Manual de Operacion WJ-1 PDF

OPERATION MANUAL OF WJ-1
SCRAPER
Kama Electrical and Mechanical Industrial Park, Dingxiang Rd., Changbei National Economic and
technology Development Zone, 330101, Nanchang, China, www.nckama.cn/en/
OPERATION MANUAL OF WJ-1 SCRAPER
Part A Preface
WJ-1 diesel scraper is driven by BF4L2011 diesel engine, where the centrally articulated
front and rear axles are driven simultaneously. It’s equipped with cut-resistant smooth tread
rubber tires, front-located bucket and front-tilting equipment for underground ore loading and
hauling use. It uses the advanced technology of static hydraulic drive system, gear transfer
case, wheel-side planetary reducer and hydraulic disk brake, etc. WJ-1 scraper is applicable in
the extracting, ore-drawing, roadway driving and mucking, construction and leveling of worksite
and road as well as the transport of materials and other auxiliary operations, when the sublevel
caving, open stope, pillar-and-room, shrinkage stoping, layering back-fill and other mining
methods are used. The scraper is in compact structure and in a small size, but free in play,
easy to operate and highly efficient at working, and it can be operated by a single operator to
shovel, load, hual and unload independently. WJ-1 diesel scraper is of good maneuverability,
featuring the advantages of less exhaust pollution, low noise and energy saving.
The Manual introduces briefly the technical performance parameters, basic structural
principles and requirements for operation, maintenance and adjustment of main parts, only for
the reference use of operators and other people concerned. In order for the correct, safe and
highly efficient operation and to prolong the service life of scraper, the operator must read
carefully the Manual before operation. It’s recommended to use the spare parts from original
equipment manufacturer so as to ensure that the scraper runs safely in a highly efficient way
and brings its functions into full play.
Part B Main Technical Performance Parameters
3 3
1. Bucket capacity: 0.85 m (struck), 1 m (heaped, SAE)
2. Rated load capacity: 2 T
3. Maximum tractive force: 41 kN
4. Maximum breakout force: 39 kN
5. Running speed (F/R): 0～8 km/h
6. Maximum climbing ability: ≥12 degrees
7. Maximum dumping height (up to tip): 995 mm
8. Minimum turning radius: 4100 mm (outside), 2350 mm (inside)
9. Maximum angle of turning: +/-36 degrees
10. Minimum ground clearance: 165 mm
11. Rated power: 53 KW (BF4L2011)
12. Maximum lifting height of bucket: 3285 mm
13. Overall operating weight (incld. hydraulic oil): 6500 kg
14. Overall dimension: 5450 mm in length (at transport);
1250 mm in width;
1900 mm in height (up to the top of driver’s cab).
The technical data, figures and sizes in the Manual are not binding upon us, and the users
must not set any demands on us therefor. We reserve the right to improve the scraper without
altering the Manual.
Fig. 1 Geometric Dimensions Figure of WJ-1 Scraper
Part C Operation of Scraper
1. Before starting the motor, please check carefully as follows:

a. Check if the oil level both in the oil tanks of working hydraulic system and driving
hydraulic system is lower than the position marked by oil leveler;
b. Check if every lubricating point is well lubricated;
c. Check if the brake oil is sufficient;
d. Check if the tire inflation pressure is enough and rim nuts are loose;
e. Make a direct viewing check on the machine, check the oil leakage, hose looseness
and other places obviously to be repaired.
2. Starting of scraper
Warning: Sound the horn before starting, and ensure no obstructions around the scraper,
particularly between the front and rear frames. Never try to start diesel engine if without a
thorough understanding about stopping and braking.
a. Turn the driving lock lever to the position of Neutral Lock, otherwise the scraper won’t
run;
b. Check if the control levers of lifting oil cylinder and tilting oil cylinder are in the neutral
position;
c. Insert key into keyhole and turn clockwise to the starting position 3;
d. The duration of starting the motor must not exceed 20 seconds, and if the motor fails
to start, just try again one minute later;
e. After starting, check if the meter readings are normal. The readings of pressure gauge
for slippage pump must be 1.50～1.73 Mpa. Check if there are any abnormal sounds
elsewhere, if the brake is reliable, if the oil leaks out of hydraulic system, if every
control handle is free in play and reliable and if the working devices are normal.
3. Starting and driving
a. Tilt up the bucket to the position of transport;
b. Set the shift gear lever to the speed gear as required, top gear at driving and low gear
at shoveling and loading;
c. Turn the driving lock lever to the position of Driving;
d. Set the parking brake to the position of Releasing;
e. Slowly step down the control pedal of advancing/reversing speed regulation so that the
scraper runs at the selected speed and direction. Step down the left pedal to advance
and right pedal to reverse.
4. Operation and control of scraper
When the scraper is ready, push forward the lifting control lever until the movable arm
descends to the lowest position, push forward the control lever of tilting oil cylinder until the
tips fall down to the ground, approach the stockpiles slowly at the low speed gear and ensure
the scraper advances straightway to shovel and load. Provided that the front and rear wheels
are not in a straight line, the thrust force will be reduced and the scraper will be damaged for
its similarity to a clasp knife. Before shoveling and loading, it’s essential to remove the
scattered ores within the loading range and avoid collision against the vehicle bottom and
damage of tires. The shoveling and loading of scraper is just to shovel the piled ores by the
aid of composition of insertion force at driving and breakout force at lifting. At shoveling and
loading, it is not to press downward the pedal in a sudden squeeze, but to step down the
pedal slightly and advance slowly to gain a maximum power. Attention: to step down slowly
results in a high power, and to step down rapidly results in a high speed.
At shoveling and loading, do not rush into, but to insert into the piled ores. When the
bucket inserts into the piled ores, the advancing speed will slow down. Just step down the
accelerating pedal slowly to increase the pushing force of bucket. If the control valve is pushed
out excessively to the extent that the bucket is depressed excessively and front wheels are
raised off the ground, the machine will be driven by the two rear wheels only and the power of
the machine will be affected accordingly. Also, do not apply the excessive breakout force to the
extent that the rear wheels are raised off the ground. If so, just back the machine and turn up
the bucket a little bit. At shoveling and loading, it’s always required to operate reasonably the
bucket control lever and accelerating mechanism so that all wheels are in normal motion.
Pushing the bucket control lever forward and backward will pry up the bucket, and the
acceleration will enable the machine to move forward towards the piled ores without slippage.
In case of wheel slippage, just slightly raise up the accelerating pedal and turn up a little bit the
bucket to reduce the downward pressure of bucket anyway and increase some downward
pressure of front wheels. When the bucket is full, turn up the bucket to the state of transport,
vibrate the bucket to shake off loose ores in the bucket to avoid the ores’ drop-off to the
passage during the period of transport. When the bucket is full, release the advancing pedal
and step down the reversing pedal, then the scraper will run in a reverse direction. When the
scraper approaches the unloading site, it’s required to reduce the driving speed and approach
the unloading site slowly. At unloading, it is required to release the pedals of advancing and
reversing speed regulation and lift the bucket up to the height as required at unloading, then
push forward the bucket control lever to tilt the bucket downward and empty the bucket. If the
bucket has not been emptied completely, just turn the bucket upward a little bit, push forward
the bucket control lever rapidly and enable the bucket to strike against the limit stop of movable
arm, then repeat the above steps to shake off the ores remained in bucket. After the unloading
is completed, it is required to turn the bucket up to the limiting position, descend the movable
arm to the lowest position and restore the bucket to its state of transport before the next
shoveling and loading operations.
5. Parking
Upon completion of shoveling and loading, the scraper must park according to the
following steps:
a. If the scraper parks outside the roadway, it would be best to park on the flat ground or
near the pillar so as to avoid the possible damage caused at the secondary blasting;
b. Descend the movable arm to the lowest position and turn the bucket down to the
ground;
c. Turn the parking lock switch to the locking position;
d. Press the stop button, turn the electronic key counterclockwise to the switch-off
position, pull out the key and turn off the main switch.
Warning: If the scraper parks on the slope, the bucket must be in the downslope direction.
Then wedge the wheels with trigs or rocks against the slippage of scraper itself.
Part D Basic Structure of Major Components and Adjustment
WJ-1 diesel scraper consists of two major parts, namely the centrally articulated front
frame and rear frame. The front frame mainly includes the front body, bucket, movable arm,
working oil cylinder, steering hydraulic system, front axle and cab, etc. The rear frame mainly
includes the static hydraulic drive device, engine, transfer case, rear body, rear axle and
hydraulic oil tank, etc. See Fig. 2.
1. Bucket 2. Movable arm 3. Oil cylinder for movable arm 4. Steering control device
5. Control device of advancing/reversing speed regulation 6. Steering oil cylinder
7. Parking brake 8. Driving oil tank 9. Static hydraulic drive device
10. Working hydraulic oil tank 11. Diesel engine 12. Front axle
13. Front drive shaft 14. Tilting oil cylinder 15. Front frame
16. Central articulation axle 17. Working control device
18. Transfer case 19. Rear drive shaft 20. Rear axle 21. Diesel oil tank
22. Rear frame 23. Rear end cover
◎ Transmission system for driving (see Fig. 3)
The transmission system for the driving of WJ-1 diesel scraper is designed for static hydraulic
and mechanic drive, which consists of static hydraulic drive system and mechanic drive system.
Fig. 2 Structural Diagram of Scraper
Fig. 3 Schematic Diagram of Drive System
1. Diesel engine 2. Oil pump 3. Oil motor 4. Transfer case
5. Front drive shaft 6. Front axle 7. Rear drive shaft 8. Rear axle
(1) Static hydraulic drive system

