components, oil leakage and installation
Warning! Turn off the engine before filling oil!
Be careful the hot surface of the loader if the loader is just operated.

6.3 MAINTENANCE AFTER 50 WORKING HOURS

1. Replace the transmission oil filter.
2. Check and screw down the bolts of the exhaust pipe.
3. Check the connection tightness of the air filter with intake pipe.
4. Check and screw down the bolts of the oil tank and frame.
5. Check the bolts of axle, gearbox and other main components.
6. Screw down the screws of the oscillation axle.
7. Check the V belt.
8. Check the loader appearance if there is leakage or damage.

6.4 LUBRICATION
6.4.1 ENGINE

Engine oil is recommended higher grade than API CD/SE (or MIL-L-2104C) SAE
15W/40 lubricant.
Grade API CD or CE, CCMC D4 or D5.
Notes: if you use API CC oil, the replacement interval will be halved. Diesel oil sulfur
content is up to 0.5%. In order to void the sulfur content increasing from 0.5% to 1.0% or
the surrounding temperature below -10℃, the oil replacement interval should be halved.
Viscosity:
-300C┉+150C SAE 10W
-250C┉+200C SAE 10W/30
-250C┉+300C SAE 10W/40
Over-200C SAE 15W/40
+50C┉+300C SAE 30
Over +250C SAE 40
Please see the DEUTZ manual for more references.

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6.4.2 TRANSMISSION SYSTEM

Recommendation: 8# hydraulic transmission oil made in China

Optional
Grade: C-3 Dexron
Viscosity: above -20 ℃, SAE 10W
Above +0 ℃, SAE 30
6.4.3 BUCKET HYDRAULIC SYSTEM

Recommendation: 46# antiwear hydraulic oil

The antiwear hydraulic oil consistent with API CC grade performance can be used.
Viscosity: above -15℃ SAE 10W
6.4.4 AXLE

Grade: MIL-L--2105 C or API GL-5

Viscosity: above -15℃ SAE 80W/140
-25℃…+40℃ SAE 80W/90
6.4.5 GREASE FITTING

Penetrometer is 265/295(NLGI 2), dropping point 180oC lithium grease.

6.4.6 OIL CAPACITY

Hydraulic Transmission oil 37L

Axle 2 X 35L
Bucket & steering hydraulic system 160L
Diesel oil tank 180L

6.5 PRESSURE TEST

6.5.1 OVERVIEW

1. Hydraulic oil temperature should be between 60℃ and 80℃.

2. When there is no pressure in the return circuit, please connect or disconnect the
pressure gauge.
3. Test the pressure with special connection.
4. The connection is not too tight. Tightening it with hand is sufficient if it is special
connection. Over tightening will result in leakage.
5. A long enough hose should be used to read the number shown on the gauge sitting

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in the cab.
6.5.2 TEST

1. Pilot system
Pressure should be 25 bar (2.5Mpa).
2. Steering system
Turn the loader to the left limit.
Steering system pressure is 160 bar (16Mpa).
3. Check the main relief valve and control valve of the bucket hydraulic system, and
put the arm to the lowest position.
Pressure is 160 bar (16Mpa).
6.5.3 COOLING SYSTEM

If the engine is overheating or the coolant is dirty, please drain the coolant and clean
the cooling system.
Attention! Over heating shows that the engine has failure. Stop the engine
immediately and eliminate the malfunction to prevent further damage. Make sure that the
engine radiator is not covered and not blocked.
No matter when drain and refill the coolant of the cooling system, recheck the coolant
level after the engine reaching normal working temperature
Attention! Never open the cover when the radiator temperature is high.
When check the coolant level, please stop the engine and wait for the engine and
radiator cooling down. If stopping the overheating engine is necessary, check the level
after the radiator cooling down. If you cannot wait for the cooling down, please wear thick
gloves and protective clothing and then open the coolant port cover. Stand on the side and
turn the face away when opening the cover. Open the cover a little first, open the cover
completely slowly after the pressure is released and the coolant stops flowing.
Do not add the coolant quickly, otherwise it bring gasbag in the cooling system.
The cooling system works relying on the thermostat throughout the year.
For more information about the cooling system, please see the DEUTZ manual.
6.5.4 REFUELLING

Please take the following preventive measures when refueling.

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Do not refuel when the engine is running.

