XC6-3514 Telescopic Handlers

Operator’s Manual

Xuzhou Xugong Special Construction Machinery Co., Ltd.

1
 Foreword
XC6-3514 telescopic forklift loader is one multi-purpose lifting and handling machine that

integrates the stability and high efficiency and is applicable for handling of various materials.

The telescopic forklift loader is of unique structure, with the working device arranged on the

front. The working device includes telescopic boom and floating forks. During the lifting

operations, the wing-shaped outriggers arranged on the front of the frame provide powerful

support to the machine to significantly improve the working stability. The telescopic forklift

loader is an ideal high-efficiency loading and handling machine for modern industry,

construction industry, and agriculture and is applied in urban construction, power and airport

projects, municipal construction, rural residence, and construction projects engaged by various

construction teams.

This operation and maintenance manual is prepared to help the users better understand and

master this machine and fulfill the operations and maintenances of the machine. This manual

describes the safety precautions and technical specifications of the telescopic forklift loader and

details the operation and maintenance methods of the machine.

Before the publication of new operation and maintenance manual, this manual shall prevail

for the operations and maintenances of XC6-3514 telescopic forklift loader and other materials

shall be taken for reference only.

It’s welcome for the users to timely feed back any problem detected during operations for

research and modification.

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 Contents
1. Safety..............................................................................................................................6

1.1 Safety Warning Signs............................................................................................6

1.2 Identifications of Machine.....................................................................................7

1.3 General Safety Precautions..................................................................................16

1.4 Compressed Air...................................................................................................20

1.5 High Pressure Solution........................................................................................20

1.6 Safe Disposal of Waste Fluids.............................................................................21

1.7 Precautions for Operation of Accumulator..........................................................21

1.8 Guard against Squeezing and Cutoff...................................................................22

1.9 Guard against Scalding........................................................................................23

1.10. Coolant................................................................................................................23

1.11. Battery.................................................................................................................24

1.12. Guard against Fire and Explosion........................................................................24

1.13. Diethyl Ether.......................................................................................................25

1.14. Pipelines, Pipes, and Hoses.................................................................................25

1.15. Fire Extinguisher and First-Aid kit......................................................................26

1.16. Guard against Thunder and Lightning.................................................................27

1.17. Tires....................................................................................................................27

1.18. Cab Protection.....................................................................................................29

1.19. Precautions for Accessories.................................................................................30

1.20. Safe Operations of Machine................................................................................30

1.21. Understanding Your Machine.............................................................................31

1.22. Understanding Your Working Area.....................................................................32

1.23. Before Start of Engine.........................................................................................32

1.24. Engine Start.........................................................................................................33

1.25. Before Operations of Machine.............................................................................34

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 1.26. Parking of Machine.............................................................................................37

1.27. Safe Maintenance of Machine.............................................................................38

1.28. Welding Operations.............................................................................................39

1.29. Periodic Cleaning of Machine.............................................................................40

2. Technical Specification...............................................................................................41

2.1. Diagram of Overall Dimensions..........................................................................41

2.2. Main Performance Parameters.............................................................................41

2.3. Part Specification................................................................................................42

2.4. Table of Fuel/Oil/Fluid and Capacity..................................................................45

3. Operations....................................................................................................................46

3.1. Introduction.........................................................................................................46

3.2. Before Entering Cab............................................................................................46

3.3 Seat Control.........................................................................................................48

3.4. Seat Belt..............................................................................................................49

3.5. Driving Control, Switches, and Instruments........................................................52

3.6. Operating Levers.................................................................................................61

3.7. Load Diagram......................................................................................................71

3.8. Before start of engine..........................................................................................78

3.9 Start of Engine.....................................................................................................80

3.10. Traveling Preparations of Machine......................................................................82

3.11. Movement of machine.........................................................................................84

3.12. Braking and Parking............................................................................................88

3.13. Operation Instructions of Machine......................................................................90

3.14. Operation at low and high temperatures............................................................112

3.15. Resetting the steering system............................................................................115

3.16. Transfer of faulty machine................................................................................116

3.17. Transportation of machine.................................................................................117

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 3.18. Storage of machine............................................................................................121

4. Maintenance...............................................................................................................122

4.1. Introduction......................................................................................................122

4.2. Health and safety.............................................................................................124

4.3. Guide for maintenance....................................................................................130

4.4. Running-in of new vehicle..............................................................................134

4.5. Details for maintenance...................................................................................135

4.6 Washing machine.............................................................................................143

4.7 Check the damage............................................................................................145

4.8 Change the diesel filter....................................................................................148

4.9 Lubrication.......................................................................................................151

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1. Safety
1.1 Safety Warning Signs
The safety warning signs are indicated on the machine, on the safety signs, and on

the important safety information at other places. Upon sight of this sign, please

abide by the instructions specified in the safety information and keep alerted

against the possible personal injury or death.

Safety Sign Words

The safety sign words “Danger”, “Warning”, and “Caution” indicated on the machine are

defined as below:

Danger
Danger: It denotes imminent danger. The negligence will lead to serious injury or death.

Warning
Warning: It denotes potential danger. The negligence will lead to serious injury or death.

Caution
Caution: It denotes potential danger. The negligence will lead to minor or medium injury.

“Caution” is used to denote the related safety precautions against the unsafe operations that

probably lead to personal injuries. “Danger” denotes the most serious dangerous issues.

“Danger” and “Warning” safety signs are arranged near the specific dangerous places. The

general precautions are listed in the “Caution” safety signs.

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1.2 Identifications of Machine

FIGURE 1-1 IDENTIFICATION FIGURE 1

1 XCMG roduct model 2 Parking shift 3 Read the 4 Fasten seat belt 5 Guard against
identification identification manual rollover

6. Guard against electric 7 Interlock logic 8 Operation 9 Energy curve 10 Energy curve
shock identification identification 1 identification 2

11. Product model 12 Fuel tank 13 Escape 14 Mind Your Hands 15 Customer
identification 1 identification identification identification service hotline
identification

16 Observe Energy Curve 17 Guard against 18 White bar 19 Periodic 20 Power master
identification Door Collision maintenance switch

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 identification identification identification

21 Power master switch 22. Product 23 Body 24 Product nameplate 25 Rivet 4×10
identification 3 model reflective
identification 3 sticker

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 G direction A direction
rotation Radiator
B direction F direction
rotation rotation

C direction D/E direction

rotation rotation

Telescopic boom

FIGURE 1-2 IDENTIFICATION FIGURE 2

26 BUMPING 27 Never Touch 28. PRODUCT 29 XCMG GROUP 30 No Standing

PREVENTION OF Hot Surface MODEL IDENTIFICATION on Attachment
LEGS identification IDENTIFICATION 2 identification

31 Lifting point 32 Guard against 33 Hydraulic oil 34 XCMG 35 Safe

identification Fan Vanes” tank identification IDENTIFICATION distance
identification identification

36 Placement and 37 Boom cylinder 38 TIRE PRESSURE 39 TIRE PRESSURE 40 No

movement support lock identification 525 (FRONT 325 (REAR WHEEL) Trampling
identification WHEEL) identification

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41 Distance 42 Distance 43 CHASSIS NO.
identification 1 identification 2

1、11、18、22、28、29、34.Product XC6-3514，XCMG
model identification

(Located on the left and right sides of

the boom, on the rear of the oil tank,
hood and frame.)

2. Parking shift identification

(Located on right side glass in the cab.)

Warning: Require Parking shift

3~6. Safety warning identification

(Located on the inner right window of

the cab, near the operating lever)

Warning: Guard against electric shock,

Guard against rollover, read manual,
fasten seat belt.

7. Interlock logic

(Located on the inner right window of

the cab, near the operating lever)

It describes the notes of the deploying

and retracting of outriggers and the
frame leveling.

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8. Operation identification

(Located on the inner right window of

the cab, near the operating lever)

It describes how to operate the

operating lever and the functions of
buttons on operating lever.

9~10. Energy curve identification

(Located on the inner right window of

the cab, near the operating lever)

12. Fuel tank identification

(located on the fuel tank)

13. Escape identification

(On the inner right lower portion of

cab rear window)

14. Mind Your Hands identification

(On the inner right lower portion of

cab rear window)

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15. Customer service hotline
identification

(Located on the left front corner of cab

front windscreen)

16.“Observe Energy Curve”

identification

(Located on the top center of the cab

front windscreen)

17.“Guard against Door Collision”

identification

(Located on the door lower glass of cab)

19. Periodic maintenance identification

(Located on the door lower glass of cab)

20、21. Power master switch

identification

(Located beneath the cab, on the pedal,

and near the power master switch)

23. Body reflective sticker

(located on fuel tank on two sides of

body, on engine hood, and on
counterweight)

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24、25. Product nameplate

(Located near the left side plate rear

lamp holder of the frame)

26 Identification for bumping

prevention of legs

(Located at both sides of the front legs)

27. “Never Touch Hot Surface”

identification

(Located on luffing cylinder and near

muffler)

30. "No Standing on Attachment”

identification

(Located on the front panel of telescopic

boom head)

Warning: It’s prohibited to stand on

forks or any other attachment.

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31. Lifting point identification

(Located on front and rear sides of

frame)

32.“Guard against Fan Vanes”

identification

(Located on the radiator)

33. Hydraulic oil tank identification

(Located on hydraulic oil tank)

35. Safe distance identification

(Located on front panel of frame and

two sides of boom head)

36. Placement and movement support

identification

(Located on front panel of frame)

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37. Boom cylinder lock identification

(Located on the front panel of frame and

near boom safety lock)

Front wheel:
38 and 39 Tire pressure identification

Rear wheel:

40. “No Trampling” identification

(Located on mudguards on two sides of

body)

41、42. Distance identification

(Located on the swing arm of other

sections other than the first section of
swing arm)

Figures 1-7 are used to measure the

distance stretched by the swing arm

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through visual inspection.

43. Chassis No.

(Located inside the fender at the left and

right sides of frame and outside the
frame)

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1.3 General Safety Precautions
Please read and get familiar with all safety precautions, otherwise it will lead to occurrence

of series injury accidents.

Only the trained personnel with corresponding qualification are allowed for operation and

maintenance of this machine.

If feeling physically uncomfortable or sleepy after taking medicine or after driving, do not

operate this machine. Otherwise, it will lead to your judgment error and possibility for

occurrence of accident.

Before repairing the machine, please hang a label "No operation” or similar information to

the starter switch or operating lever.

Under Repair
No Operation

Do not wear loose clothing or jewelry or have long hair. They will probably be blocked or

entangled into control system or motion parts to cause serious injury or death.

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 During the operations and maintenances of the machine, please wear a cap of hard material,

safety goggles, safety shoes, face mask, and gloves.

The use of goggles, safety glasses, or face mask can protect your eyes against the injury of

high pressure fluid during the maintenance of battery and against the injury of splashing

chipping during running of engine and use of tools. Please wear a face mask while disassembling

a spring or elastic part or adding electrolyte to the battery. Wear a safety helmet or goggles

during welding or cutting by a welding gun.