The static hydraulic drive system consists of axial variable displacement plunger pump,
axial
variable displacement motor, hydraulic oil tank, oil filter, oil radiator, hydraulic hose and other
accessories. The oil pump is connected with elastic coupling and driven by diesel engine. The
oil motor is connected with transfer case for torque output. The oil pump and oil motor are
connected by hydraulic hose, and the hydraulic diagram can be referred to in Fig.4.
a. Circuit of auxiliary cycloid pump
The hydraulic oil from oil tank comes into the oil inlet of auxiliary pump. The auxiliary pump
is
mounted inside the rear end cover of main oil pump and is driven together with main shaft at
the same rotating speed. The auxiliary pump is to:
i. Drive the servo oil cylinder with the low-pressure oil of a definite pressure through
servo mechanism and change the swash plate inclination of main pump arbitrarily;
ii. Make up for the internal oil leakage of the closed system;
iii. Cool the parts of main pump and motor by the aid of oil from overflow valve;
iv. Supply a definite back pressure to main pump and oil motor;
v. Supply hydraulic source to other actuating mechanisms through the external port of
main
pump housing.
b. Circuit of main pump and oil motor
The hydraulic oil comes out of auxiliary cycloid pump and directly enters into the low-
pressure
oil chamber of oil circuit through the two check valves inside the rear end cover of main pump.
One check valve is open, and as actuated by high-pressure oil, another check valve is closed
in the main oil circuit of the other side, which forms a continuous circulating oil flow.
In the traditional closed system of main pump and oil motor, an integrated valve is
mounted on the rear cover of oil motor. To ensure the normal working of traditional closed
system, the integrated valve is supplied with two safety valves, one shuttle-shaped valve and
one low-pressure overflow valve. The two safety valves are connected onto the two main oil
circuits in parallel. At a sudden overloading of any oil circuit, the safety valves will be opened
automatically to discharge and ensure the safety of oil circuits of oil pump and oil motor. One
shuttle-shaped valve will be able to set up a low-pressure oil circuit respectively in the two
main oil circuits, and its spool will be maintained in the central closing position when actuated
by spring, in which case the high-pressure oil won’t be lost in the oil circuit at the reversal time
of oil flow in the main oil circuit. One low-pressure overflow valve acts to maintain the pressure
of low-pressure oil circuit and the auxiliary pump will join for the overflow of excessive cooling
oil in the circuit.
c. Cooling circuit
The excessive cooling oil out of the low-pressure overflow valve of integrated valve enters
into
the motor housing and flows into the oil pump housing through the oil pipe of motor housing, in
such a case the oil out of auxiliary cycloid pump of main pump through overflow valve flows
orderly across every hydraulic element and help to cool, and then the cooling oil flows out of
oil pump housing and into oil tank through oil radiator.
d. Structure and functions of manual displacement control valve
The displacement control valve, as designed, ensures a smooth and reliable variation of oil
pump (or motor) displacement, and through which it controls the speed and direction. Actuated
by a lever handle, it swings to the left and right of neutral position to control the two servo oil
cylinders. Since the damping exists at the oil inlet of control cylinder, the speedup will be
limited. The control lever of valve is mounted with a spring to keep the spool at the central
position and close the oil inlets of the two servo oil cylinders. The return spring of servo oil
cylinder acts to make swash plate automatically return to the neutral position for automatic
stop.
The axial variable displacement plunger pump is connected with motor by the elastic coupling, and
the variable displacement motor is connected with the reducing gear box at a reduction rate of
2.12. The front and rear drive shafts run between the reducing gear box and front and rear
axles. When the driver steps down the advancing or reversing pedal, the control lever will
swing left and right through mechanical connecting rod to control the two servo oil cylinders
and change the deflection and angle of rotary swash plate. When the swash plate is in the
vertical position, the machine will be in the neutral position, and in which case the nine
plungers of oil pump won’t reciprocate inside the oil pump and the oil won’t flow out of the
pump. When the rotary swash plate deflects to the left, the oil will be pumped to one end of oil
motor so that the machine moves forward, and when the rotary swash plate deflects to the
right, the oil will be pumped to another end of oil motor so that the machine moves backwards.
The greater the angle of deflection of swash plate, the greater the plunger stroke and the larger
the oil volume at every turn, and as a result, the oil motor will rotate more quickly to speed up
the scraper. The oil flow of main oil pump respectively at the neutral, advancing and reversing
position are shown in Fig. 5, Fig. 6 and Fig.7.
e. Oil tank and oil filter
The hydraulic oil tank for driving is on the upper part of right rear wheel of scraper. On the
top
of oil tank is provided with an oil filling port equipped with hydraulic air filter. In the middle of oil
tank is provided with a spacer plate to separate oil return section from oil suction section. On
the rear side of oil tank is mounted with an oil leveler. In the pipeline of oil return tank is
mounted with a filter of 10μm at the oil filtering fineness and 100 L at the filtering capacity.
The filter of oil tank must be cleaned and filter element must be replaced every 500 working
hours. The oil added into oil tank must be up to the upper limit of oil leveler.
f. Radiator
The hydraulic oil radiator is mounted on the end of diesel engine. The oil out of oil return
port
of variable displacement plunger pump returns to the oil tank after being cooled by radiator.
The radiator is to blow away heat by the aid of the fan at the end of diesel engine.
g. Hydraulic oil
The driving system of the machine uses HM-N68 abrasive-resistant hydraulic oil, and its
performance parameters must be:
Kinematic viscosity (st) 50℃ 37～43
100℃ 10～13
Solidifying point (℃) No more than -38
Moisture No more than Mark
Flash point (open) (℃) No less than 170
Mechanical impurities (%) No more than 0.01
Water-soluble acid and alkali NIL
Corrosion (copper sheet, 100℃, 3 hrs) Qualified
Anti-foam test (ml) No more than 15% of mark at 75℉ and 200℉
Low-pressure oil
Fig. 5 Diagram of Oil Flow (Neutral Position)

1. Variable displacement oil motor 2. Integrated valve 3. Auxiliary pump
4. Variable displacement oil pump 5. Oil tank 6. Oil filter 7. Oil radiator
High-pressure oil
Low-pressure oil
Fig. 6 Diagram of Oil Flow (Advancing)

High-pressure oil
Low-pressure oil
Fig. 7 Diagram of Oil Flow (Reversing)

Precautions:
i. The entry of water, emulsion, dust and mechanical impurities must be avoided.
ii. At running, the oil level of oil tank must be kept at a definite height to ensure the unblocking
of the system’s oil suction pipe and oil return pipe and avoid the presence of bubbles in oil.
iii. At the continuous running, the oil temperature inside the oil tank must not exceed 70℃.
iv. At the oil change, the oil tank and pipeline of hydraulic system must be cleaned, and the
new oil must be filtered before filled into the oil tank. The oil must be10μm at the
filtering fineness.
v. Cycle of oil change: it’s required to change oil completely after being used for no more
than three months to the maximum for the first time, and afterwards you’d better change
the oil every six months.
(2) Mechanical drive system