Do not refuel too full.
Be careful that do not spill the oil onto the hot surface.
Refuel in the well ventilated place.
Smoking, open flame or spark is absolutely prohibited when refueling.
Wipe the spilled fuel before starting the engine.
Keep the oil pipe and tank contacting, or ground the refueling pipe to prevent the static
electricity bringing about spark.
If the fast refueling system is used, make sure the user well knows the usage and safety
requirements of the maker.
If the ambient temperature is below 0℃, winter grade fuel (applying temperature as
below as -20℃) should be used.
6.5.5 COMMON FAULTS AND TROUBLESHOOTING

Fault Analysis and Troubleshooting of Hydraulic Systems

Steering Systems
Faults Reasons Elimination Method
1）Pilot oil pressure is 1）Check and deal
not enough. with the pilot oil
2）Cylinder seals are pressure systems.
damaged. 2）Replace cylinder
No Action or Action Slow of 3）Systems pressure is seals.
the Cylinder too large. 3）Check and deal
4）There is air in the with system
system. resistance.
5）Safety valve or 4）Check the suction
overload valve is line of the
failured. pump,deal with

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 WJ-3A Manual

6）Piston rod is the faults of

bending,cylinder suction line.
isout of shape or 5）Adjust, maintain
piston is damaged or replace the
7）The pump is lack of overload valve.
fuel supply. 6）Replace the
piston rod and the
piston.
7）Maintain or
replace the pump.
①The oil is contaminated. 1 Clean the spool，replace
②There is dirt in the valve the oil.
or spool is damaged. 2 Clean the body of spool,
Steering spool is stuck.
③Pair springs are replace the spool.
damaged. 3 Replace the springs.
④Spool is out of shape. ④Replace the spool.

1 Handle is
not
flexible. 1 Maintain or remount.
2 There is 2 Please exhaust the
air in the system.
Steering operation is ineffective.
system. ③Check the hydraulic
③ The oil system, and remove the
pressure of troubles.
the system is
too low.
1 The steering pump
failure. 1 Maintain or replace
2 System safety valve 2 Readjust the system’s
set pressure is low. pressure.
The pressure of the system is too low.
③ Overload valve set 3 Re-adjust the
pressure is low. pressure.
④ Steering cylinder seals ④Replace the seals.
are leaked.
1 There is air in the
system.
①Exhaust the air of the
2 Hydraulic oil
system.
viscosity is not
②Adopt hydraulic oil to
The pressure of the system fluctuates. normal.
meet the requirements.
3 The oil was
③Replace the oil.
contaminated.
④Maintain or replace.
4 The valve works
insecurity.

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 WJ-3A Manual

1）Add oil to the

provisions of the oil
1）The oil level is low.
level.
2）The pipelines are
2）Check and clean
locked.
the oilline.
3）The seals of cylinder
Steering difficulties. 3）Replace the
are damaged.
cylinder seals.
4）The control valve is
4）Maintain the
leaked.
control valve.
5）The pump is damaged.
5）Maintain or
replace the pump.
Braking System
Faults Reasons Elimination Method
①System pressure
adjustment is too low.
② The brake pump is ①Re-adjust the pressure.
Braking system doesn’t have pressure failed. ③Accumulator is ②Maintain or replace.
or the pressure is too low. failed. ③Maintain or replace.
④The pre-charge ④Pressurized to 7.5MPa
pressure of the
accumulator is too low.
①The brake valve body
and pedal connections
with bolts loose. ①Re-adjust
The brake valve fails.
②The pre-charge ②Pressurized to7.5MPa
pressure of the
accumulator is too low.
1）Deal with
the leakage
of the
1）Accumulator or system,
other hydraulic parts replace the
leak. broken parts.
2）Nitrogen pressure 2）Nitrogen
The accumulator pressurized
is too low. accumulator
frequently.
3）Nitrogen pressure to the
is too high. specified
4）The pipeline is pressure.
jammed. 3）Accumulator
pressure is
reduced to
the required
pressure.
4）Clean the

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pipeline.