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 While working under high noise, wear appropriate acoustic protection device, such as ear

cap or ear plugs, in order to prevent the acoustic harm by high noise.

Ensure that all protective plates and cover plates on the machine are fixed on the machine.

Ensure that the machine, especially the instrument panel, passage, and ladder, is free of

fragments, oil sludge, tool, and irrelevant things. Properly place the loose articles, such as lunch

box and tools.

While checking an open oil tank or water tank, guard against the ingress of foreign material

into the system parts. Before uncovering a cap, empty your cloth pockets and take special cares

during movement of wrench and nut.

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 Understand the gesture signal and the signal source of the working site and take signal only

from one person.

It’s absolutely prohibited to load any maintenance solvent in a glass container.

While disposing hazardous substances, such as lubricating oil, fuel, coolant, solvent, filter,

battery, or other substances, please abide by relevant local laws and regulations.

Take cautions while using detergent and do not use any inflammable (such as diesel and

gasoline) as detergent for cleaning of parts, otherwise there is a danger of fire.

Timely report all items for which the repair is required.

All non-authorized personnel are prohibited to stay on or near the machine.

It’s prohibited to modify the machine without the permission of XCMG, otherwise XCMG

will not be liable for any consequence arising thereof.

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1.4 Compressed Air
The compressed air will probably cause personal injuries. While cleaning with compressed

air, wear face mask, protective clothing, and safety shoes. The maximum pressure of compressed

air for cleaning shall be lower than 0.2MPa.

1.5 High Pressure Solution

Warning: Guard against the scalding of high pressure oil. Before checking and repairing or

replacing any pipe of hydraulic system, check whether the system pressure is relieved. The

hydraulic oil under high pressure will cause serious injury to the skin if coming into contact with

the skin.

Take cautions while disassembling any hydraulic pipe or connector. When the oil is

spraying out, the relieved high pressure oil will probably lead to sweeping of hoses.

While checking for leakage, wear safety goggles and leather gloves and use a plate or paper

board, instead of bare hands, to check for leakage.

The leakage of high pressure fluid, even in size of pinhole, will probably penetrate muscle

and cause personal injury. If shot by spraying high pressure oil, seek for medical treatment

immediately.

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1.6 Safe Disposal of Waste Fluids
The improper disposal of waste fluid will endanger the environment and ecology. Abide by

the local laws and regulations while disposing waste fluids.

Make sure to properly load with containers the fluids splashed during the checking,

maintenance, testing, adjustment, and repair of the machine.

Before opening any fluid chamber or breaking up any fluid contained part, prepare

appropriate container for collection of fluid in advance.

Use appropriate container while draining any fluid. Do not use a food or beverage

container, as it will probably be drunk by other person by error.

1.7 Precautions for Operation of Accumulator

The accumulator contains high pressure nitrogen and is one dangerous article. Read the

following requirements and use the accumulator appropriately.

The accumulator must be checked before being charged with nitrogen. It’s absolutely

prohibited to charge the nitrogen if the accumulator has no nameplate, the characters on the

nameplate are fallen or become illegible for its type, the stamped marks are incomplete or

become illegible, or the housing has defect and can’t guarantee operation safety.

The accumulator can only be charged with nitrogen and it’s absolutely prohibited to charge

oxygen, compressed air, or other flammable gas, in order to prevent explosion.

The nitrogen shall be charged at low speed, in order to prevent bursting the rubber capsule.

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 The air valve of the accumulator shall be installed facing upward and must be securely

fixed on the bracket. Do not fix the accumulator by welding.

Never drill any bore on the accumulator and keep the accumulator away from any open fire

or heat source.

Never conduct any welding operation on the accumulator.

The accumulator is one high pressure vessel and shall be replaced and repaired only by

professionals.

Make sure to relieve the gas before disposal of accumulator.

1.8 Guard against Squeezing and Cutoff

Never place hand, arm, or any body part between moving parts, such as between working

device and cylinder and between body and working device.

Correctly support the machine before operating beneath the working device. Do not support

the working device only by hydraulic cylinder. The movement of control mechanism or leakage

of hydraulic pipeline will lead to falloff of working device.

If it’s necessary to remove any shield during repair, make sure to reinstall properly the

shield after repair.

The rotating engine blades have a danger of cutting off the fingers. Keep a safe distance or

stop the engine during repair.

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 Ensure that there is no foreign material in the engine fan blades. The fan blades will throw

out or cut the tools and foreign things fallen or pushed therein.

Unless otherwise specified, do not conduct any adjustment during running of the machine

or the engine.

If it’s necessary to perform repair procedure during running of engine, do not leave the

machine unattended. Arrange one person sitting in the operator seat and always preparing to stop

the engine.

Do not use a kinked or worn wire rope. Wear the gloves during operations and handling.

Ensure that there is no person in the surrounding area while pushing out the bayonet lock

forcibly. Wear the protective goggles to prevent eye injury.

While hammering any object, ensure that the splashing chippings will not cause personal

injury.

1.9 Guard against Scalding

Some parts will be heated after the machine runs for a while. Wait for these parts to cool

down before repair or checking.

1.10. Coolant
Under working temperature, the engine coolant is at high temperature and is pressurized

and the radiator and all pipelines to the radiator contain hot water or steam so that it will cause

serious scalding upon contact.

While checking the coolant level, stop the engine and cool down the water filler cap, till the

cap can be opened by bare hands.

Slowly loosen the filler cap of cooling system to relieve the pressure.

The coolant contains alkali that will probably cause personal injuries. Keep it away from

contact of skin, eye, or mouth.

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Oil
The hot oil and hot parts will probably cause personal injuries. Keep the hot oil and hot

parts away from skin contact.

The hydraulic oil under working temperature is hot and pressurized.

Before opening the filler cap of hydraulic oil tank, stop the engine and cool down the filler

cap till it can be opened by bare hands.

Slowly remove the oil tank cap to relieve the pressure of hydraulic oil tank and prevent the

scalding by hot oil.

Before disassembling any pipe, connector, or relevant part, relieve the system pressure.

1.11. Battery
The smoke emitted by the battery will probably lead to explosion.

Do not smoke while checking the electrolyte level of the battery.

The electrolyte is one acidic substance. Keep the electrolyte away from contact of skin or

eye.

While checking the battery, wear the protective goggles and protective gloves.

1.12. Guard against Fire and Explosion

All fuels, most lubricating oils, and some coolant mixtures are inflammable substances.

It will probably lead to fire if the fuel leaks onto a hot surface or an electric unit.

Do not smoke during refueling or in the refueling area or a place with storage of

inflammable.

Clean and tighten all electrode connectors. Check for loose and worn wires each day.

Before startup of machine, tighten loose power supply and repair or replace worn wires.

25
 Store fuel and lubricating oil in the containers of corresponding markings, in order to

prevent the use by any person other than operation personnel.

Place the oil contaminated rags and other inflammables in shielded containers and preserve

in a safe place.

Do not conduct electric welding or flame cutting for any pipe containing flammable fluid.

Before the electric welding or cutting, thoroughly clean all flammable fluids.

Thoroughly clean the flammable materials (such as fuel, lubricating oil, and other

fragments) from the machine.

Do not operate the machine near an open fire.

Keep the battery away from open fire and fire spark and do not smoke in the charging place

of battery.

To jump start the machine, make sure to connect the positive (+) cable to the positive (+)

terminal of battery connected with the coil of starter motor and connect the negative (-) cable of

the external power supply to the negative pole (-) of the starter. If the negative terminal of starter

is unavailable, connect it to the engine housing.

Do not charge a frozen battery, in order to prevent explosion.

1.13. Diethyl Ether

All attempts to start the engine by diethyl ether will probably cause serious damage of

engine or personal injuries.

1.14. Pipelines, Pipes, and Hoses

Do not bend or hammer a high pressure pipeline or install an abnormally bent or a damaged

pipe or hose onto the machine.

Timely repair any loose or damaged fuel and lubricating oil pipeline or pipe or hose of

hydraulic system. Any leakage will probably cause fire. Please contact an XCMG’s designated

dealer for repair or replacement.

Replace upon detection of any of the following problems.

1. Damage or leakage of connector.

26
2. Wear or separation of hose outer layer or exposure of hose reinforcement wire.

3. Partial bulge of hose.

4. Clear distortion or flattening of hose.

5. Embedment of hose reinforcement wire into the hose outer layer.

6. Misplacement of end connector.

Ensure the correct installation of all pipe clamps, protective plates, and insulation caps, in

order to prevent overheating due to vibration or friction with other parts.

While disassembling any connecting pipeline of A/C compressor, keep away any open fire,

otherwise it will generate toxic gas and cause intoxication.

1.15. Fire Extinguisher and First-Aid kit

Make sure to prepare fire extinguishers and carefully read the operation instructions to

understand how to use them.

A first-aid kit must be prepared in the working site. Check it periodically and when

necessary add some medicines.

Know how to handle in event of fire or injury.

Prepare the telephone numbers of some persons (such as doctor, emergency center, and fire

station) for emergency contact. Stick there contact numbers at the specified place and ensure that

all personnel know these numbers and correct contact methods.

Frequently check and maintain the fire extinguishers. Abide by the operation methods

recommended in the instruction panel.

1.16. Guard against Thunder and Lightning

Never attempt to get on or off the machine when there is lightning near the machine.

In event of thunder and lightning, please stay in the cab (if within the cab) or keep away

from the machine (if on the ground).

27
1.17. Tires
The maintenance, disassembly, repair, and installation of tires and wheel rims require

special equipment and expertise. Therefore, it’s better to have them repaired and maintained by a

tire repair shop.

The inflated tires will explode if the internal gas of the tire is heated or combusted, which is

generally caused by the expansion or combustion of gas due to the heating or electric welding of

wheel rim, the external flame, or frequent application of brake.

The explosion of tire is much more powerful than the air deflation and may fly the tire,

wheel rim, and drive parts to be 500m away from the machine, in which the explosive force and

fragments will lead to personal injuries and property damage.

Never close to a heated tire and maintain a minimum distance (at least 15m).(As shown in

the figure) stand away from the hatched areas.

It’s recommended to inflate the tires with dry nitrogen (N2). If the tires are originally

inflated by air, it’s recommended to adjust the tire pressure with nitrogen, as the nitrogen can

mix with the atmospheric air. The nitrogen inflated tires can prevent the possibility of explosion,

28
as the nitrogen is non-flammable. Meanwhile, the nitrogen helps prevent the oxidation and

rubber aging and prevent the corrosion of wheel rim parts.

Avoid the excessive inflation. The correct inflation equipment and the training for the

operations of equipment are required, as the incorrect equipment or improper use of equipment

will lead to burst of tires or damage of wheel rims.

The incorrect maintenances of tires and wheel rims will probably lead to burst of tires. This

burst force can lead to serious personal injuries. The maintenance of tires and wheel rims can be

conducted only by trained personnel with use of correct tools and correct procedures. XCMG

recommends inflating the tires with dry nitrogen and adjusting the pressure of tires. This

includes all machines equipped with rubber tires. The nitrogen is one inert gas that will not help

the combustion within tires.