The front and rear wheels are driven simultaneously when the machine is running. The
output
torque of oil motor of static hydraulic system, after being decelerated by transfer case, drives
the front and rear axles through the front and rear drive shafts, and then the front and rear
wheels after the secondary deceleration.
a. Transfer case
The transfer case is in helical gear, which features the advantages of less noise, reliable
load
carrying capacity and more compact structure. The structure is shown in Fig. 8 and Table 4-1.
b. Front and rear drive shafts
The front universal joint flange of front drive shaft (see Fig. 9 and Table 4-2) is connected with
front axle, and the rear universal joint flange is connected with brake disc flange of transfer
case. The front drive shaft is supplied with three universal joints. To take the central universal
joint as a dividing line, the front drive shaft can be divided into front and rear sections. The front
section is
supplied with a support bearing to support the front half of drive shaft on the front frame.
Among the two universal joint forks in the rear half of front drive shaft, one is spline shaft and
another is spline housing. The spline shaft can make relative movement within the spline
housing to adapt to the length change of drive shaft at steering. Every universal joint fork,
bearing and spline of front drive shaft is supplied respectively with a grease fitting for the
regular greasing use.
The rear drive shaft transfers the driving torque from transfer case to rear axle. It is
supplied with two universal joints, where the universal joint forks are also supplied respectively
with a grease fitting for the regular greasing use. See Fig. 10 and Table 4-3.
c. Driving axle
The scraper is to transfer motive power from front and rear drive shafts to front and rear axles.
Both front axle and rear axle are in the same structure, which consist of master driver, half
axle, wheel side brake (see Fig. 11 and Table 4-4) and wheel side reducer (see Fig. 12 and
Table 4-5).
i. The main driver consists of a pair of spiral bevel gears and planetary differential. The
planetary differential is composed of four conical straight-toothed planetary bevel
gears and two conical straight-toothed half axle gears. The differential spider is
integral. The left and right half axles are full-floating. The wheel side reducer is
planetary wheel type and its internal teeth are fixed on the half axle sleeve by spline
without rotation. The planet carrier and hub are fixed into an integral part. Accordingly,
the sun gear receiving the torque of half axle actuates the planet carrier to drive the
hub and wheels. See Fig. 13 and Table 4-6).
ii. Adjustment of bearing preload: The axial clearance of driving spiral bevel gear
bearings is 0.05～0.1 mm. The methods of check and adjustment are: Firstly, to
dismount drive shaft, remove cotter pin, tighten castle nut at the torque of 180～220
Nm, then to measure the difference of distance between the flange on the top end of
sealing gland and the end of dust shield on the input flange before and after being
tightened. To adjust it, If exceeding 0.1 mm (or feel to exceed 0.1 mm when pushing
the input flange). At the adjustment, firstly to remove the driving spiral bevel gear and
bearing seat from master driver, then to adjust the adjusting shim between the two
bearing races. After that, the driving spiral bevel gear must be able to rotate at the
torque of 2～5 Nm. To tighten the castle nut, it’s required to rotate the driving gear
repeatedly and keep the bearing rollers in the normal position.
Table 4-1
A Detailed List of Parts for Transfer Case
No. Drawing No. Description Qty Remarks

1 K147.17A-1 Bearing cap 1
2 GB1096-79 Key 16×36 2
3 NJ130-2402050 Oil seal of angular gear 2
4 NJ130-2402041 Flange 1
5 K147.17A-4 Spline shaft 1
6 GB297-64 Bearing 7309 2
7 8-38124 Castle nut 1
8 K147.17A-5A Big gear 1
9 K147.17A-6 Brake disc 1
10 K147.17A-7A Intermediate gear 1
11 K147.17A-8 Intermediate shaft 1
12 K147.17A-9 Shaft end cover 1
13 GB297-64 Bearing 7206E 2
14 K147.17A-11 Bearing cover 1
15 GB297-64 Bearing 7509 2
16 K147.17A-15A Shaft gear 1
17 K147.17-15 Rubber washer 2
18 K146.2-26 Screw plug M24×1.5 2
19 K147.17A-17 Screw plug for air discharge 1 Altered from M10×16 bolt
20 K147.17-13 Coupling sleeve 1
21 K147.17A-13 Case body 1
22 K147.17A-21 Bearing cap 1
23 K147.17.1.00 Parking brake shield 1
24 K147.17.2.00 Brake seat 1
25 K147.17-21 Drain plug 1
Fig. 9 Front Drive Shaft (See Table 4-2)
Table 4-2
A Detailed List of Parts for Front Drive Shaft
No. Drawing No. Description Qty

1 GB5785-86 Bolt M12×1.25×35 8
2 NJ130-2201023 Flange fork of universal joint of drive shaft 4
3 GB93-87 Washer 12 8
4 GB6171-86 Nut M12×1.25 8
5 NJ130-2201050A Assembly of universal joint spider of drive shaft 3
6 NJ130-2402041 Flange of driving cone gear of rear axle 2
7 K147.4-1 Drive mandrel 1
8 JB1642-57 Spherical outside surface bearing Z90509 1
9 K147.4.1.00 Drive shaft tube 1
10 NJ130-2201040B Assembly of sleeve fork of drive shaft 1
Table 4-3
A Detailed List of Parts for Rear Drive Shaft

1 K147.21-1 Sleeve fork 1
2 NJ130-2201050A Assembly of universal joint spider of drive shaft 2
3 GB5785-86 Bolt M12×1.25×40 4
4 NJ130-2201023 Flange fork of universal joint of drive shaft 3
5 K147.21-2 Backing plate 1
6 GB93-87 Washer 12 4
7 GB6171-86 Nut M12×1.25 4
Fig. 10 Rear Drive Axle (See Table 4-3)
Fig. 11 Brake Assembly (See Table 4-4)
Table 4-4
A Detailed List of Parts for Brake Assembly

1 Q1501020 Bolt M10×25 2
2 Q40310 Washer 10 2
3 K147.3.3-2 Brake bottom plate 1
4 Bleed bolt 1
5 NJ130-3502060 Brake cylinder assembly 1
6 Return spring 2
7 Leather cup 2
8 Piston 2
9 Guard 2
10 Push rod 2
11 NJ130-3502065 Return tension spring 1
12 NJ130-3502080 Brake shoe assembly (left rear, right rear) 1 each
13 Brake band 2
14 Aluminum rivet 36
15 NJ130-3501132 Brake shoe backing pin 2
16 NJ130-3501134 Locking plate 2
17 NJ130-3501133 Bearing plate of brake shoe backing pin 1
18 Q340316 Nut M16 2
19 GB93-87 Washer 16 2
Fig. 12 Driving Axle (See Table 4 -5)
Table 4-5
A Detailed List of Parts for Driving Axle

1 HG-692-67 Oil seal SG140×170×16 2
2 GB297-64 Bearing 7222 2
3 K147.3-7 Half axle 2
4 JB1001-77 Screw plug M18×1.5 2
5 K147.3-7 Hub 2
6 GB297-64 Bearing 2007120 2
7 K147.3-19 Internal gear 2
8 K147.3-13 Lock washer 2
9 K147.3-14/15 Internal & external nut 2, each
10 K147.3-17 Sun gear 2
11 K1473-16 Washer of supporting axle 2
12 K147.3-1/4/6 Planetary gearing assembly (planet carrier, planet gear, planet 2/6/6
axle)
13 GB5782-86 Bolt M14×45 32
14 GB93-87 Washer 14 32
15 CA10B Bolt and nut (right-hand rotation) of front rim 24
16 K147.3.1.00 Main reducer assembly 1
17 K147.3.2.00 Axle housing assembly 1
18 GB5782-86 Bolt M12×35 12
19 GB93-87 Washer 12 12
20 K147.3.3-3 Bolt M14×45 16
21 GB93-87 Washer 14 16
22 GB6170-86 Nut M14 16
23 GB5782-86 Bolt M16×40 16
24 GB93-87 Washer 16 16
25 K147.3.3-1 Brake drum 2
26 K147.3.3.00 Brake assembly 2
Fig. 13 Main Reducer (See Table 4-6)
Table 4-6
A Detailed List of Parts for Main Reducer