1）Add oil to the

provisions of the
oil level.
1）The oil level is 2）Maintain or
inadequate. replace the
2）Pump failure. pump.
3）Relief valve 3）Maintain or
Pressurized pressure is too low. failure. replace the relief
4）Charge pressure valve.
valve failure. 4）Maintain or
5）System leakage replace the relief
seriously. valve.
5）Check the
system, deal
with the
leakage.
Working System.
Faults Reasons Elimination Method
1 The liquid level of
the tank is too low. ①Charge the oil.
The cylinder doesn’t work. ②The system ②Re-adjust the pressure.
pressure is low. ③Reduce the load.
③Super-load work.
①The cylinder has
faults.
①Repair the cylinder.
②The system’s pressure
The cylinder’s action is slow. ②Re-adjust the pressure.
is too low.
③Exhaust the air.
③Mixed with air in the
system.
①Oil filter is blocked. ①Replace the filter.
②Lack of hydraulic oil. ②Supplement the
Hydraulic oil temperature is too high.
③Mixed with air in the hydraulic oil.
system. ③Exhaust the air.
①Oil level is too low. ①Check the oil level,
②Mixed with air in the and supplement the
system. hydraulic oil.
③Suction pipe is ②Exhaust the air.
Hydraulic system vibration noise. blocked. ③Check the suction
④hydraulic oil emulsion filter, replace it if
deterioration. necessary.
⑤Main relief valve ④Replace the hydraulic
tremor. oil.

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⑤Check the relief valve,

and replace it if
necessary.

①Hydraulic piping
①Check the piping
leaks.
whether leakage.
②Main relief valve set
Lifting cylinder has no power. ②Adjust the relief valve.
pressure is too low.
③Main the reversing
③Reversing valve is
valve.
stuck.
Hydraulic Drive System
Faults Reason Elimination Method
1）Seals are 1)Replace the
damaged. seals.
The torque converter output pressure
2）The oil pump is 2)Replace the
is low.
damaged. oil pump.
3）Safety valve is 3)Maintain
stuck. safety valve.
1）The cooler’s
pipeline is
blocked.
2）The proportion 1)Clean the cooler
The torque converter output pressure
of oil is too pipeline.
is high.
large. 2)Replace the oil.
3）The oil
temperature is
low.

1）The cooler or the

pipeline is
blocked.
1)Clean the cooler and
2）The cooler
pipeline.2)Increase the
cooling capacity
cooler.
is not enough.
3)Check and deal with
The torque converter, transmission 3）There is air in the
the suction pipe.
case overheating. suction pipe.
4)Replace the oil pump.
4）The pump wore
5)Correct installation of
down.
the gravity return lines.
5）Gravity return
6)Fuel to the
lines is not
transmission case.
properly installed.
6）The oil level of
the transmission

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 WJ-3A Manual

case is low.

1）Transmission gear
damages. 1)Replace the
2）The oil pump gear.
wore down. 2)Replace the
The torque converter produces the
3）The bearing is oil pump.
noise.
damaged. 3)Replace the
4）The drive gear of bearing.
torque converter 4)Replace the
wears. drive gear.

1)Add oil to
1）The oil level is the oil level
low. of the
2）The core of the requirements
regulating valve 2)Maintain
is stuck. the regulating
3）The oil pump valve.
wears. 3)Replace the
The pressure of the clutch is low.
4）The clutch shaft oil pump.
or piston seals 4)Replace the
wear. clutch shaft or
5）Oil drain valve of the seals.
the clutch is 5)Clean the
stuck. oil drain
6）The suction pipe valve.
inhales air. 6)Check the
suction pipe.
1）The engine
1)Re-match
matches
2)Adjust the
unreasonable.
speed of the
2）The engine speed
engine.
low the rated
3)Maintain
speed.
The torque converter output power is the charging
3）The output
not enough. system.
pressure of torque
4)Check and
converter is low.
deal with the
4）The oil inlet air.
suction pipe.
5）It’s not right for
5)Replace the
the transmission
transmission
oil.
oil.

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6.6 Periodic Maintenance and Lubrication Procedures

6.6.1 Each class of maintenance

① Engine
6.6.1.1 Check V-belt
② Appearance

Check the oil level with the

Check the oil
engine stopped. The oil
6.6.1.2 level of the
level must between the
engine.
dipstick mark.

Check the air

6.6.1.3 filter arrow and
assembly.

① Make the engine idling

rotation.
②Make the joystick in the
Check the level of neutral position.
6.6.1.4
the hydraulic oil. ③ The hydraulic oil is in
the normal temperature.
④ Stop the LHD in the
level of the ground.

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Check all hoses,

fuel pipes
appearance. Check
6.6.1.5 the main
components of oil
leaks and
installation.
① Status
Check the nuts of ② Wear pattern of the
6.6.1.6
the rims. tyres.
③ Loose rim nuts.
① Turn off the engine
before filling.
Add fuel and water
② Don’t overflow.
6.6.1.7 to the fuel tank
③ The fuel shall not fill
and water tank.
full, when the fuel gets hot,
the oil will overflow.
Check indicator and
warning lights.
6.6.1.8

① Head lights
6.6.1.9 Check lights ② Taillights

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Lubrication of drive
6.6.1.10 shaft couplings in Use lubricating gun.
the central hinge.