The use of nitrogen (N2) can not only reduce the explosion danger, but also help prevent

the oxidation and rubber aging and prevent the corrosion of wheel rim parts. This is especially

important for the wheel rims to be used for more than 4 years.

Warning: The necessary training must be taken for the operation personnel of inflation

equipment, otherwise the incorrect tire inflation technique will cause personal injuries.

Do not set the pressure of tire inflation equipment to be higher by 1 .4 kg/cm2 than the

recommended tire pressure.

Check and adjust the inflation pressure of tires after the tires are sufficiently cooled down.

Notify all other personnel away from the dangerous area (surrounding area of wheel reducer).

The pressure of nitrogen inflated tires is same with that of air inflated tires. XCMG

recommends choosing inflation pressure of tires depending on the working condition of the

machine and consulting your tire supplier.

The tire inflation pressure listed in the table is the inflation pressure under normal

temperature.

Front/rear wheel

29
 front/rear wheel（kPa）

Standard tires 15.5-25-16PR L-2E 525±20/325±20

While driving the machine under frozen temperature, the tire pressure originally under

18~21ºC will vary greatly. The tires inflated to normal pressure under normal temperature will

have insufficient inflation pressure under frozen temperature. The insufficient pressure will

shorten the service life of tires.

1.18. Cab Protection

The XCMG’s rollover protection system (ROPS) and falling object protection system

(FOPS) are located within the cab framework.

If the cab is damaged by falling object or due to rollover, its strength will be impaired so

that its normal function can’t be met. In such case, please contact a XCMG’s designated dealer

and consult for repair method.

Even if the ROPS is installed, the effective protection can be provided only when the

operator fastens the seat belt. Make sure to fasten the seat belt during the operations of the

machine.

It’s prohibited to conduct drilling or electric welding inside or outside the cab, in order to

prevent damaging the built-in ROPS.

If the modification of cab is required due to certain cause, please consult with XCMG to

prevent possible damage of ROPS.

30
1.19. Precautions for Accessories
Make sure to install and adjust by relevant qualified personnel. The operation personnel

must be trained and conduct operations and maintenances strictly as per the operation manual of

the accessories.

During the installation and operations of the accessories, please read the manuals and

brochures of relevant accessories and the related information of accessories specified in the

manual.

The incorrect installation of accessories or optional parts will not only cause safety issues,

but also have adverse influence on the operations and the service life of the machine.

Do not use any accessories not approved by XCMG. The use of non-approved accessory

will probably cause safety issues, which will impair the normal operations of the machine and

influence its service life.

It’s prohibited to modify any accessory without permission, otherwise all consequences

arising thereof shall be borne solely by yourself.

XCMG will not be liable for any damage, accident, or machine damage arising from the use

of non-approved accessory.

1.20. Safe Operations of Machine

Getting on/off the machine
Clean the oil stain and sludge from the handrails and ladder steps before getting on or off

the machine. In addition, all damaged parts shall be repaired and all loose bolts shall be

tightened.

Get on or off the machine only from the locations with ladder or handrail. While getting on

or off the machine, face towards the machine, hold the handrail by hand, and step the ladder to

maintain three-point contact (two feet and one hand or two hands and one foot).

31
 It’s prohibited to jump off the machine.

It’s prohibited to get on or off the machine during the running of the machine.

It’s absolutely prohibited to take any operating lever as handrail while getting on or off the

machine. While carrying a tool or other thing, do not get on or off the machine. Instead, hoist the

required tools onto the operating platform by a rope.

Before entering or leaving the cab, ensure that the machine is completely stopped and

reliably parked. While getting on or off the machine, always keep three-point contact with

handrail and ladder footstep. As shown in the figure, do not use an operating lever or steering

wheel as handrail.

1.21. Understanding Your Machine

Be capable of operating all devices on the machine.

Understand all control systems and the purposes of instruments and indicator lamps.

Understand the rated carrying capacity, speed range, braking and steering characteristics,

turning radius, and operating height.

Bear in mind that the rain, snow, ice, gravel, and soft road will change the working capacity

of the machine.

Study the safety signs on the machine (Danger, Warning, and Caution) and other signs.

32
1.22. Understanding Your Working Area
Whenever possible, understand the area you are ready to work in advance. Please check the

position of slope, open trench, fallen or hung object, soil condition (soft or hard), pond and

swamp, rock and stump, embedded foundation, root pillar, and wall border, buried garbage or

filled border, hole, obstacle, mud and ice, traffic volume, heavy dust, smoke, or mist, and

accurate locations of buried or hung electricity, gas, telephone, water, sewage, and other utility

pipelines. If necessary, please have them marked by the public utility companies and close or

move away these utilities before starting working.

1.23. Before Start of Engine

Before starting working, carefully check the machine to ensure that all systems are under

good operating state. Keep all other personnel around the machine away from the working site.

Before getting on this machine, thoroughly remove the sludge and tiny sands from your

shoes.

Check all structural parts and covering parts for presence of collision impact and damage.

Check all safety protection devices (such as doors, shields, and covers) for correct

installation and guard them against damage of motion parts. Any damaged device shall be timely

repaired.

Check the hydraulic system for presence of oil leakage and check the hoses and pipes for

presence of wear.

Check all fasteners for presence of looseness and missing.

Check electric harnesses for presence of wear or rubbing damage, check the fuses for

intactness, and check the connectors for secure connections.

Check the engine and fuel system for normal oil/fuel level and timely drain the water or

sediment from the oil-water separator.

Replace all damaged or missing parts and fulfill the necessary lubrication works as per the

lubricating points specified in the periodical maintenance schedule.

33
 Remove all loose articles from the cab, as the loose articles will probably influence the

operations and cause accidents.

Ensure that all windows of the cab are clean and the wiper can function normally.

Adjust seat to appropriate position and check the seat belt and seat belt fastening devices for

presence of damage. Replace the seat belt once it’s in service for 3 years.

Ensure that the lighting system of the machine works normally and the working site is

sufficiently illuminated.

1.24. Engine Start

If a “No operation” warning label is hung on an operating lever, it’s absolutely prohibited to

start the engine.

Under Repair
No Operation

Ensure that the operator already sits in the seat and fastens the seat belt securely before

starting the machine.

Before starting the engine, ensure that the hydraulic operating lever is at position HOLD

and the gearshift operating lever is at neutral gear.

At the start of the engine, sound the horn for warning.

Start the engine only within the cab. It’s prohibited to start the engine by short circuiting the

starter motor, otherwise starting the system by bypass will damage the electric system of the

machine.

After the start of engine, observe the pressure gauge, instruments, and warning lamps to

ensure that they are functioning normally and their readings are within the working range.

34
 Observe and carefully listen the inside of the machine for presence of malfunction. Upon

detection of malfunction or abnormality, immediately stop the engine and solve the malfunction

before further operations.

The exhaust gas of engine will cause illness or death. If it’s necessary to start the engine in

an enclosed or poorly ventilated place, open the doors and windows to ensure sufficient

ventilation, in order to prevent gas intoxication. If it still can’t provide sufficient ventilation after

the doors and windows are opened, it’s necessary to install fans.

1.25. Before Operations of Machine

Ensure there is no person on or near the machine and fasten the seat belt.

Ensure that all windows, lamp shades, and rearview mirrors are clean and properly fix the

opened or closed doors and windows.

Adjust the position of rearview mirrors to provide a best visual field for the operator sitting

in the operator’s seat.

Clear all obstacles from the driving path of the machine. Take cautions against the

dangerous articles, such as high voltage wires and trenches.

Ensure that the horn, reversing alarm, and other alarm devices of the machine function

normally.

Operation of Machine

Before driving on a public road, please check whether the machine conforms to the local

road driving laws and regulations and obtain the road driving license from relevant

35
administration department. While driving on public roads, please abide by the local road traffic

regulations.

Before driving the machine, make sure to verify the surrounding safety and ascertain your

desired driving direction and the relationship of driving pedal/operating lever.

Keep a correct sitting posture on the seat. The operations of machine by sitting in the seat

incorrectly or leaving the seat will probably cause accidents.

It’s prohibited to carry other person, unless the additional seat, safety belt, and rollover

protection system (ROPS) are provided.

Before starting official working, slowly drive the machine to an open field and check all

operating levers and protection devices for normal functioning.

Upon detection of any machine item (such as noise, vibration, smell, incorrect indication of

instrument, air leakage, and oil leakage) needing repair during the operations, immediately report

the required repair item.

The dust, heavy rain, and heavy mist will dim the sight line. Keep the windows, mirrors,

and lamps under clean and good state. In event of reduced visibility, slow down and use

appropriate lighting.

While driving or operating the machine in an area with poor visibility or in a crowded area,

please appoint a signaler. Keep the signaler within the visual range and coordinate the hand

signals.

Avoid all conditions that probably lead to rollover of machine. The machine will probably

roll over while working on a hill, bank, or slope. The machine will probably roll over while

crossing over a trench, mound, or unexpected obstacle.

Drive the machine up or down a slope straightly and do not make turn or drive laterally on a

slope, in order to prevent rollover.

To prevent rollover of machine or damage of working device due to overload, make sure to

keep the machine load within the specified maximum load.

36
 Take special cautions while working near a high voltage grid. Before the machine starts

working in a working site with a possible danger of touching power cables, consult the electric

power company and check whether the determined operation is feasible as per the relevant

governing laws and regulations.

Touching the power cables will cause serious accidents or injury/death. Keep all parts of the

machine away from power cables. Check the above space of the machine and understand the

sufficient clearances between power cables and machine and the ground. If possible, it’s better to

cut off the power supply. If impossible, appoint a signaler for guidance.

If any part of the machine touches high voltage power supply:

1. Warn all other personnel not to touch the machine and keep away from the machine.

2. If it’s possible to separate the touch, change the operation leading to touch with high

voltage power supply and drive the machine away from dangerous area.

3. If it’s impossible to separate the touch, stay in the machine, till the electric power company

cuts off the power cables and notify you that the power supply is cut off.

4. If it’s really necessary to leave the machine in event of extreme case (such as fire) due to

touch of high voltage power supply, do not walk out the machine step by step. Instead, jump off

the machine with your feet together whenever possible and do not touch the ground by hand.

Then, jump with your feet together, till you are a safe distance away from the machine and

power supply.

1.26. Parking of Machine

Select a level ground without danger of falling rock or landslide for parking of machine. If

the terrain is low, there shall be free of the flooding danger.

If it’s necessary to park the machine on a slope, block the wheels by stop blocks to prevent

the movement of machine.

Do not park the machine on a construction road. If it’s necessary to park in such places,

make sure to use flags in daytime and use signal lamp or flasher lamp in nighttime to alert other

personnel or vehicle as per the local regulations.

37
 After the machine is parked, lower the bucket onto the ground.

Shift the hydraulic operating lever to neutral position and shift the gearshift operating lever

to neutral gear.

Apply the parking brake.

Keep the engine idling for further 5min to gradually cool down.

Stop the engine and withdraw the key.