1 K147.3.1-2/6 Left/right differential housing 1 each
2 NJ130-2402012 Driven bevel gear 1
3 NJ130-2403052 Thrust washer of half axle gear 2
4 NJ130-2403051 Half axle gear 2
5 NJ130-2403058 Thrust washer of planet gear 4
6 NJ130-2403055 Differential planet gear 4
7 NJ130-2403061 Differential spider 1
8 K147.3.1-4 Bearing cap 2
9 GB5782-86 Bolt M16×12 2
10 K147.3.1-9 Locking washer 2
11 K147.3.1-3 Adjusting nut 2
12/13 Thrust bearing 807813 (internal, external) 2
14 K147.3.1-1 Differential carrier 1
15 NJ130-2402020 Bearing housing of drive gear, thrust bearing 27709 1
16 NJ130-2402017/18/19 Adjusting shim of bearing housing of drive gear 1 set
17 NJ130-2402051 Bearing cap of drive gear 1
18 GB5782-86 Bolt M12×45 6
19 GB93-87 Washer 12 6
20 NJ130-2402041 Flange of drive bevel gear 1
21 8-38124 Nut M24×1.5 1
22 NJ130-2402042 Washer 1
23 NJ130-2402043 Dust shield of drive bevel gear flange 1
24 NJ130-2402050 Bearing oil seal of drive bevel gear 1
25 NJ130-2402029 Spacer 1
26 GB93-87 Washer 16 4
27 GB32.1-88 Bolt M16×70 4
28 NJ130-2402011 Drive gear 1
29 NJ130-2402022 Roller bearing 102605 1
30 NJ130-2402013 Rivet 12
iii. It is required to adjust the preload of differential planet bearing by moving the
adjusting nuts on both ends before it is mounted into the drive gear, then to tighten
the fastening bolt of bearing cap at the torque of 170～200 Nm. After being
adjusted, the differential assembly must be rotated at the torque of 2.5～3.5 Nm. It
is required to rotate the spiral bevel driven gear repeatedly at preloading and keep
the bearing roller in the normal position.
iv. Adjustment of clearance between thrust bolt and spiral bevel driven gear: The
clearance must be 0.35～0.5 mm. At the adjustment, to screw the thrust bolt to the
reverse side of driven gear and then unscrew 1/4 turns. After the adjustment, to
tighten the locking nut (not to drive the thrust bolt) and lock with locking plate.
v. Adjustment of tooth surface meshing and backlash: Firstly to adjust the tooth surface
meshing, and the tooth surface meshing is marked by the double side coloring method.
To check the tooth surface of spiral bevel driven gear (3～4 points evenly distributed
around the circumference, 1～2 teeth each point). The correct mesh mark is illustrated
in Fig. 14. Its length is about 60% of tooth width, inclining slightly to the small end of
tooth and 0.8～2 mm lower than the crest. The adjustment of mesh mark is to increase
or reduce the quantity of adjusting shims between the spiral bevel drive gear bearing
sleeves, that is to change the position of spiral bevel drive gear.
Fig.14 Correct Meshing of Spiral Bevel Driven Gear
vi. The backlash of spiral bevel drive (or driven) gear is 0.15～0.35 mm. Just to adjust the
adjusting nut of differential bearing (that is to change the axial position of driven gear).
The value of backlash can be measured on the big end of driven gear with dial
indicator. At the measuring, the contact of dial indicator must be perpendicular to the
big end. The contact of dial indicator must be perpendicular to the convex surface of
big end and it’s required to measure at least four teeth evenly distributed around the
circumference. It’s required to adjust the bearing preload well before adjusting the
backlash. To ensure no change of bearing preload at the adjustment of backlash, it’s
required that the tightening (loosening) degree of adjusting nut on one end must be
appropriate to that of adjusting nut on the other end.
vii. The backlash between differential’s half axle gear and planet gear is 0.1 mm. To
adjust with the gasket for half axle gear, and after being assembled it must be assured
that they can be rotated easily with hand, but without being seized up.
viii. To repair and replace the gear of wheel side reducer, it is required to check the contact
by coloring. The contact area and depth of tooth must be more than 45% and the
length along the axle must be more than 60%.
ix. Adjustment of hub bearing preload: Firstly to mount the internal gear of planetary
reducer, screw up the round nut tightly until the hub can rotate narrowly, then to
unscrew the round nut for 1/10 turns. At this moment, the hub will rotate freely without
axial float. At the adjustment, it’s required to rotate the hub repeatedly and keep the
bearing roller in the correct position.
Tire: 10.00-20G2, 14-ply off-the-road tire, 0.6 Mpa at the inflation pressure.
◎Working device for shoveling and loading
The hydraulic system of the working device consists of oil tank, oil pump, multiple change
valve, lifting oil cylinder, tilting oil cylinder and pipeline fittings as required. It’s equipped with
single-bucket forward tilting mechanism. The bucket can be with tips or without tips. The
movable arm is in the box section. The front end of movable arm is articulated with the bottom
of bucket by pin shaft, and its rear end is articulated with the front frame by pin shaft. The tilting
oil cylinder is connected with the bucket by the connecting rod. See Fig. 15.
Fig. 15 Schematic Diagram of Working Device and Hydraulic System
1. Bucket 2. Movable arm 3. Tilting Oil cylinder 4. Multiple change valve

5. Lifting oil cylinder 6. Oil pump 7. Connecting rod
WORKING PRINCIPLE OF WORKING DEVICE FOR SHOVELING AND LOADING
The lifting and tilting of the bucket are controlled by the lifting control lever and tilting
control lever respectively. These two levers are both mounted on the same axle. See Fig. 16.
a. Position of no actuation (zero position)

When the motor starts up the oil pump, the spool of multiple change valve does not move. The
oil from oil pump flows back directly to oil tank via multiple change valve, and won’t enter into
the lifting oil cylinder and tilting oil cylinder. See Fig. 17.
b. Lifting position
When the lifting spool of multiple change valve moves to the lifting position, the oil from the
oil
pump flows to the oil port on the bottom of lifting oil cylinder via multiple change valve and lift
up the movable arm by actuating the piston rod of oil cylinder. The return oil from oil cylinder
flows back to multiple change valve via the oil port at the end of piston rod of oil cylinder, and
returns from the return oil port to the oil tank through oil hose. See Fig. 18.
There is a floating position when the multiple change valve lifts the slide valve, and on
this position, the hydraulic oil enters or comes out of two ports of the cylinder freely.
When the bucket is set on the position of shoveling and loading and the lifting control
lever is pushed to the floating position, the movable arm will float up and down only to
the height of working face and facilitate to clear the ground.
Fig. 16 Operating System for Working Device
1. Cotter pin 2. Pin shaft 3. Connecting fork 4. Handle ball

5. Control lever of tilting oil cylinder 6. Control lever of lifting oil cylinder
7. Bottom plate 8. Connecting-rod sleeve 9. Bolt 10. Nut
Fig. 17 Operating Conditions of Lifting and Tilting (Diagram of Oil Flow on the Zero
Position)
Fig. 18 Operating Conditions of Lifting and Tilting (Diagram of Oil Flow at Lifting)
c. Tilting and unloading device

To tilt forward, just push forward the tilting control lever, then the piston rod of tilting oil cylinder
will extend out and the bucket will tilt forward. At this moment, the spool of tilting slide valve of
multiple change valve will move to the tilting position, and the oil will flow from oil pump to the
oil port on the bottom of tilting oil cylinder via change valve, actuate the piston rod to extend
out and enable the bucket to tilt, then the return oil will flow out of the oil port at the end of
piston rod and return to the oil tank via multiple change valve. However, to contract the oil
cylinder and tilt the bucket, the oil flowing direction is contrary to that at tilting.
Fig. 19 Operating Conditions of Lifting and Tilting (Diagram of Oil Flow at Tilting)
Fig. 20 Lifting oil cylinder
Table 4-7
A Detailed List of Parts for Lifting oil cylinder

1 GB304.7-81 Joint bearing GE60C 1
2 K147.1.4-1 Cylinder head 1
3 K147.1.4-2 Piston rod 1
4 GB894.1-86 Retainer ring 50 1
5 K147.1.4-3 Clip key sleeve 1
6 K147.1.4-4 Clip key 1
7 JB/ZQ4264-86 Yx seal ring for hole 2
8 K147.1.4-5 Retainer ring 2
9 JB/ZQ4224-86 O-ring 50×3.5 1
10 K147.1.4-6 Guide ring 1
11 K147.1.4-7 Piston 1
12 K147.1.4-8 Cylinder barrel 1
13 K147.1.4-9 Guide sleeve 1
14 K147.1.4-10 Cylinder sleeve 1
15 JB/ZQ4224-86 O-ring 140×5.7 1
16 K147.1.4-11 Clip key 1
17 JB/ZQ4265-86 Yx seal ring for axle d70 1
18 K147.1.4-12 Retainer ring 70 1
19 K147.1.4-13 Thrust sleeve 1
21 JB/ZQ4607-86 Dustproof ring 70 1
22 K147.1.4-14 Axle sleeve 1
23 K147.1.3-15 Elbow 1
24 K147.1.4-15 Oil pipe 1
25 K147.1.4-16 Elbow 1
Table 4-8
A Detailed List of Parts for Tilting oil cylinder
No. Drawing No. Decription Qty

4 K147.1.3-3 Clip key 1
5 JB/ZQ4246-86 Yx seal ring for hole D125 2
7 K147.1.3-5 Guide ring 1
8 JB/ZQ4224-86 O-ring 45×3.5 1
9 K147.1.3-6 Piston 1
10 K147.1.3-7 Guide sleeve 1
11 K147.1.3-8 Cylinder sleeve 1
13 JB/ZQ4224-86 O-ring 125×5.7 1
14 K147.1.3-10 Clip key 1
17 K147.1.3-12 Thrust sleeve 1
20 K147.1.3-13 Piston rod 1
21 K147.1.3-14 Axle sleeve 1
22 K147.1.3-15 Elbow 1
23 K147.1.3-16 Oil pipe 1
24 K147.1.3-17 Elbow 1
25 K147.1.3-18 Sleeve 1
Fig. 22 Bucket
Table 4-9
A Detailed List of Parts for Bucket