The lubrication point is

Lubricate the swing located in the central
6.6.1.11
axle. lubrication pipe of the rack
frame.

The lubrication point is

Lubricate the located in the central
6.6.1.12
central hinge pin. lubrication pipe of the rear
frame.

Through the rear pin of the

Lubricate the
rear frame’s lubrication
6.6.1.13 steering cylinder
pipeline and the front pin of
pin.
the front frame’s pipeline.

Lubrication of Through the central

6.6.1.14 lifting, tipping pin lubricating pipeline of the
and lifting arm pin. front frame.

①Leakage
Check the walking ②Brake must be valid.
6.6.1.15 and parking brake ③Brake Second/2300rpm
fuction. ④ Emergency brake
Second/2300rpm

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⑤ Park brake
Second/2300rpm

6.6.2 Maintenance for every 60 hours

Operating Components
6.6.2.1 General Clean-up
Engine Components

Lubricating the
6.6.2.2 fixed end of the
arm pin.

Lubricating all
Use manual lubrication
6.6.2.3 drive shaft
gun.
coupling.

① The level of the

electrolyte.
6.6.2.4 Check battery.
②Clean the battery.

① Front wheel ：
680kPa(6.8bar)
6.6.2.5 Clean tire pressure
② Rear wheel ：
580kPa(5.8bar)

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 WJ-3A Manual

6.6.2.6 Check the air filter The connection of hose.

6.6.3 Maintenance for every 125 hours

① Engine must be
stopped!
② Compressed air,
cleaning agents and water
or high pressure steam
mixed.
Clean the shim of
③ Remove the cooling air
6.6.3.1 the cooler and oil
cover，and cover the
cooler.
electrical equipment.
④ Blown into the air from
the exhaust end, injected
into the detergent water jet
cleaning, or use the steam
jet cleaning.

①13~17 liters API CD oil.

②Replace the oil when the

Replace engine oil
6.6.3.2 engine is hot. Be careful
by API CD.
when the emission of the

hot oil.

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 WJ-3A Manual

③Use oil ruler to

determine the fluid position

often.

Attention！When the fuel

sulfur content is less

than 1%, and use the

API CC oil.

（0.5~1%S，replace

the oil every 60

hours.）

Drain water from

6.6.3.3
the fuel tank.

Check the central Check the appearance of

6.6.3.4
hinge. the wear.

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 WJ-3A Manual

① Operator
② Timer
Check the
③ Correction lubrication
automatic central
6.6.3.5 volume.
lubrication
④ Check the various
system(If option)
lubrication points
respectively.

6.6.4 Maintenance for every 250 hours

①13~17 liters API CD oil.

②Replace the oil when the

engine is hot. Be careful

when the emission of the

Replace engine oil
6.6.4.1
by PI CD or CE. hot oil.

③Use oil ruler to

determine the fluid position

often.

① Check the wear and

breakage.
6.6.4.2 Check V-belt
② Be adjusted if
necessary.

Replace return
6.6.4.3
filters.

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 WJ-3A Manual

Check the wheel

6.6.4.4
and differential oil.

6.6.5 Maintenance for every 500 hours

①Remove the oil filter and
screw.
② Clean the surface of
Replace the engine seals, coat with a layer of
oil filter and clean film on the new filter.
6.6.5.1
the centrifugal oil ③Remove the hex bolts，
cleaner. come up with the rotor to
clean up. Use new seals to
re-assemble. Check the
function.

① Loose anchor bolts.

Check the engine
6.6.5.2 ② Correct torque.
mounting.
③ Rubber installation.

① Remove the clamping

bolt ， take out the
Replace the back of
components and use fuel to
the fuel filter and
6.6.5.3 clean the shell.
clean up the front
② Insert new components
of fuel filter.
and O-ring, coat with a
layer of film on the

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 WJ-3A Manual

O-ring and reinstall the

shell.
③ Release the system’s
fuel.

Replace the
6.6.5.4 hydraulic oil filter
element.

6.6.5.5 Change oil filter

Check the flange of ① Tighten torque：

6.6.5.6 the drive shaft Support bearings：M20 410
and bolts. Nm

Check the locknut

①Wheel nut 410Nm
of the wheel ,
② Lockscrew of the axle
6.6.5.7 lockscrew of the
500Nm
axle, bolts of the
swing system.