Before leaving the machine, lock all devices by key. Withdraw the key and carry it with

you.

Lower the working device when the engine is stopped.

Before lowering the working device, ensure that there is no person around the machine.

Preservation of accessories

Preserve the accessories and tools safely, in order to prevent serious injury or death due to

falloff. Keep all playing children and bystanders away from preservation area.

1.27. Safe Maintenance of Machine

Preparation of working area
Choose a spacious, well illuminated, well ventilated, and clean and level area for repair

works. Clean the working ground, wipe away the fuel, lubricating oil, and water, and pave sands

or other absorbing material on slip ground. Keep clean and dry the working area.

Correct support of mechanisms

38
 During working, the accessories or apparatuses are generally located on low ground. If it’s

necessary to operate on or beneath any hoisted mechanism or accessory, please support the

machine or accessory safely.

Make sure to support the mechanism on solid supports.

Do not operate beneath any mechanism supported only by single support.

Disassembly of machine
Abide by the relevant national and local regulations on the weight, length, width, and height of

the materials during loading and handling.

Understand the correct loading procedure.

Load on a level ground.

Block the wheels of transport vehicle against movement by wedge blocks.

Use ramps of appropriate size, sufficient strength, low angle, and appropriate height. Ensure

that the ramps are slip-proof without mud or snow.

Fix the machine by chains and cushion blocks.

Keep all bystanders away.

Fix all working devices and place them to transport positions.

1.28. Welding Operations

All personnel for electric welding operations must bear professional certificate and must

conduct the electric welding in a place with appropriate equipment. During welding, the

operation personnel must abide by the following precautions:

39
 1. Before the welding on the machine, make sure to turn off the power master switch and

disconnect the connectors of instrument system, otherwise it will burn the units on the

instrument panel.

2. Remove paint from the area to be welded, in order to prevent the generation of harmful

gas.

3. Do not inhale the smoke of paint.

4. It’s prohibited to weld in a place near rubber hoses or electric wires or on a pressurized

pipe.

5. During welding, wear protective goggles and protective clothing.

6. Keep well ventilated in the electric welding site.

7. Clear all flammable materials and make sure to prepare fire extinguishers in the

working site.

1.29. Periodic Cleaning of Machine

To prevent possible injuries or machine damage, periodically clean the machine, remove all

deposited grease, oil, and fragments, and keep clean the engine compartment, radiator, battery,

hydraulic pipes, fuel tank, and cab.

During cleaning, wear antiskid shoes to prevent slip on wet surface.

40
 While flushing the machine by high pressure water, take cautions to keep away from the

shot of high pressure water and keep dirt and sludge away from splashing into eyes.

Do not spray the water directly to the sensors, connectors, and instruments of the electric

system. The ingress of water into electric system will lead to danger of operation failure.

41
2. Technical Specification
2.1. Diagram of Overall Dimensions

Figure 2-1 Exterior Diagram of Machine

2.2. Main Performance Parameters

Engine Power 70kW

Overall weight (±5%) 10500kg

Overall dimensions (±2％) 6360×2500×2700

Maximum traveling speed 30km/h

Turning radius 4238mm

Maximum effective load 3500kg

Effective load at maximum extending length 635kg

Maximum lifting height (±100) 13700 mm

Maximum forward reach (±100) 9400mm

42
 Center distance of load 600mm

Luffing angle (±1º) -4～73°

Inclination of fork carrier (forward (±1.5)/backward (±1)) 90/18°

Maximum traction force 70KN

Wheelbase (±2%) 3250mm

Wheeltread (±2%) 1970mm

2.3. Part Specification

Model WP4G95E221
In-line-four cylinder, four stroke,
Type water cooled, turbocharged, direct
injection type
Cylinder bore × Stroke 105mm×130mm
Total displacement 4.5L
Power Cummins Ignition sequence 1-3-4-2
System engine
Clockwise (observed from flywheel
Crankshaft rotation direction
end)
Rated power 70kw (1-hour power)
Rated speed 2200r/min
Top torque output 380N.m/(1400-1600)r/min

Minimum fuel consumption ≤215g/kW.h

1st forward gear 11km/h

2nd forward gear 30 km/h

Maximum
traveling
speed 1st reverse gear 11 km/h

2nd reverse gear 30 km/h

Model CA395142S
Drive
system
Shift number 2
Gearbox
Speed ratios for forward gears 4.286/1.359

Speed ratios for reverse gears 4.286/1.359

Model Steering drive axle

Drive axle
Model CA394933S

43
 Maximu
m 28°30′32″ on outer side and 40° on
Front steering drive steering inner side
axle angle
Speed
18.46
ratio
Model CA394934S
Maximu
m 28°30′32″ on outer side and 40° on
Rear steering drive
steering inner side
axle
angle
Speed
18.46
ratio
Tire specification 15.5-25-16PR L-2E
Tires
Tire pressure Front tires 525kPa Rear tires 325kPa

Service Type Wet type

Brake brake
Brake oil pressure, MPa 4.4
system
Parking Spring brake hydraulic pressure
Type
brake release
Hydraulic System working pressure , MPa 16
system Steering
hydraulic Model of steering gear BZZ-200/FK-/20
system
Steering gear manufacturer EATON
Working System working pressure, MPa 20
device
hydraulic KP30.51D0-A8S9-LMD/MC-N-CSC-
system Working duplex oil pump
QW

Oil pump manufacturer CASAPPA, Italy

Displacement 51.83ml/r
Model DC20-6-82
Structural
characteristic Split type
Multi-way valve s
Regulated
pressure, 20
MPa
Model B2-3-6

Pilot valve Regulated

pressure, 2.5
MPa
Pilot valve Model QBF-ETM-1F-OB-R

44
 Regulated
pressure, 3
MPa
Luffing cylinder, mm Ф90/Ф190

The second section of arm

Ф60/Ф110
telescopic cylinder, mm

The third section of arm telescopic

Ф60/Ф110
cylinder, mm

Outrigger cylinder, mm Ф60/Ф131

Auxiliary cylinder, mm Ф50/Ф131

Attachment carrier tilting

Ф75/Ф166
cylinder, mm

Electric System voltage 12V

system
Battery 6-QW-80R/L(6-QW-80)

45
2.4. Table of Fuel/Oil/Fluid and Capacity

Location Fuel/oil/fluid Capacity

Engine oil CF-4 15W/40 Diesel engine oil 16 L

Gearbox API GL4 4L

Front axle 13.1 L

API GL4
Rear axle 13.1 L

Summer: L-HM46 high pressure anti-wear hydraulic oil

Hydraulic oil tank 204 L
Winter: L-HM32 high pressure anti-wear hydraulic oil

Summer: 0#, 10#

Fuel 109 L
Winter: -10#, -35#

Coolant No. -45 engine coolant 40 L

Caution: The user shall adjust the appropriate fuel/oil/fluid timely depending on the air
temperature.

46
3. Operations
3.1. Introduction
This chapter is intended to learn how to operate the machine efficiently and safely and

guide the operator step by step. Please fully read this part from beginning to end.

Before starting the machine, sit in the driver seat and get familiar with the arrangement of

cab. Understand all operating levers, switches, instruments, buttons, and pedals with reference to

this manual, instead of by own guess. In event of anything unclear, please consult with a XCMG

dealer.

The operator shall always understand the things occurred inside and outside the cab. The

operation safety of the machine is of most importance.

If you are already familiar with the operating levers, switches, and instruments, practice

how to use them. Drive the machine to an open space and keep away from crowd. Attempt to

feel the machine and its operations and controls to the greatest extent.

At last, do not complete the learning of the manual hastily to ensure the complete

understanding of the contents of the operation manual. Only the carefulness and deliberation can

ensure safe and efficient operations.

3.2. Before Entering Cab

Fulfill the following checking items when returning to the machine, no matter how long you

leave the machine. It’s recommended to occasionally stop the machine and fulfill the checking

items once again during the long-term working of the machine.

All checking items are related to the working capacity of the machine and some of them are

related to your safety. Ask your service engineer to check and correct all problems.

1. Checking and cleaning

a. Clean the windows, lamps, and rearview mirrors.

b. Remove dusts and fragments, especially the surrounding area of linkage, hinge pins, and
radiator.
c. Keep clean and dry the footsteps and handrails of the cab.

47
d. Clean all safety labels. If missing or illegible, immediately replace with new one.
2. Checking of damages

a. Periodically check the machine for presence of damage or missing part.

b. Ensure that all hinge pins are safely at correct positions.
c. Check the windows for presence of cracking and damage. The glass splinters and fragments
are nearly invisible.
d. Check for leakage of engine oil, fuel, and coolant beneath the machine.
3. Ensure that the tires are properly inflated.

Check the rubber for presence of cutoff and puncture by sharp object. Do not operate the

machine with damaged tire.

4. Ensure that all filler caps are correctly installed.

5. Ensure that all instrument panel interfaces are sealed and safe.

Caution: If the filler caps and instrument panel are fitted with a lock, it’s recommended to lock
them, in order to prevent theft or other destructions.

Warning
It’s extremely dangerous to walk or operate beneath the lifted boom. The falloff of boom or

lowering of boom due to artificial negligence will probably crush you.

Before these checking items, make sure to fully lower the boom. If you are not familiar

with the machine, ask an experienced operator to help you lower the boom.

If no one can help you, study this manual till you know how to lower the boom. Of course,

before these checking items, ensure that the parking brake is already applied.

The burst of machine tire will probably cause injury or even death to you. Do not use

damaged or inappropriately inflated tires or operate a really old machine.

48
3.3 Seat Control
The seat can be adjusted to meet your comfort needs. The correctly adjusted seat can relieve

the operator’s fatigue for comfortable operations and controls. During the driving of the

machine, the seat can be adjusted by leaning the seat backrest with your back to completely

depress the foot pedal.

Warning

It’s prohibited to adjust the seat during the operations of machine.

Cushioned seat

Caution: The seat can be adjusted only when the operator already sits in the seat.

a. Horizontal adjustment
b. Vertical adjustment
c. Sitting height indicator. Refer to vertical adjustment.
d. Backrest angle adjustment
e. File bag

49
3.4. Seat Belt
Caution: If the seat belt is locked before the tab is locked into the buckle, completely retract
the seat belt and retry. In event of sudden pulling of seat belt or sudden inclination of
machine, the inertial device will be probably locked. In such case, gently and slowly pull out
from the retractor.

Check the normal functioning of seat belt

a. Sit correctly in the seat and fasten the seat belt as described.
b. Hold the middle portion of belt shown in the figure and pull forcibly to lock the seat
belt.

Warning

If the seat belt fails to lock during the checking of normal functioning, do not drive the

machine. Repair the seat belt or replace with new one.

The failure to fasten the seat belt will probably cause you to be thrown or even thrown

out of the machine or crushed. Make sure to fasten the seat belt during operations of the

machine. Make sure to fasten the seat belt before starting the machine.

If the seat belt is damaged or worn or if the machine just encounters an accident,

timely replace with new seat belt. Replace at least once every 3 years.