1 K147.1.1.1-10 Side plate 2
2 K147.1.1.1-20 Side rib 2
3 K147.1.1.1-17 Central rib 2
4 K147.1.1.1-8 Cutting blade 1
5 K147.1.1.1-5 Limit stop 1
6 K147.1.1.1-6 Bottom plate 1
7 K147.1.1.1-16 Connecting-rod seat 1
Fig. 23 Movable Arm
Table 4-10
A Detailed List of Parts for Movable Arm

1 K147.1.2.00 Movable arm 1
2 K147.1-15 Nut 2
3 K147.1-22 Moving stop 2
4 K147.1-5 Front/rear axle liner 4
5 GB1152-79 Oil cup M10×1 4
6 K147.1-19 Central axle pin 2
7 GB91-88 Cotter pin 4×40 1
8 K147.1-11 Rear axle 1
9 K147.1-10 Flat washer of rear axle 2
10 K147.1-6 Gland 2
11 K147.1-7 Front axle 1
Fig. 24 Connecting Rod
Table 4-11
A Detailed List of Parts for Connecting Rod

1 K147.1-8 Connecting rod 1
2 K147.1-17 Rear axle pin of connecting rod 1
3 K147.1-1 Front axle liner of connecting rod 1
4 K147.1-1 Rear axle of connecting rod 1
5 K147.1-3 Front axle of connecting rod 1
6 K147.1-2 Flat washer of front axle of connecting rod 2
◎Steering device and hydraulic system
The front and rear frames of WJ-1 diesel scraper may deflect left or right around the
central articulated axle, when actuated by the double-acting oil cylinder on the front and rear
frames. The oil cylinder head is connected with the front frame, and the piston rod is
connected with the rear frame. As actuated by hydraulic pressure, the piston will move to
drive the front and rear frames to deflect relatively and accomplish the steering of scraper.
The steering hydraulic system mainly consists of steering control system, fully hydraulic
steering gear, steering oil cylinder, gear pump and oil tank, etc. See Fig. 25.
The schematic diagram of its hydraulic system can be referred to in Fig.25.
Fig. 25 Schematic Diagram of Steering Hydraulic System
(1) Fully hydraulic steering gear

The fully hydraulic steering gear is mainly composed of oil distributing section and
metering
section, and its rotor and stator are a pair of cycloid internal gears. At the power steering, it
acts as the metering motor to ensure that the rate of flow into oil cylinder is directly proportional
to the turn angle of steering wheel. At the manual steering, it acts as the oil pump. The spool,
valve sleeve and valve body constitute the follow-up rotary valve to control the direction of oil
flow. This steering gear is supplied with the FKAR valve block which includes the overflow
valve, two-way cushion valve and check valve. The overflow valve is located between oil inlet
and oil outlet to limit the maximum pressure of steering gear and protect the steering hydraulic
system. The two-way cushion valve is to act as a cushion to the valve action when the
machine encounters a large resistance (for example, rock and pit) anywhere, so as to reduce
the pressure inside the system and protect steering oil cylinder. The check valve is to avoid the
reverse flow of high-pressure oil through the steering gear and avoid the entry of air into oil
pump at manual steering, when the pressure on the side of oil cylinder is higher than that of
pump. See Fig. 26 and Table 4-12.
Fig. 26 Steering Control Mechanism
Table 4-12
A Detailed List of Parts for Steering Control Mechanism

1 GB6175-86 Nut M16×1.5 1
2 8470429.301 Steering column (with the horn wire) 1
3 FKAR-102010 Valve block (M20×1.5 for PO, M18×1.5 for A, B) 1
4 JB1002-77 Washer 18 1
5 GB1235-76 O-ring 20×2.4 1
6 BYZ1-320 Fully hydraulic steering gear 1
7 GB70-85- Screw M10×30 4
8 GB70-93 Washer 10 4
9 JB1002-77 Washer 20 3
10 GB5631.2 Pipe joint 14 1
11 K147.9-1 PO joint 2
12 K147.9-2 A joint 1
13 K147.9.1.00 Steering wheel 1
14 K147.9.3.00 Mounting bracket 1
(2) Steering oil cylinder. See Fig. 27 and Table 4-13.
Fig. 27 Steering oil cylinder
Table 4-13
A Detailed List of Parts for Steering oil cylinder

1 GB304.7-81 Joint bearing GE40C 1
5 K147.11.1-4 Elbow 1
8 K147.11.1-6 Clip key 1
9 K147.11.1-7 Guide ring 1
10 JB/ZQ4224-86 O-ring 28×3.1
12 JB/ZQ4264-86 Yx seal ring for hole D80 2
13 K147.11.1.1-2 Cylinder sleeve 1
15 K147.11.1-11 Elbow 1
16 JB/ZQ4224-86 O-ring 80×3.5 1
17 K147.11.1-12 Clip key 1
20 K147.11.1-14 Sleeve 1
22 K147.11.1.1.00 Cylinder sleeve 1
24 K147.11.1-15 Piston rod 1
25 K147.11.1-16 Axle sleeve 1
26 K147.11.1-17 Oil pipe 21
(3) Working principle of steering system

The steering system can be on the three operating conditions of straight-line running,
power steering and manual steering whilst at working.
a. Straight-line running
When the scraper is on the straight-line running condition, the motor drives the gear pump
to
pump hydraulic oil into fully hydraulic steering gear, but the steering wheel does not rotate
at this moment and the spool and valve sleeve of steering gear are in the neutral position.
The hydraulic oil flows back into oil tank directly through the inner chamber of steering gear
and the hydraulic oil of steering system is in the state of idle circulation.
b. Power steering
When the scraper turns (for example, left turn), the steering wheel drives the spool to rotate
counterclockwise, and six short slots on the spool will link up respectively with six holes on the
valve sleeve so that the pressure oil drives through cycloidal gear pair (metering motor) the
rotor to rotate clockwise around the axial line of stator tooth, squeeze a given amount of oil into
the right chamber of steering oil cylinder and actuate the piston of oil cylinder. However, the
hydraulic oil of left chamber is connected to the oil tank to achieve the power steering.
When the rotor of metering motor, actuated by pressure oil, rotates clockwise around the axial
line of stator, it also rotates counterclockwise around the axial line of its own and drives the valve
sleeve to rotate counterclockwise via pin shaft. In which case, the relative position of valve sleeve to
spool also restores gradually to the neutral position and the pressure oil returns to the oil tank
through the inner chamber of spool to stop steering. If the steering wheel continues to rotate
counterclockwise, the system will continue to repeat the above steps in the follow-up motion.
When the scraper turns to the right, the steering wheel actuates spool to rotate counter-
clockwise, and its working principles are the same as those for left turn.
c. Manual steering
When the scraper loses its power source and must be towed by other equipment without entry
of pressure oil into steering system, its steering wheel can be rotated manually for the purpose
of hydraulic steering to ensure a free steering even if it is being towed without presence of
power source.
At the manual rotation of steering wheel, it is to drive the rotor of metering motor through
spool pin and coupling, squeeze the oil of one chamber of steering oil cylinder into another
chamber and actuate the machine to steer. The capacity deficiency of two chambers of oil
cylinder is made up by hydraulic oil in oil tank through the oil return port.
◎Engine
The engine is BF4L2011 engine from Germany. Its configuration structure can be referred
to in Fig. 28.
The engine is a two-stage combustion air-cooled diesel engine for downhole operation.
1. Cooling system of the engine