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 WJ-3A Manual

Check the central

Runout should be 0.2 ～
6.6.5.8 hinge with dial
0.4mm
gauge.

①Clean the inner of the

purifier with a dry brush.
②Clean the outer of the
purifier with air.
Clean up the
③Immerse the purifier in
6.6.5.9 catalytic purifier (If
the decontamination
installed)
solution (1 hour).
④Don’t use solvent which
contains chlorine, sulfer,
metals or leaded gasoline.

Remove the cover of the

rocker.
Check and adjust Check until engine cooling.
6.6.5.10 the gap of the Intake is 0.3mm
valve. Exhaust is 0.5mm
Reinstall with the new
seals.

6.6.6 Maintenance for every 1000 hours

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 WJ-3A Manual

Clean the hydraulic oil

tank.
Replace the Clean or replace the level
6.6.6.1
hydraulic oil. screen.
Clean or replace the
breather.

Replace the drive Clean up the magnetic oil

6.6.6.2
shafts. drain plug.

① Replace the oil

of the front and rear
① 2×22 liters
6.6.6.3 differential.
② 4×6.5 liters
② Replace wheel
oil.
Check the lock nut
of the intake and
exhaust.，exhaust
6.6.6.4
flanges and other
connections for
fastening.

① Measure the wear of

Check the brake the brake lining.
6.6.6.5
system. ② Check the nitrogen
pressure of the

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 WJ-3A Manual

accumulator.（60bar）
Inspect, clean or
6.6.6.6 replace the Injection pressure:275Bar
injection nozzle.

6.6.7 Inspection, point inspection and maintenance record sheet

Each Class Completion
Check the engine oil
Check the driving belt
Inspect intuitively the state of the air filter assembly.
Check the intake and exhaust pipes and fittings whether leakage.
Check the oil level of the transmission case.
Check the nuts of the tires and wheels.
Check the oil level of the hydraulic oil.
Check the air conditioner.
Check the level of the engine’s coolant.
Test the functions of the driving and parking brake.
Check all control device whether function properly.
Check the emergency steering system(optional).
Check the function of the brake & release system.
Check main components whether leak oil and status of
installation.
Check the hand-held fire extinguisher(Optional).
Check the running lights and work lights.
Check the indicator lights.
Filling to the oil tank.
Inspect intuitively the fire extinguishing system(Optional).
Inspect intuitively the automatic central lubrication
system(Optional).
Fill butter to the rocker pin.
Fill butter to the lift cylinder pin, dump cylinder pin and lift arm
pin.
Fill butter to the central hinge pin.
Fill butter to the steering cylinder pin.
Fill butter to the swing axle.
Fill butter to the central hinge at the drive shaft universal joint.
Fill butter to the push plate cylinder pin(Optional).
Check the remote system(Optional).

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Completion of Date Engine hours

Remarks

Acceptance

CHAPTER Ⅶ MAIN PARTS, WEARING PARTS & TOOLS LIST

7.1 Main parts, wearing parts list
Item Name Part No. Qty. Remarks
1 Torque Converter C273 1 DANA
2 Transmission Case R32366 1 DANA
3 Axle 16D2149 1 DANA
4 Multi-valve 1 Import
5 Working Pump 1 Import
6 Steering Pump 1 Import
7 Steering Valve 1 Import
8 Foot Brake Valve 1 Import
9 Flushing Valve 1 Import
10 Suction Filter 2 Import
11 High Pressure Filter GU-H63×20P 1
12 Return Oil Filter GP-A500×20Q2Y 1
13 Seal Kit 160/90 2 Import
14 Seal Kit 160/90 1 Import
15 Seal Kit 100/50 2 Import
16 Tire 17.5-25-20TT L-5S 4
17 Rim 4
18 Oil Filter BF6M1013EC 1 Deutz
19 Fuel Filter BF6M1013EC 1 Deutz

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7.2 Tools List

Item Name Part No. Qty.
8，9，10，11，12，13，14，15，16，
1 Box Wrench 1 set
17，19，21，22，24，27，30，32
2 Hexagon Wrench 1.5，2，2.5，3，4，5，6，8，10 1 set
3 Tire Wrench 36 1 pc
4 Grease gun 1 pc
Fire powder fire
5 MFZ/ABC2 1 pc
extinguisher

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