Fastening of seat belt

a. Correctly sit in the seat.

b. Insert the tab a into the buckle b, till it’s locked in place. Ensure that the seat belt is free
of kink and is affixed onto your upper hip instead of your stomach.

Warning

Upon detection that the seat belt can’t be locked during the checking of normal
functioning, do not start the machine. Repair the seat belt immediately or replace.

50
Release of seat belt

Warning

Release the seat belt after the engine is stopped.

Push down the button C and pull out the tab A from the buckle B.

Adjust the seat belt to ensure that the belt crosses over your upper hip instead of your
stomach.

Adjust the tab A

1. Depending on the required distance, pull down the toggle switch along the belt.
a. To increase the length of belt, pull the end E till an appropriate length is reached.
b. To reduce the length of belt, pull the end F till an appropriate length is reached.

51
Arrangement of Cab

Caution: The arrangement of cab adopts the figure of one typical model. In event of any
difference, please refer to the related contents in the manual.

Steering wheel

Gearshift lever

Accelerator pedal and Brake pedal

Angle gauge

Instrument panel

Pilot valve handle

Load table

52
3.5. Driving Control, Switches, and Instruments

Driving Control

Steering wheel

Rotate the steering wheel towards the desired steering direction. Please be noted that the
machine is of four-wheel drive mode.

Inclination adjustment

After sitting in the seat correctly, adjust the angle of the steering column to the most

comfortable position.

Rotate the lever A counter-clockwise to loosen the steering column. Pull or push the

steering wheel to a position appropriate to you. Rotate the lever A clockwise to clamp the

steering column.

Warning

Check and ensure that the steering column is clamped in place. Do not attempt to
adjust the steering column during driving.

53
Accelerator pedal

Depress the pedal to increase the engine speed and release to enable the return of pedal and

reduce the engine speed. Do not depress the pedal while the engine is idling.

Brake pedal

Depress the brake pedal to slow down or stop the machine. While driving down a slope, use

the brake pedal to prevent excessive driving speed of the machine.

The stop lamp will turn on when the brake pedal is depressed. Do not drive the machine,

unless that two stop lamps function normally.

Gearshift lever (2-speed transmission model)

Function

+/- Gear selection

F/N/R Driving direction selection

Gear selection

When the machine is stopped, ensure that the direction selection lever is at neutral position

(N). Before selecting a gear, ensure that the engine is idling.

The machine can move at any gear, depending on the ground condition.

54
 Warning

Do to shift the gear when the forklift truck is in driving state, and whether shift from
the high-speed gear to the low speed gear or shift from the low speed gear to the high speed
gear, the forklift truck will produce a greater traction force difference, so that you have a
major injury, and even death, while damage the forklift truck. If need to shift the gear,
please be sure to adjust the driving and reverse gear to the neutral position, and parking
the forklift truck, after that you can shift the high speed gear and low speed gear.

Driving direction selection

Warning

Operating the direction selection lever during the driving will probably cause serious

injury or even death to you and others. The machine will not change the driving direction

suddenly without any warning. Abide by the following recommended procedure to

correctly operate the driving direction selection lever.

Before operating the direction selection lever, stop the machine and select forward (F),

reverse (R), or neutral (N). Lift and move the direction selection lever to the designated position.

High/low gears can be operational in both forward and backward driving. There will be warning

sound when the reverse (R) is selected. The engine can be started only at neutral gear.

There is a retention position of gearshift lever at forward, reverse, or neutral position. Pull

the gearshift lever towards you to depart it from the retention position.

Driving direction selection procedure:

a. Stop the machine and depress and hold the brake pedal.
b. Drop the engine speed to idling state.
c. Select a new driving direction.
d. Release the brake pedal and depress the accelerator pedal to drive away.

55
 If the parking brake is applied, when rotating the gearshift lever from the neutral gear, the

parking brake indicator lamp turns on.

Horn

The horn button is located on the middle of the steering wheel. Push down the button to

sound the horn. The horn is operational only when the starter switch is position ON.

Multi-functional operating handle

1. Turn signal lamp (right)

Pull the operating handle towards you to indicate the right turn. At completion of the turn,

turn off the indicator lamp. This function is operational only when the starter switch is at

position I.

2. Turn signal lamp (left)

Push the operating handle away from you to indicate the left turn. At completion of the

turn, turn off the indicator lamp. This function is operational only when the starter switch is at

position I.

3. Instrument indicator
Turn the operating lever once away from your direction, and the indicator light is on. The

function only takes effect when the start switch in the I position.

4. Work indicator (low beam)

Turn the operating lever twice away from your direction, and the indicator light is on. The

function only takes effect when the start switch in the I position.

5. Work indicator (high beam)

Push up the operating lever, the work indicator (high beam) is on. The function only takes

effect when the start switch in the I position.

56
Starter switch

The starter switch is controlled by the starter key. It has four positions. The key can be

inserted or withdrawn only at position O.

O The engine will be stopped if the key is rotated to this position. Before stopping the

engine, ensure that the gearshift lever is at neutral position, the attachment is already lowered

onto ground, and the parking brake is already applied.

I When the key is rotated to this position, all electric circuits are connected with the
battery, except the lamp and 4- type hazard warning lamp circuit (the lamps and the hazard
warning lamp circuit is permanently electrified). Upon release from the position II or III, the
starter key will return to this position. At -6ºC, the warning lamp 5 will turn on to indicate
that the multi-branch heater at the cold start entry is already started.

II This position is not used in this operation.

III The starter motor is driven to rotate the engine.

Caution: If the engine fails to start continuously, do not operate the starter motor
continuously for more than 10s. If the engine is ignited, but is not completely started, do not
operate the starter motor continuously for more than 40s. Make sure to leave at least 2min
cooling time for the starter motor between two consecutive starts.

57
Cab lamp

Push down one end of the unit a to turn on the cab lamp. Push down the other end to turn

off the cab lamp.

Before leaving the machine for a while, ensure that the cab lamp is already turned off.

Selection of four-wheel drive disengagement switch

Drive by two-wheel drive mode whenever possible during driving. Drive by four-wheel

drive mode only when the traction force is restrained on soft and uneven roads.

58
Combination Instrument

1. Voltmeter
It indicates the voltage of system
2. Rear axle center position indicator
When the two rear wheels alignment, the indicator light is on.
3. Front axle center position indicator
When the two front wheels alignment, the indicator light is on.
4. Low oil pressure indicator
When the engine oil pressure is lower than 1bar, the indicator light is on, and at the same time

the combination instruments make a alarming sound.

5. Engine oil pressure gauge

It indicates the engine oil pressure.
6. Tachometer
It indicates the engine speed.
7. Water temperature gauge
It indicates the temperature of water.

59
8. Indicator of Low Brake Pressure

When the brake pressure is lower than the value set, the indicator would be on.

9. Charging indicator
When the generator is normal, the indicator lamp is off. Under normal circumstances,

after the car start, the indicator is off.

10. Parking brake indicator

When press down the parking brake rocker switch, in other words, press down the
handbrake, the indicator is on, and the car is in the parking brake state.

11. Diesel oil gauge

Display the quantity of the diesel oil.
12. Engine water temperature alarm indicator
When the engine water temperature is higher than 105 ℃, the indicator is on.

13. Hours counter

Display the total working time.

60
14. The left support leg indicator
When the left support leg landing, the indicator is on.
15. The right support leg indicator
When the right support leg landing, the indicator is on.
16. Alarm Indicator of Low Oil Level

When the oil level in the diesel is lower than the setting value, the indicator would be on,
reminding the driver to refuel.

17. Air filter blocking indicator

When the air filter is blocked, the indicator is on.

61
3.6. Operating Levers

Warning
The operations of the machine from the outside will probably cause injury or even death to

you and others. Operate the machine only when sitting within the cab correctly.

Boom/driving of machine

Operating the boom during driving will probably cause accidents and lose your complete

control on the machine. Therefore, it’s absolutely prohibited to operate the boom during driving.

Danger
Overhead Power Cables

It will probably cause electric shock if your machine or attachment is too close to the power

cables. Observe the working area for presence of power cables before starting the working. If

yes, contact your local power supplier and inquire which safety measures shall be taken.

Meanwhile, understand the requirements of local laws and regulations on the operations near

power cables.

After you understand the safety measures to be taken in the working site and understand the

laws and regulations, make sure to abide by these requirements.

Warning
Ensure there is no obstacle above before lifting the boom. Keep a sufficient safe distance

from all power cables. Contact local power company to obtain safe procedures.

Release the boom operating lever immediately after the boom is completely lifted. Holding

the operating lever at the lifted position will lead to slow lag of the attachment.

The functions of operating lever/switch vary on different machines. The labels nearby

indicate the functions of operating lever/switch. Before the operations, check the label to

determine the operations to be selected.

The operating lever is fitted with spring that can automatically return it to central position.

The action of the corresponding hydraulic cylinder depends on the movement distance of the

62
operating lever. The farther the movement is, the faster the action of the hydraulic cylinder is.

The hydraulic cylinder will hold at original position, until the operating lever or switch is

operated.

63
Single-Lever Control

Lifting/lowering of boom

A Lift

B Lower

64
Extension/retraction of boom

Important: If the hydraulic cylinder is not fully retracted periodically, the

three-section boom will run out of original phase. Fully retract the boom at
least once a day. Observe the reset of two-section boom.

C Extend

D Retract

65
Reverse forward/backward of attachment

E Forward

F Backward

66
 Frame Leveling (swinging）

Warning
When the swing arm is higher than the horizontal position, it is
forbidden to control the frame leveling (swinging).If the machine is not at a
horizontal level, the swing arm is forbidden to be operated.

Before operating the machine, control the frame leveling (swinging) to

level the machine. If it is impossible to adjust the machine to the horizontal
position, the machine shall be re-placed.

It is forbidden to control the frame leveling (swinging) in the case of

machine movement.

If you fail to abide by those safety regulations, the machine is likely to

be overturned.

Warning
67
 Control

You and others may be hurt and dead in the case of operation outside
the machine.You only can operate the machine when correctly sitting the
cab.

Before the loading and unloading, the leveling can be carried out for the

machine from one side to the other side by the frame leveling (swinging) control

switch. Before driving, the switch must be used for leveling.

Before the hydraulic cylinder is moved by operating the switch again, the

hydraulic cylinder is always kept on the original position.

When the angle of swing arm is 10¡ã greater than the horizontal level, the

operation is not allowed for the frame leveling (swing) control.

68
 Before the swing arm is operated, the banking indicator A is used to check

the horizontal level of machine. When the banking indicator turns to zero (0¡ã),

the machine is in the horizontal level condition.

Turning left/right

There is an indication on the identification for the movement of switch and

the horizontal swing of frame:

E: turn left

F: turn right

Control of outrigger

Warning

69
 It is not allowed to pile minces in the holes between the cylinder and the
outrigger.Remove all minces and clean it.

Outriggers can be used to increase the stability of machine when lifting.