As the direct air-cooled engine runs, one of its functions is to directly control the
temperature rise of engine. At the temperature rise, the engine will reach its working
temperature very quickly because no coolant is heated.
The air-cooling system of the engine only supplies the necessary cold air volume
appropriate to the working cycle. Under every operating condition, it is to maintain the best oil
temperature of engine against unnecessary energy loss. As compared with some indirect air-
cooled engines, the direct air-cooled engine will reach its working temperature more quickly,
and at preheating, it will largely reduce frictional loss (less fuel consumption) and reduce the
discharge of harmful pollutant by half.
2. Two-stage combustion system of the engine
This kind of combustion system is to inject fuel into a swirl chamber with hot air, where the hot
air volume is only half of the volume as required for fuel combustion. At the precombustion, the
insufficient air supply will limit the generation of nitric oxide and thus the harmful substance, as
generated, is very little.
The supercharging at precombustion will push the comburent in the first stage
combustion that has not been combusted completely into the twin swirl combustion chamber
for a further combustion. Because of sufficient air supply, very low temperature and highly
turbulent flow in the second stage combustion, the generation of nitric oxide is further limited
and harmful substance is further reduced. Also, since the combustion is in the two stages, and
additionally, the fuel is highly mixed with air, it helps to reduce carbonization and carbon
oxides remarkably, without the smell of diesel oil typically from the direct injection diesel
engine.
3. Exhaust gas cleaning system of the engine
The exhaust gas emitted from diesel engine contains CO and other inflammable gases,
and following their entry into exhaust system, very small amount of CO in the exhaust gas will
limit the increase of heat when catalyzed. The usual way of check on the cleaning effect of
exhaust gas from diesel engine is to smell the exhaust gas. The exhaust gas, after being
cleaned, contains carbon dioxide, steam and other transformation substances only.
4. Simple working principle of four-stroke diesel engine
Every working cycle of four-stroke diesel engine consists of four processes, such as air
intake, compression, expansion and exhaust. The working cycle of four-stroke diesel engine is
shown in the figure.
Intake stroke: The pistons moving downwards from the top dead center, intake valve
opened, exhaust valve closed and the pure air sucked into cylinder.
Compression stroke: The pistons moving upwards from the bottom dead center, intake
valve and exhaust valve closed and the air compressed inside cylinder. By the end of compression
2
stroke, the pressure inside cylinder is 30～50 kg/cm , and the temperature rises to 500～700℃.
Expansion stroke: When the compression stroke approaches the top dead center, a
certain amount of misty diesel oil will be injected, through injection pump, into the combustion
chamber via injection nozzle to expose in the hot air and ignite itself. For a rapid burning of
diesel oil and sharp rise of temperature of fuel gas, the pressure inside cylinder may increase
2
to 60～100 kg/cm and drive the pistons for work.
Exhaust stroke: the pistons moving upwards from the bottom dead center, the waste gas
is exhausted from the opened exhaust valve until the pistons move upwards to the top dead
center and a working cycle is completed.
By the end of exhaust stroke, another cyclic intake stroke is followed rapidly in such a
way that numerous working cycles are repeated for a continuous running of diesel engine.
Working Cycle of Four-stroke Diesel Engine

A: Intake B: Compression C: Expansion D: Exhaust
BF4L2011 保养面(右面) BF4L2011 maintenance side (right)
1. Oil filling port
2. Supercharging air pipe
3. Cooling fan and integral generator
4. V-belt
5. Stopping electromagnet
6. Notched synchronous timing belt guard
7. Crankshaft belt pulley
8. Oil sump
9. Shutdown handle
10. Throttle pull-rod
11. Oil leveler
12. Crankcase
13. Oil filling port
14. Oil transfer pump
15. diesel oil filter element
16. Cab’s warm air connector
17. Control valve (CPD)
18. Oil filter element
19. Fan guard
20. High-pressure pump (inside fan guard)
21. Oil radiator
BF4L2011 排气面(左面) BF4L2011 exhausting side (left)

22. Cylinder head
23. Exhaust manifold
24. Flywheel
25. Starter motor
26. Crankcase
27. Oil inlet pipe of supercharger lubricating oil
28. Oil return pipe of supercharger lubricating oil
29. Air inlet of supercharger
30. Supercharger
31. Connector of supercharger and supercharging air
pipe
32. Supercharging air pipe
5. Braking device
The scraper’s braking device
consists of two independent systems, such as service brake and parking brake.
a. Service brake
The scraper’s service brake mainly consists of brake master cylinder, brake pedal, brake
(brake cylinder, brake shoes, brake bottom plate, brake drum), pipe and joint, etc. The
structure of brake assembly can be referred to in Fig. 14. The schematic diagram of brake
system can be referred to in Fig. 30.
Fig. 30 Schematic Diagram of Brake System

1. Brake pedal 2. Brake master cylinder 3. Brake assembly
The brake master cylinder is within the driver’s cab of front frame. When the operator
steps down the brake pedal of brake master cylinder, the pressure oil from master cylinder will
flow into brake cylinder through the pipe. Then the brake cylinder will overcome the acting
force of tension spring of brake shoes to push the brake shoes out and the friction linings on
the brake shoes will be pressed against the brake drum to stop the machine. The brake
cylinder and brake shoes are all mounted on the brake bottom plate connected with drive axle
housing. The brake drum is connected with the wheel hub and it rotates with wheel. When the
brake pedal of master cylinder is released, the brake oil on the top of brake cylinder will, as
actuated by tension spring, return to master cylinder through the pipe, and the brake shoes will
be pulled back to cause no brake action and the machine can run then.
Adjustment of clearance between brake shoes and brake drum:
Firstly, loosen the lock nut, then turn the adjusting bolt. At adjusting, check with feeler
gauge in the inspection hole to keep the clearance highest to 0.25 mm and lowest to 0.12 mm
between shoes and drum. Then, tighten the lock nut.
b. Parking brake
The scraper’s parking brake is central hydraulic spot-type disc brake of spring brake and
hydraulic release. The parking brake mainly consists of supercharging cylinder, manual change
valve, brake, brake disc mounted on the reducing gear box and pipe, etc. After the machine is
started, the motor drives the axial variable displacement plunger pump, and its slippage pump
pumps out the pressure oil at 1.37 Mpa, which comes into the supercharging cylinder through
manual change valve to supercharge. Then, the supercharged pressure oil pushes the brake
pistons, the pistons compress the spring, the brake shoes are released and the machine runs.
At parking and disconnecting the oil flow of slippage pump, the spring returns to push brake
pistons to press against brake shoes and the brake shoes press tightly against brake disc to
stop the machine. The schematic diagram of its system can be referred to in Fig. 31. If the
hydraulic oil in the supercharging cylinder leaks out, just keep the manual change valve at the
position of oil refilling.
Electrical system
This chapter describes the electrical system of WJ-1 diesel engine from us in details. The
user must read carefully and have a thorough understanding of the scraper’s electrical control
in order for the correct operation and maintenance of its electrical system. Since the product is
being updated and its electrical system is altered constantly, we’ won’t notify you of any
possible discrepancy between this chapter and your newly-purchased WJ-1 diesel engine with
regard to the electrical system, and the Electrical Schematic Diagram herein shall prevail. The
electrical system of WJ-1 diesel engine is described as below.
The prime mover of WJ-1 diesel engine is diesel generator. The electrical system is to
control the starting, running and stopping of engine and designed for power supply to the
monitoring, illuminating, radio and sound systems of the scraper.
a. Configuration of electrical system
Fig. 32
The configuration of electrical system is shown in the above figure, and the specific
meaning of every item designation herein is shown in the Electrical Schematic Diagram.
1. Electrical system of engine (see the Engine above-mentioned);
2. Electrical cabinet;
3. Instrument case (see Fig. 2);
4. Illumination system;
5. Monitoring system;
6. Radio and sound system.
Fig. 33
b. Electrical principle
i. Electrical Schematic Diagram (see Fig. 3)
ii. Principle
The voltage of electrical system is 24V, DC. The storage battery supplies power source to
the starter and system. When the generator receives the exciting current and creates
a magnetic field, the rotor of generator rotates and generator starts to generate
electricity. The voltage of generator is automatically controlled by voltage regulator.
When the key switch turns counterclockwise from position 0, the engine is preheated.
The preheating time is automatically controlled by the preheating relay. The
preheating is ended when the yellow light of preheating signal lamp lights out. The
engine stops when the stopping electromagnet loses excitation. The alarm sounds
when the oil is lower than the specified value, and the alarm sounds when the oil
temperature is higher than the specified value. The performance of alarm signal lamp
and buzzer can be identified by pressing the test button.
c. Operation
When all systems of the scraper are ready, switch on the limit switch S4 and master power
switch S1. Press the horn button to remind the people nearby of keeping away from the
machine. Insert the key into key hole to rotate counterclockwise and preheat (at -30℃～-10℃).
The yellow light lights up, and the preheating ends until the yellow light is off. Then turn the key
to the end clockwise until the starter and engine run, release your hand, keep the key at the
position 1, and the starting is completed. At stopping, set the key at the position 0, and the
engine stops.
d. Precautions at starting
i. If not started up, to start again until the gear returns to the inoperating position.
ii. Preheat the engine at starting in winter.
iii. The starting time of starter must not exceed 10 seconds, and the starting interval must
be one minute.
iv. If not started up several times, to check the engine, starter, storage battery and wiring
connections, etc. Find the reasons and eliminate the troubles, if any.
v. Release the key immediately after the engine is started so that the starter’s gear returns to
the original position.
Wiring diagram of terminal box on the top of engine
Part E Lubrication, Maintenance and Safety System
1. Lubrication
Since the scraper is used for underground mining under the severe operating conditions,
the
regular maintenance and service must be ensured. So and so only, you can increase its reliability,
always keep it in the good technical conditions without earlier wear-out and prolong its service life.
The lubricating points are shown in Fig. 34 and Table 5-1.
Fig. 34 Lubricating Points
Table 5-1
A List of Lubrication System
No. Description Lubricant Interval Remarks