The position from the machine to the side is indicated by the banking

indicator A installed in the cab. Before the swing arm is operated, the banking

indicator is used to check the horizontal level of machine. When the banking

indicator turns to zero (0¡ã), the machine is in the horizontal level condition.

70
 If the machine can not be adjusted to the horizontal level status at a certain position, it shall

be re-placed at a new position.

Ensure the outriggers are laid down, and support the machine at the same time. The swing

arm is not stretched if not necessary. Before the machine is operated, it is necessary to

disconnect the control of outriggers at first.

Outrigger Laying Down and Withdrawing

The outrigger of the machine can not be withdrawn if the swing arm can not be withdrawn

completely. If the arm is withdrawn completely, the indicator of arm withdrawing turns on.

D: Lay down

E: Withdraw

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3.7. Load Diagram
The safe working load (SWL) of machine depends on the extended boom length and the

lifted angle.

It's really important to ensure that the machine is fitted with following types before the

operations of the machine:

Observe the load indicator (LMI)

Observe the boom indicator

The load diagram is described as below.

Introduction of load diagram

Caution
The load diagram shown in the figure is only one example. Do not use it to look up
the load limit of your machine. Before lifting or placing a load, observe the load
diagram within the cab of your machine.

The safe working loads under different extended lengths of the boom are described in the

load diagram within the cab.

The load diagram describes how long and how high can the boom be extended, provided

that the safe working load is not exceeded. Each model has a load diagram for standard forks and

an additional load diagram for outrigger or frame leveling (swing) operation. When the boom is

equipped with different attachment or accessory, there will probably have other load diagram for

operations.

The load diagram in this manual is taken for reference only. Before lifting or placing a load,

make sure to observe the load diagram within the cab of your machine.

Check the applicability of relevant load diagram for irregular attachment or accessory. At

appropriate locations, the load diagram describes the part number A for the related attachments

72
or accessories. If you are not sure about the correct load diagram to be used, please contact your

XCMG dealer for help.

If damaged or missing, replace as soon as possible.

Use of load diagram

Caution
The limits on the load diagram are based on the condition that the machine is
level and stationary. Do not lift or extend the boom during movement of the machine.
Before driving under loaded condition, fully retract the boom and lower the boom as
low as possible.

1. Determine the accessory equipped on the boom of your machine and turn over to select

the load diagram within the cab.

2. Make clear the weight of load before lifting or lowering. Ensure that the distance X

from gravity center of the load to the vertical surface of forks is no more than

600mm(20in).

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Caution: The center of the load is not always the gravity center of the load Y. It’s really
necessary to find out the gravity center.

3. After making clear the weight of the load, look up the load diagram to find out the

neighboring color zone of next maximum load.

For instance, in the load diagram example shown, if your load is 2100kg, find out the

2200kg zone, which is the maximum load zone of your load.

74
 In this zone, the left boundary B and the top boundary C indicate the stability load limits of

the machine under your load. Do not operate beyond these boundaries while lifting and

extending the boom.

Warning
There are two working statuses for the type of machine, namely, outrigger support
and withdrawing. When checking which load diagram is used, it is necessary to identify the
suitable working status. Please select correct load diagram, or it may cause the machine
overturned and personnel injury, even death.

4. After the forks are forked into the load, before the lifting, observe the readings of angle

gauge and boom length indicator. Find out the same readings on the load diagram.
On the diagram, you can see the lines that vary along with the readings of boom angle and

boom length in the colored zone. Find out the intersection point between the lines of your

readings. If the point is within or on the right side of the maximum load zone, the load is within

the safety limit.

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 If the point is above or on the left side of the zone, do not attempt to lift the load again.

Withdraw the forks, retract the boom, and attempt once again. Even if the boom is fully

retracted, the angle and extending readings of the boom may still be beyond your maximum load

zone. Therefore, do not attempt to lift the load once again.

5. When the forks are loaded with a load, retract the boom before lifting or lowering the

boom. This can reduce the instability danger of the boom. While moving the boom,

observe the readings of the angle gauge and the extending indicator of the boom. Keep

the readings within your load limit.

Caution: When the load is high (such as scaffold), make clear the situation before fully
retracting the boom.

6. Before placing the load, use the load diagram to find out how far your machine needs to

be from the load location. The load must be placed without going beyond the left or top

limit of your maximum load zone.

Boom Indicator

The boom is probably equipped with additional boom indicator A and B.

The safe working loads at different positions of boom are described in the load diagram
within the cab. The boom is integrally fitted with boom angle indicator and extending
indicator. The extending length of boom is indicated by number B in unit of meter. The
angle of boom is indicated by indicator A in graduation of degree.

Always look up the load diagram within the cab before lifting or placing a load. Refer to the

load diagram.

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Warning lamp

Important: It’s recommended to use flashing warning lamp when the machine is
traveling on public roads. In some regions, driving the machine without warning lamp is
illegal. Please abide by the local traffic regulations.

Two types of yellow or amber beacon kits, namely magnetic disc type and telescopic type,

are at your choice.

The magnetic basement of warning lamp B is installed on the top of cab.

77
78
3.8. Before start of engine
Caution: If working in a high temperature or low temperature environment, please read the
operation manual for working under high temperature or low temperature environment.

Caution: If the fuel in the fuel tank or any other system is used up or out of supply, make
sure to add sufficient fuel before restarting the engine.

1. Apply the parking brake when the machine is finally stopped. If not applied, apply the
parking brake now.

Danger

Before lowering the attachment onto the ground, ensure that the machine and all
personnel nearby are not in the dangerous zone. The personnel on or near the machine
will probably be crushed by the attachment or fall off from the machine.

2. The attachment shall be lowered to the lowest point before the engine is stopped. If not
lowered to the lowest point, restart the engine and lower the attachment to the lowest point.
Then stop the engine and perform step 3.

3. For the safety of you and others and the service life of the machine, please fulfill the
thorough checking before start of engine.

a. If the machine is driving outside and the thorough checking is not completed, please refer
to section Before Entering Cab. Of course, the detailed daily checking as specified in the
maintenance schedule shall be completed.

b. Remove dirt and waste from the cab, especially from the pedals and the operating shaft.

Warning

Keep clean and dry the control part of the machine. The slip of your hand or foot
will probably lead to out-of-control of machine.

c. Wipe dry the oil and mud from the steering wheel and operating levers.

d. Keep clean and dry the operator’s hands and shoes.

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 Warning

The unstable things will fall off to probably hit you or roll beneath your feet. You
might be knocked unconscious or be blocked by operating parts to cause out-of-control
of the machine.

e. Throw away all unsafe things from the cab, such as lunch box and tools.

f. Check the damage state of ROPS/FOPS structure. Always contact and consult a XCMG
dealer for repair of any damage. Make sure that all bolts are correctly installed and
reasonably reinforced.

g. When necessary, check the bolts around the cab for looseness and missing and repair
timely.

h. Check the damage and wear extent of the seat belt and its devices.

Warning

If the seat belt is damaged or seriously worn or the machine ever encounters an
accident, timely replace with new seat belt. Replace the seat belt once every three
years.

I Check the following items in due time:

Lamps, warning lamps, horn, indicator lamps, all switches, turn indicator lamps, hazard
warning lamp, and windscreen washer and wiper (if equipped).

4. Adjust the seat for you to drive the machine comfortably. You may lean against the seat
by your back to fully depress the brake pedal. Please refer to section Seat Control.

5. Adjust the driving devices so that you can operate the steering wheel and operating levers
comfortably.

6. The correct setup of rearview mirrors can provide a good visual field for you within the
cab.

7. Fasten the seat belt. Refer to the section Seat Belt.

3.9 Start of Engine

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1. Before starting the machine, carefully read and abide by the operation and maintenance
manual.

2. Before starting the engine, make sure to apply the parking brake of the whole machine.

3. Before starting the machine, make sure to install and use the battery fuse. Refer to the
section Operations of Battery.

4. The engine can be started only when the handbrake is applied.

Caution: If the engine fails to start, do not run the starter motor for more than 10s. If the
engine is ignited, but is not completely started, do not run the starter motor for more than
40s. Wait for at least 2min interval between two consecutive starts.

5. Once the engine is started, release the engine key. The key will automatically return to
position “IGN”.

Warning

Do not use diethyl ether or other liquid to assist the cold start. The use of such
liquid will probably cause explosion and injuries or damage the engine.

6. Slightly release the accelerator pedal to reduce the engine speed.

7. Once the engine is started, check whether all warning lamps are turned off. Do not
accelerate the engine till the low oil pressure indicator lamp turns off. The earlier
acceleration of engine will probably damage the turbine unit due to insufficient lubrication.
Check whether the audible alarm sounds.

Caution: This is a normal symptom that the engine noise is relatively high under cold
environment. It can achieve normal noise by adjusting the fuel injector nozzle to meet the
requirement.

Caution: If any warning lamp turns on during running of engine, stop the engine for
checking as soon as possible to ensure safety.

8. Turn on the hydraulic device, in order to ensure the normal functioning of each system
and help the preheating of hydraulic system. Do not operate any accessory before the
hydraulic oil reaches the normal temperature.

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9. The operation of the boom has three phases:

If the boom fails to extend normally after three phases, check the hydraulic cylinder for

normal retraction. Before start of machine, correctly check the boom by phases.

Reset of three-section boom

Caution: The new engine requires no run-in. This engine shall be running normally shortly
within one period. Following the running of the engine, it probably leads to the accelerated
oil consumption due to piston and cylinder bore. In any case, do not leave the machine
unused for a long time (for instance, preheat the machine under unloaded condition for a
while).

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3.10. Traveling Preparations of Machine
While traveling outside or in a parking lot, abide by the local traffic safety laws and

regulations.

Before traveling on road

Important: Always abide by all relevant local laws and regulations while traveling on
public roads.

1. Fully retract the boom. Lower the boom sufficiently and then lift slowly. Tilt backward
the attachment carrier, till the root point A is off the ground by 300mm (12in).

Caution: Some nations require folding the forks while traveling the machine on public
roads.

Warning

The forks are really heavy. Take cautions to separate and fold the forks.

83
 When the boom is at traveling position, install ropes to the lifting points on the boom and

frame.

2. If other optional attachment is installed, ensure that the safety requirements of the
optional attachment are met.

If the machine is traveling with the bucket, the bucket tooth protective plate must be

installed.

84
 Caution

Do not travel under loaded condition on public roads.

3. Lock the controls (depending on actual needs).

4. Adjust four wheels to linear alignment and select two-wheel steering mode. Do not select
crab steering or four-wheel steering while traveling on public roads. Lock the steering mode
selection lever.

5. Some regions legally require turning on the warning lamp while traveling on public roads.
Check and ensure that the lamps of all circuits are functioning normally.

3.11. Movement of machine

Operation practice

Warning
Hillsides

There is a danger to operate the machine on hillsides, unless the appropriate

preventative measures are taken. The ground conditions may be altered or destructed
by rain, snow, or ice. Carefully check the working area and operate the machine at 1st
gear on the hillsides. During the operations, keep all attachments close to the ground.
Do not slide down the slopes with the engine not running or the transmission not at
neutral gear.

This forklift truck is provided with a high speed gear and low speed gear. However, it is not

necessary to use a high speed gear to overload the engine, such as in the mountains. High speed

gear is only used for the forklift truck transition and operation in high speed gear can result the

overheating of the hydraulic oil in the hydro-static transmission system.

Always keep the machine under control during the movement of the machine. Always keep

alerted against the obstacles and the possible occurred danger moments.

85
Do not get off the machine during movement of machine.

Do not use any pedal as footrest.

Do not shift to neutral gear while driving down a slope, as the machine can’t be completely

controlled and the sliding will damage the transmission of the machine.

Slopes

Under loaded condition, drive forward to drive up a slope and drive backward
to drive down a slope.

Under unloaded condition, generally drive backward to drive up a slope and

drive forward to drive down a slope.

Do not make turns on a slope or cross over slopes.

Select a necessary gear before driving down a slope. To drive down a slope, use the gear

same with that used to drive up the slope. Do not conduct gearshift on slopes.

Under loaded condition, select 1st gear to drive down a slope.

Use the brake while driving down a slope, in order to prevent the over-speed and downslide

of the machine.

If entrapped in mud, shift to 1st gear and align forward the front wheels.

Take special cautions during steering. Ensure that your visual field is not obstructed from

the rearview mirrors. Ensure that the road is free of obstruction before the steering. Ensure that

the alarm functions normally so that all personnel nearby can hear it clearly.

Caution: To adapt to different operating environment, the machine is fitted with all kinds
of steering alarms. The types of the alarm are probably controlled by some local laws and
regulations and the alarm can be applied only in some specific fields. Please correct use
the reversing alarm.

86
 Warning

It will probably cause grinding injury if the machine starts rolling and you attempt to
get off the cab. Do not attempt to jump off the cab when the machine starts rolling.
Please stay within the cab and fasten the seat belt.

Operation procedure

After the preheating of the machine and the parking brake test are completed, operate as per

the following instructions.

Caution: This manual provides the locations of switches and operating levers.

1、 Check your seat and seat belt.

a Ensure that your seat belt is fastened correctly.

b Ensure the correct adjustment of seat.

2、 Select one desired driving mode.

Important: Please bear in mind that the driving mode will probably remain temporarily at
previous mode and restore current mode till the rear wheels are aligned forward.

Warning: The rear seat of the machine will swing out during four-wheel steering. Please
check carefully before steering.

3、 Start the gear selection. Select one desired gear switch.

Warning

Gearshift

Do to shift the gear when the forklift truck is in driving state, and whether shift from
the high-speed gear to the low speed gear or shift from the low speed gear to the high
speed gear, the forklift truck will produce a greater traction force difference, so that you
have a major injury, and even death, while damage the forklift truck. If need to shift the
gear, please be sure to adjust the driving and reverse gear to the neutral position, and
parking the forklift truck, after that you can shift the high speed gear and low speed gear.

87
 Operating the gearshift lever during the driving will probably cause serious injury or even

death to you or others, as the machine will probably move suddenly without any warning. Please

correctly perform this operation as per the recommended operation procedure.

4、 Select a forward gear or steering operation or leave.

Warning

Reversing

The high speed reversing will lead to occurrence of accidents. Do not reverse the machine

at full accelerator and highest gear. Always drive safely depending on the working environment.

a Check and ensure that the boom is at traveling position.

b Depress the brake pedal.

c Under braked state, operate the gearshift lever to select forward or reverse.

Caution: When the parking brake is applied, if the gearshift lever is shifted to forward or
reverse, there is a warning lamp indicating that the parking brake is applied.

d Release the parking brake.

e After the parking bake is released and the safety is guaranteed, release the brake pedal and
depress the accelerator pedal to slowly move the machine.

Warning
Failure of Engine/Steering

If the engine or steering fails, stop the machine as soon as possible. Do not operate further

before the problem is solved.

f While checking the steering and brake, please drive the machine slowly. When the control
or brake of the machine is malfunctioned, do not operate the machine, even if the
malfunction is not confirmed or considered by you.

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3.12. Braking and Parking
1、 There is no danger or threat to park the machine on a dry level ground.

Parking

The incorrectly parked machine will probably move without the operator. Please abide by

the relevant instructions in this manual for correct parking of the machine.

2、 Slightly release the accelerator pedal and depress the brake pedal to stop the machine
successfully. Depress and hold the brake pedal, till the machine is completely stopped
(step 3 and step 4).

Caution: The parking brake can’t be used to slow down the traveling speed, unless in event
of emergency. Otherwise the braking efficiency of the parking brake will be reduced. If the
parking brake is used in event of emergency, replace with new brake lining.

3、 Sufficiently pull up the parking brake handle. Ensure that the parking brake indicator
lamp turns on. Release the brake pedal.

Warning

Do not get off the machine during movement of machine.

4、 Shift the gearshift lever to neutral gear. Ensure that the operating levers are in place and
that the brake indicator lamp turns off.

Danger

Before lowering the attachment onto the ground, ensure that the machine and all personnel

nearby are not in the dangerous zone. The personnel on or near the machine will probably be

crushed by the attachment or fall off from the machine.

5、 Retract and lower the boom and level the forks closing to the ground.

Caution: Do not leave the machine when the boom is sufficiently lifted and extended,
otherwise it will cause permeation of hydraulic oil from one hydraulic refilling valve and
cause partial out-of-phase of boom, which will lead to destruction of boom pipeline system
during retraction of boom.

89
 Warning

Hydraulic cylinder

The efficiency of the hydraulic cylinders will be influenced if the dusts thereon are not

removed. Periodically remove the dusts from the surrounding area of the hydraulic cylinders.

Before leaving or stopping the machine, close all hydraulic cylinders to minimize the weathering

corrosion.

6、 It’s recommended to increase the engine speed to 1000r/min and unload for 2~3min
before stop. This can cool down the turbocharger.

7、 Before leaving the machine, please ensure that all switching devices are already turned
off. If necessary, leave the hazard warning lamp and the side lamp on. Withdraw the
key.

8、 Use the handrail and foot ladder to get off the machine. When leaving the machine,
close and lock all windows and two doors. Ensure that the all filler caps are locked.

Warning

Entering and Leaving

Make sure to use the provided handrails and foot ladder to leave or enter the cab or driving

shed. Face towards the machine while entering or leaving the machine. Ensure that the foot

ladder, handrails, and bottom of your shoes are dry and clean. Do not jump off the machine. Use

the handrails, instead of any operating lever of the machine, to enter or leave the machine.

9、 When the machine is not to be used for a long time after one working cycle, please take
away the battery (if equipped) if no lighting is needed. Battery isolator\

90
3.13. Operation Instructions of Machine

Introduction
This section can tell you the methods and techniques for safe and effective operations of the

machine.

Your machine can be applied in various conditions. Therefore, in all cases, the driver must

determine the operation manual and the working conditions depending on the actual situation, in

order to meet the relevant laws and regulations.

We provide the most useful information with deep sincerity. XCMG accepts in a

responsible way the suggestions, opinions, statements, viewpoints, clear conclusions, and

baseless views, which will be equally valued.

Ensure that you have passed sufficient training and believe that you are capable for

operations of machine before driving the machine safely.

The carefulness, well training, and rich experiences are your magic keys for safe and

effective operations of machine. Lacking of experiences or carelessness will make your driving

dangerous. Do not threaten your life or others due to your irresponsible driving.

Danger

The influencing factors for the stability of machine include driving mode, load type,

elevation and reach of boom, ground condition, and wind speed and direction. Before the

operations, it’s the operator’s responsibility to evaluate the wind direction and speed and

load scale. Before the operations, it’s operator’s responsibility to evaluate the terrain,

ground roughness (bear in mind that the roughness is different between wet and dry

grounds), and ground hardness.

Before starting the operations, read and understand the load table of this manual and

the boom manual. Ensure that you can correctly control the machine before the actual

operations.

91
 Use a load of standard weight for testing. Do not use any unknown load, unless you

can handle a load of standard weight safely and confidently.

Read and understand this part. Use the load diagram and boom indicator before operating

this machine. Practice continuously, till the operations are correctly understood.

Firstly practice the operations of flat loads and, after the flat loads can be operated safely

and skillfully, operate the complicated loads.

The machines covered by this part are equipped with standard fork attachment. Please

operate other attachments with refer to the part Optional Attachments.

Before using any attachment, take the possible safety influence of attachment into

consideration. When the attachment is equipped, the gravity center or the overall dimensions of

the machine may vary, which will probably influence the stability of the machine. Therefore, pay

attention to the safety of ground operations and the safe distance from the power cables.

Pay attention to the maximum wading depth of this machine. If the water is too deep, the

water will enter into the engine, axles, and cooling fan to damage the machine.

The operation regulation shall be properly considered before starting any operation not

covered by this manual. You may contact a XCMG dealer, who will serve you with pleasure.

Read the part Safe Operations in the preface and the following information:

Safety Rules

Clothing and safety equipment

At the control or motion device part of the machine, do not wear loose clothing or jewelry.

Wear the protective clothing and labor protection articles as per the working conditions or local

laws and regulations or the owner’s requirements.

Forking and handling of load

Ensure that the place for the placement of load can carry the load safely.

92
 Make clear the direction and keep calm during driving. If the load is too large to block the

visual field, appoint a person to assist the guidance.

Pay special attention to the level condition of the ground during driving. Refer to the part

Operations of Machine on Slopes (Operation Instructions).

The stacking height of the loads shall not be higher than the forks.

The driving speed shall depend on the driving conditions. Drive at low speed on moisture,

slip, or loose ground.

Drive with care on bump roads, as it will probably bump off the load.

Risk evaluation

In consideration of specific operating environment and working conditions, it’s the

operator’s responsible to prepare appropriate operation regulation for the safe operations of the

machine.

It’s of great importance to fulfill correct risk evaluation and ensure effective safety

protection measures for fulfillment of works.

If you don’t know how to handle specific works, please contact a XCMG dealer, who will

serve you with pleasure.

During the risk evaluation, some factors below shall be taken into consideration as

suggestions. Sometimes, the consideration shall be taken for other factors.

Important: The correct risk evaluation is originated from the well training and rick
experiences. Never neglect your life or others.

Basic knowledge:

In the loading/unlocking area, the working area shall be enough to accommodate the

machine body and outriggers (if equipped). It’s unnecessary to operate the machine in a narrow

space.

93
 The working area shall be hard enough to carry the machine and load without clear

deformation. The ideal condition is that the working area can accommodate two machines and its

gradient is no higher than 2.5%(1:40).

When the machine is working in a loading/unloading environment probably not handled

specially, the operator may handle with well training and rick experiences. If equipped, the

lateral regulator can enhance the working capacity of your machine.

The traveling path shall be solid and reliable and its gradient shall be no higher than:

Maximum upslope gradient: 15%(1in7)

Maximum downslope gradient: 15%(1in7)

Maximum lateral gradient: 15%(1in7)

These data can be used only for normal driving mode of the machine, namely the boom is

retracted, the root of the forks is more than 500mm (20in) above the ground, and the machine is

not speeding. It’s necessary to restrain the loads of certain shapes, especially on lateral slopes.