1 Connecting pin of movable arm and bucket Calcium base grease 10～12h Squeeze grease
2 Connecting pin of rolling bucket arm and bucket Calcium base grease 10～12h Squeeze grease
3 Rear axle of small rocker arm Calcium base grease 10～12h Squeeze grease
4 Lubricating point of rear axle of movable arm Calcium base grease 10～12h Squeeze grease
5 Lubricating point of rear axle of tilting cylinder Calcium base grease 10～12h Squeeze grease
6 oiling point of service brake master cylinder Brake oil 10～12h Squeeze grease
7 Pin of steering cylinder Calcium base grease 10～12h Squeeze grease
8 Parking brake Calcium base grease 125h Squeeze grease
9 Oiling point of driving hydraulic oil SC 40# hydraulic oil 600h Replace
10 Oiling point of service hydraulic oil 40# hydraulic oil 600h Replace
11 Advancing/reversing pedal axle Calcium base grease 10～12h Squeeze grease
13 Oiling point of diesel oil Diesel oil

14 Supporting seat of front drive shaft Calcium base grease 10～12h Squeeze grease
15 Front drive shaft fork Calcium base grease 10～12h Squeeze grease
16 Front/rear axle housing Gear oil 1000h Fill
17 Planet hub Gear oil 1000h Fill
18 Transfer case Gear oil 1000h Fill
19 Central articulating pin Calcium base grease 250h Squeeze grease
20 Swing span Calcium base grease 50h Squeeze grease
2. Regular maintenance
The regular maintenance refers to the maintenance of scraper every 100 hours, every 400
hours and every 1200 hours.
a. Every 100 hours
i. Fasten the coupling bolts of driving axles;

ii. Check every air vent and remove dust;
iii. Check every pin of oil cylinder;
iv. Check the driving axles and oil level;
v. Check if the front and rear frames, bucket and movable arms are broken, curved
or torn up at the welded joints. Repair, if any.
b. Every 400 hours
i. Replace the grease of every system;
ii. Replace the filter element of oil filter;
iii. Check the fastening of parking brake, spot-type disc brake and the wear of service brake
lining.
c. Every 1200 hours
i. Replace the oil of every hydraulic system;

ii. Replace the lubricating oil of driving axles and transfer case;
iii. Check the pressure regulating devices of service hydraulic system and steering hydraulic
system.
d. To check oil level, the machine must be on a horizontal level;

e. To fill oil to the upper limit of service oil tank and driving oil tank, and five minutes after the
motor runs, to check again if the oil level is at the specified value.
f. Enclosed herewith the routine maintenance of BF4L2011 diesel engine only for reference
use.
3. Safety system
To avoid the accidents, you must strictly observe the following safety system when the
scraper is running:
a. The driver must, before operation, inspect carefully the conditions of each part of the
machine and also working environment, then operate strictly according to the
operational procedures;
b. Restricted by the underground working conditions, the people are forbidden to stand
around the machine or pile up other machine parts on the road;
c. At the lifting of movable arm, the people are forbidden to stand under the arm, and the
arm must be reliably supported at repairing;
d. At inspecting, repairing and oil filling, each part of the machine must be in the
stationary and stable state;
e. At the braking failure, it is required to check and repair, and often check the brake oil
and fill the oil, if necessary;
f. At parking, check if the parking brake is reliable, and the bucket must fall to the
ground;
g. Any people other than driver must not pull the control handle and operate the machine
at will;
h. It is required to release the air before dismounting and repairing the tires;
i. Often check the looseness of axle-end fastening bolts and tire bolts to avoid the
unexpected accident;
j. At inspecting, repairing and oil filling, it is required to stop the machine and lay the
bucket down to the ground.
4. Precautions for safety at the lubrication and maintenance
a. Before lifting the bucket and movable arm for the purpose of inspection and
maintenance, it is required to empty the bucket, support the movable arm reliably and
disconnect the power source;
b. At lubricating, it is required to clean the oil filler and lubricating points.
Part F Elimination of Common Troubles
1. Driving system
Trouble Causes Settlement
Low oil level. Check oil level of the tank, refill
an appropriate amount of oil, if
necessary.
Oil Leakage. Find the leaking point and
eliminate the trouble.
Connection trouble of control Check all connecting levers.
lever with oil pump. The control lever and control
handle of oil pump must be
reliably connected and free in
play without being pulled.
The scraper does not move at Serious leakage of slippage Check and repair the variable
advancing and reversing. pump, variable displacement displacement pump, variable
plunger pump and variable displacement motor and
displacement motor, causing slippage pump.
no driving due to a pressure of
1.59 Mpa or below within the
slippage pump.
Shaft coupling disjoined. Check the shaft coupling of
electric motor and oil pump.
The shaft coupling sleeve of oil
motor and reducing box must
not slip and break.
Trouble of control lever. Check lever mechanism.
The scraper moves only in one
Trouble of high-pressure Check high-pressure safety
direction.
safety valve valve.
Presence of air in the system. Bleed and tighten the leaking
point.
Seriously wear or increasing Replace or repair the key parts
outward leakage of port plate, of sealing surface.
Low or fluctuating pressure of lining plate and other key
driving hydraulic system. parts.
Failure of pressure valve of the Replace or repair the pressure
system. valve.
Shearing fracture of drive shaft Replace the oil pump.
of oil pump.
Low or zero pressure of Oil level excessively low or oil Fill new oil or clean oil suction.
slippage pump. suction blocked.
Pressure valve of slippage Dismount to clean the related
pump or integrated valve of elements, and replace, if
motor damaged or spool necessary.
seized up
Seriously wear or increasing Replace or repair the key parts
outward leakage of port plate, of seal surface.
lining plate and other key
parts.
Shearing fracture of drive shaft Replace the pump.
of slippage pump.
Presence of air in the system. Bleed and block up the leaking
point.
Seal surface seized by dirts or Clean and remove impurities
outward leakage increased. and filter the oil.
Slow at accelerating or Seriously wear or increasing Replace or repair the related
decelerating. outward leakage of port plate, parts, filter the oil and remove
lining plate and other key the factors of damage.
parts.
Serious outward leakage of Check the leaking point and
hydraulic system. block up the leakage.
Low oil level. Fill oil.
Blockage of filter or suction Replace the filter, clean or
pipe. replace the suction pipe.
Serious wear of pump or Repair the worn parts.
motor, too much oil refilled and
Too quick a temperature rise of less cooling oil.
hydraulic system. Low-pressure overflow valve of Adjust the pressure to be 0.28
variable displacement motor Mpa lower than that of
excessively high as adjusted. slippage pump.
Oil radiator blocked or too Clean or replace the radiator.
much dirt on the radiating fins
to affect the radiation.
2. Working hydraulic system
Insufficient oil in the working oil Check the oil level, replenish
tank, oil frozen or deteriorated hydraulic oil or heat to dilute
in quality. the oil or replace the oil.
Trouble at the connection of Check, repair or replace.
No action of hydraulic oil principal machine, causing no
cylinder. working of the pump.
Serious leakage of gear oil Check, repair or replace.
pump.
Too loose the belt and fail to Adjust the belt tension.
drive the oil pump.
Seal damage of pistons of oil Repair.
cylinder, serious internal
leakage and serious leakage in
the working oil pump.
Presence of air in the system. Check the possible air suction
Slow and weak action of and oil leakage between the oil
cylinder. inlets of oil tank and oil pump.
Overflow valve seized. Remove to clean and check
the change valve, and if any
impurities found, to clean the
system.
Piston rod curved or deformed. Remove to check or replace.
Lifting oil cylinder fails to reach Check, repair or replace the
Other troubles of working oil the floating position, trouble at parts.
cylinder the 4-position valve of multiple
change valve.
1. Piston seal damage of oil 1. Replace;
cylinder for movable arm;
Movable arm depressed.
2. Serious leakage of multiple 2. Replace the seal, inspect or
change valve. replace the check valve.
1. Piston seal damage of oil 1. Replace;
cylinder for bucket;
Bucket tilted downwards. 2. Leakage in the multiple 2. Replace the seal, check or
change valve, and central replace the check valve.
position fails to lock itself.
Insufficient oil level of oil tank, Increase or replace.
and bad oil quality.
Too high a temperature rise of
Too high the pressure of the Adjust the pressure of safety
hydraulic system.
system, as adjusted. valve again.
Too long the working duration. Stop the machine and cool.
3. Steering system
Steering wheel fails to return Breakage of positioning spring. Replace.
automatically to the central
position.
Steering wheel fails to turn at Dirts in the hydraulic system. Drain oil and clean hydraulic
system, replace filter and refill
the slow rotation.
oil into the system.
Presence of dirts in the Drain oil and clean hydraulic
hydraulic system. system, replace filter and refill
oil into the system.
Low oil level. Fill oil to a proper level.
Insufficient pressure of oil Check the pressure at the oil
pump. outlet hose of oil pump, and
Slow or hard to steer. repair or replace the oil pump,
if necessary.
Breakage of piston, piston ring Carry out the leakage test of
or seal of oil cylinder. steering cylinder, and repair, if
necessary.
Presence of air in the hydraulic Bleed the system, and check if
system. the oil suction pipe leaks.
Steering control pipe reversely Correctly connect and align the
Wrong action of steering connected, and the metering metering gear to the driving
wheel. gear not aligned to the driving device.
device.
Part G A List of Fittings, Bearings and Rubber Pieces
1. A detailed list of fittings

No. Code Name & Spec. Qty Remarks
1 BYZ1-320 Full hydraulic steering gear (with safety 1
valve, cushion valve)
2 Z120E-04T-04T Multiple change valve 1
3 CBC2036-103R Gear pump 1
4 6SX/6SS Purifier 1
5 Corrugated pipe Ø 65-15 1
6 ACA332314R0A Manual variable displacement pump 1
7 NJ130-2402050 Oil seal of angular gear 4
8 10.00-20G2 Tire 4
9 TZX2-100×10 Filter element of low-grade oil filter 1 ZU-A100 × 10S
filter element
10 TXX-160×30 Filter element of notched wire oil filter 1 XU-A160 × 30S
filter element
11 TXX-63×30 Filter element of notched wire oil filter 1 XU-A63×30S filter
element
12 ZX-63×180 Filter element of oil filter 1 LXZ-63×180L filter
element
13 K147.1.4.00 Lifting oil cylinder 1
14 K147.1.3.00 Tilting oil cylinder 1
15 K147.11.1.0 Steering oil cylinder 1
16 K147.17A-5A Big gear 1
17 K147.17A-15A Shaft gear 1
18 ACE544123MAA Manual variable displacement motor 1
19 Hydraulic pump 1 Hefei Automobile
Putty Pump Plant
20 K147.17A-7A Intermediate gear 1
21 K147.1-7 Front axle of movable arm 1
22 K147.1-11 Rear axle of moveable arm 1
23 K147.1-5 Front/rear axle sleeve of movable arm 4
24 K147.1-3 Front axle of connecting rod 1
25 K147.1-16 Rear axle of connecting rod 1
26 K147.1-1 Front axle sleeve of connecting rod 1
27 K147.1-20 Centre shaft of moveable arm 1
28 K147.1.1.1.00 Bucket assembly 1
29 K147.6-6 Pin shaft 1
30 K147.6-7 Rear axle of actuating cylinder 1
31 NJ130-2402041 Flange 1
32 K147.1.1-1 Bucket tip 5
33 BL2011F Diesel engine 53 Kw 1
2. A detailed list of bearings
No. Name Spec. Qty Assembly Drawing Remarks
No.
Single-row tapered roller bearing 7309 2 GB297-64
1 K147.17A.00
7509 2
2 Single-row tapered roller bearing 7222 2 K147.3.00 GB297-64
Single-row tapered roller bearing 2007120 2 K147.3.00 GB297-64
3
2007114 1 K147.22.00
4 Single-row tapered roller bearing 2007122 2 K147.22.00 GB297-64
5 Double-row radial spherical roller 3518 2 K147.13.00 GB297-64
bearing
6 GB297-64
7 GB297-64
8 GB297-64
9 Single-row radial ball bearing 7206E 2 K147.17A.00 GB297-64
10 Annular ball bearing 80205 2 K147.12.00 GB278-82
11 Single-row radial ball bearing with 60205 8 K147.28.00 GB278-82
dust cap
12
13
14 Spherical outside surface ball bearing Z90509 1 K147.4.00 JB1642-57
3. A detailed list of rubber seals
No. Name Spec. Qty Material Remarks
PD50×70×12 2
PD50×80×12 2 Oil-proof
1 Framework oil seal JB2600-80
PD60×80×12 2 rubber
PD140×170×16 2
D140 2 JB/ZQ4264-86
D125 2 (seal rings
D80 2 from different
2 Yx seal ring for hole D63 1 Polyurethone suppliers may
D30 1 be different in
shape and
size)
d70 1
JB/ZQ4265-86
3 Yx seal ring for axle d60 1 Polyurethone
(Ditto)
d35 1
Dust 70 1
Dust 60 1 JB/ZQ4607-86
4 Dust ring Polyurethone
Dust 35 1 (Ditto)
Dust 22 1
Type-L seal ring 60 1 Oil-proof
5 L-ring HG4-331-66
rubber
15×2.4 2
22×2.4 3
18×2.4 2
20×2.4 2
26×2.4 3
30×3.1 7 Oil-proof
6 O-rubber ring JB/ZQ4224-82
36×3.5 2 rubber
40×3.1 1
45×3.1 2
65×3.1 2
60×3.1 2
85×3.1 1
Combined seal ring 10 6
7 Combined seal ring JB982-77
4. A detailed list of hoses
No. Code Name & Spec. Remarks Component for Qty
1 JF500-81 Type-WC rubber hose
joint 13I-1100 WC, two end Driving part 1
joint 13II-1300 WC, one end Steering part 1
joint 16I-700 WC, one end Driving part 1
joint 19I-1200 WC, one end Driving part 1
joint 19II-2200 WC, one end Working part 2
joint 22I-1600 WC, one end Working part 1
o o
7 JF500-81 Type-WC rubber hose 2-90 X270 Working part 1
joint 25I-1250
joint 32I-800 WC, one end Working part 1
9 JB1887-77 Type-C rubber hose joint
4I-450 Driving part 1
11 JB1887-77 Type-C rubber hose joint Driving part
6I-1050 Braking part 1Each
10I-360 Braking part 1
13I-3000 Steering part 1
13II-4200 Steering part 1
19II-500 Working part 2
19I-2800 Working part 1
19II-1800 Working part 1
19.4S-550 Driving part 2
24 JB1887-77 Type-C rubber hose joint Steering part 1
13II-1260

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OPERATION MANUAL OF WJ-1

Fig. 1 Geometric Dimensions Figure of WJ-1 Scraper

1. Before starting the motor, please check carefully as follows:

Part D Basic Structure of Major Components and Adjustment

◎ Transmission system for driving (see Fig. 3)

Fig. 2 Structural Diagram of Scraper

(1) Static hydraulic drive system

Fig. 5 Diagram of Oil Flow (Neutral Position)

Fig. 6 Diagram of Oil Flow (Advancing)

Fig. 7 Diagram of Oil Flow (Reversing)

(2) Mechanical drive system

No. Drawing No. Description Qty Remarks

No. Drawing No. Description Qty

No. Drawing No. Description Qty

Fig. 11 Brake Assembly (See Table 4-4)

A Detailed List of Parts for Brake Assembly

No. Drawing No. Description Qty

A Detailed List of Parts for Driving Axle

A Detailed List of Parts for Main Reducer

◎Working device for shoveling and loading

1. Bucket 2. Movable arm 3. Tilting Oil cylinder 4. Multiple change valve

WORKING PRINCIPLE OF WORKING DEVICE FOR SHOVELING AND LOADING

a. Position of no actuation (zero position)

1. Cotter pin 2. Pin shaft 3. Connecting fork 4. Handle ball

c. Tilting and unloading device

A Detailed List of Parts for Lifting oil cylinder

No. Drawing No. Description Qty

A Detailed List of Parts for Tilting oil cylinder

No. Drawing No. Decription Qty

A Detailed List of Parts for Bucket

No. Drawing No. Description Qty

A Detailed List of Parts for Movable Arm

No. Drawing No. Description Qty

A Detailed List of Parts for Connecting Rod

No. Drawing No. Description Qty

◎Steering device and hydraulic system

The schematic diagram of its hydraulic system can be referred to in Fig.25.

(1) Fully hydraulic steering gear

A Detailed List of Parts for Steering Control Mechanism

No. Drawing No. Description Qty

Fig. 27 Steering oil cylinder

No. Drawing No. Description Qty

(3) Working principle of steering system

1. Cooling system of the engine

Working Cycle of Four-stroke Diesel Engine

BF4L2011 排气面(左面) BF4L2011 exhausting side (left)

Fig. 30 Schematic Diagram of Brake System

a. Configuration of electrical system

Fig. 34 Lubricating Points

A List of Lubrication System

No. Description Lubricant Interval Remarks

13 Oiling point of diesel oil Diesel oil

a. Every 100 hours

i. Fasten the coupling bolts of driving axles;

b. Every 400 hours

i. Replace the grease of every system;

c. Every 1200 hours

i. Replace the oil of every hydraulic system;

d. To check oil level, the machine must be on a horizontal level;

4. Precautions for safety at the lubrication and maintenance

1. A detailed list of fittings

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