Personnel:

Among the personnel for this operation, who is better trained? Who is better experienced?

Who is better competent for this operation? Are they well rested? The driving under ill or fatigue

state is really dangerous.

Is the supervision necessary? Is the supervisor well trained and experienced?

Is an assistant or other assistance needed for the driver?

Machine:

Is the working state good?

Is the malfunction report corrected?

Is the daily checking fulfilled?

94
 Do the tires for fulfillment of operation have sufficient pressure? Are they under good

state? Is the fuel sufficient?

Load:

How heavy is it? Is it within the load capacity of the machine?

How large is it? A large surface area will be influenced by wind speed.

Is it a shape load? Where is its gravity center? An unbalanced load is difficult to handle.

Is it smooth and easily sliding? If yes, can it be handled by forks?

Loading/unloading area:

Is it level? The careful consideration shall be given if its gradient exceeds 2.5% (1:40).

Is there more than one direction to access the load? If possible, avoid crossing over any
slope.

Is the ground solid? Can the ground carry the weight of machine under full load?

Is the ground really rough? Is it harmful to the machine, especially to the tires in event of
emergency?

Is there any obstacle or dangerous article nearby? Such as fragments, large pits, and electric
wires.

Is the operation space enough? Is there the accessing of other vehicle or personnel during
the working of the machine?

Crossing path:

Is the ground solid? Can it provide sufficient traction force and braking force?

How about the steepness of the slope (upslope/downslope/lateral slope)? It’s really
dangerous to cross over a slope. Is it possible to make a detour?

Weather:

95
How strong is the wind? A strong wind is harmful to the stability of the loaded machine,
especially when the surface area of the load is large.

Is it raining or is there a possibility of raining? The influences on traction, steering, and

braking of the machine are different between dry and wet roads.

Safety warning:

Warning

Carefully check the working site before starting the machine for operations. The

stacked materials near the working site will collapse once being impacted by the machine,

which will probably cause injury or even death to you. Check the dangerous factors that

may cause out-of-control of the machine (including pits, fragments, log, and steel blocks).

Dander

Without permission, it’s prohibited to lift anyone in the high air or stand on the non-
protected forks. The violation will probably cause serious injury or even death.

Caution

Driving the machine too fast or the over-high load will probably lead to rollover of the

machine. During the traveling of the machine, keep the load close to the ground.

Under loaded condition, do not drive the machine too fast. Drive with care on bumpy

roads.

Do not operate the boom/attachment during the traveling of the machine.

Warning

High slopes and earth ditches

The high slopes and earth ditches will probably collapse. It’s probably dangerous to park

or drive the machine near a high slope or earth ditch.

96
 Safety railing

It’s probably dangerous to leave the machine unattended in a public place. In a public

place, if the environmental visibility is reduced, setup a safety railing in the working are to

keep away the people.

Caution

Make sure to understand the weight of load before lifting the load. Firstly check the
stability of the machine, even if the load is to be lifted only for centimeters. If feeling that
the machine is unstable, immediately lower the load. While lifting or extending the boom, if
feeling that the machine is unstable, lower and retract the boom.

The load shall not exceed the values indicated on the load diagram (Refer to the load
diagram and boom description in the manual).

Caution

During loading/unloading, if the ground is not solid, it will probably lead to rollover of the
machine and cause serious injury or even death to you. Before the loading/unloading,
ensure the leveling of the ground. Whenever possible, do not carry the load on a non-solid
ground.

Dander

Overhead power cables

It will probably cause electric shock if your machine or attachment is too close to the

power cables. Observe the working area for presence of power cables before starting the

working. If yes, contact your local power supplier and inquire which safety measures shall

be taken. Meanwhile, understand the requirements of local laws and regulations on the

operations near power cables.

After you understand the safety measures to be taken in the working site and

understand the laws and regulations, make sure to abide by these requirements.

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 Caution

Driving the machine too fast or the over-high load will probably lead to rollover of the

machine. During the traveling of the machine, keep the load close to the ground.

Under loaded condition, do not drive the machine too fast. Drive with care on bumpy

roads.

Do not operate the boom/attachment during the traveling of the machine.

Make sure to understand the weight of load before lifting the load. Firstly check the

stability of the machine, even if the load is to be lifted only for centimeters. If feeling that

the machine is unstable, immediately lower the load. While lifting or extending the boom, if

feeling that the machine is unstable, lower and retract the boom.

The load shall not exceed the values indicated on the load diagram (Refer to the load

diagram and boom description in the manual).

During loading/unloading, if the ground is not solid, it will probably lead to rollover of

the machine and cause serious injury or even death to you. Before the loading/unloading,

ensure the leveling of the ground. Whenever possible, do not carry the load on a non-solid

ground.

Spacing of forks

The load will probably fall off if the spacing between forks is not incorrect. With

respect to the load, the forks are always correctly placed. Before the lifting, ensure that the

forks are completely beneath the load.

Lifting by single fork

The load on single fork will fall off. It’s prohibited to lift the load by single fork.

Unloading

It’s prohibited to unload the load from the forks by suddenly stopping the machine.

Follow the unloading procedure specified in the operation manual.

Load grades of forks

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 Warning

Do not exceed the load grade of the forks. The forks will probably break to cause loss

of load or possible damages.

Warning

Maintain a correct pressure for the tires and prevent the lateral instability of the
machine. Daily check the tires for damage trace, cut, and piercing object. These detects will
probably lead to pressure loss of the tires.

Caution

When the machine is started or idled for more than 5 minutes, first need to turn the
steering to charge the accumulator, then the machine can work normally.

The forks must be used by pair.

The maximum carrying capacity is described in the performance part of the machine

(Technical Specification). The carrying capacity of the forks for this machine must be equal to or

higher than the maximum carrying capacity of the machine.

If the carrying capacity of the machine differs from that of the forks, the smaller value shall

be taken as the carrying capacity of the machine.

Important: All lifting equipment, including the forks and its equipment, shall be
periodically checked and tested by qualified personnel, in order to guarantee their
performances.

Some nations probably require checking at least once every half year or one year. To

guarantee the safety, the local laws and regulations shall prevail.

If you have any questions, please further consult with local XCMG dealers.

Regular Loads

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 Caution
Load and unload on a solid and level ground. Take cautions against possible dangers,

especially during steering and reversing.

Warning
Before lifting or handling a load, ensure the weight of own braking load.

Never exceed the safe working load of your machine. Do not exceed the lifting angle

and the limit extending length indicated in the load diagram within the cab. Observe and

use the load diagram and boom indicator (in the operation part).

Take cautions to separate or stack the fork bodies, as the forks are really heavy.

Loading

1. Separate the fork bodies as far as possible, depending on the size of the load.

2. Place the forks at horizontal position and fully retract the boom.
3. While closing to the load slowly, keep four tires forward and do not form any angle.
Stop the machine and keep a sufficient space for movement of boom. Apply the parking
brake and shift the transmission to neutral gear.

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Caution: If the load is on a high platform, it’s necessary to lift the boom so that the machine
can close to the load sufficiently.

4. Extend the boom or move the machine to insert the forks into the load. Stop the machine
when the attachment comes into contact with the load. Check the extending
length/lifting angle of the boom and ensure they are within the limit.
Warning
If the machine starts to become unstable when starting the lifting of load, immediately

lower the load.

5. Lightly lift the load, tilt backward, fully retract the boom, and lower the boom to the
traveling position.

6. Slowly drive the machine to the unloading position.

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Unloading
Caution
Load and unload on a solid and level ground. Take cautions against possible dangers,

especially during steering and reversing.

Warning
Before lifting or handling a load, ensure the weight of own braking load.

Never exceed the safe working load of your machine. Do not exceed the lifting angle

and the limit extending length indicated in the load diagram within the cab. Observe and

use the load diagram and boom indicator (in the operation part).

1. Slowly close to the center of unloading area, keep four tires forward, and do not form
any angle. Ensure not to exceed the load limit indicated in the load diagram.
2. Apply the parking brake and shift the transmission to neutral gear.
3. Place the load at a position slightly above the required position. While stacking box
loads, ensure that the loads are stacked straightly and squarely. For better stability,
stagger the topmost row of load.
4. Lower the load to the required position and ensure that the load is level.
5. Carefully withdraw the forks. Depending on the height of the load, it’s necessary to lift
or lower the boom while withdrawing the forks.
6. After withdrawing the forks from the load, fully retract the boom and lower the boom to
the traveling position.

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Irregular loads

Important: While handling irregular loads, take special cautions to operate the boom and
attachment.

1. Find out the gravity center of the load. For a properly packed load, the gravity center is
probably marked on the box.
2. Properly place the machine to ensure that the gravity center of the load is at the
symmetric center between two fork bodies.
3. Fork/place the load, depending on the type of the load. For regular loads, follow the
procedure for regular loads. For irregular loads, the appropriate chains are probably
required to ensure that the load is safely placed on the forks. Stop the engine before
anyone is allowed to close to the forks.
Caution: If it’s impossible to find out the gravity center of the load, follow the procedure
below: Attempt to load the load at different locations, till it’s considered that the load is
stable on the forks. While attempting to load the load, lift the load only by centimeters.

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Handling of package load

Handle the package loads only after fully understanding how to handle regular loads. The

procedure is the same. However, pay attention to the following items:

Lifting

1. Lower the boom and tilt the forks as forward as possible.

2. Extend the boom, lift lightly, and fork into the load. Then, tilt backward the forks and
place the boom to traveling position.

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Placement

1. Properly place the boom and place the package at the position slightly above the
required position of the package. Lower the boom and tilt forward the forks lightly so
that the front edge of the package lowers onto the ground.

2. Retract the boom and withdraw the forks from the bottom of the package. After being
disengaged from the package, restore the boom and forks to the road traveling position.

Warning
The package will probably fall off the forks. In such case, stop the engine before
anyone is permitted to approach the forks.

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Operations of Bucket

Warning
Before lifting or handling a load, ensure the weight of own braking load.

Never exceed the safe working load of your machine. Do not exceed the lifting
angle and the limit extending length indicated in the load diagram within the cab.
Observe and use the load diagram and boom indicator (in the operation part).

While handling loads on high piles or embankments, remove all hanging objects.
Be aware of the falling objects. The sudden falloff of the protruding materials will
probably bury you and your machine.

Caution
Load and unload on a solid and level ground. Take cautions against possible
dangers, especially during steering and reversing.

Do not load by bucket with the boom extended, otherwise it will probably cause
serious damage to the boom.

Your machine may be equipped with diversified attachments, including bucket. Please refer

to the Attachments. The paragraphs below will introduce some related precautions to you. These

precautions may be incomplete to substitute the appropriate training. Make sure that you are

trained before operating any other attachment.

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 While digging the bucket into the material, lift the bucket and at the same time tilt

backward the bucket to sweep upward the material and top up the bucket with material.

Push down the drive dumping switch, which can provide more energy and accelerate the

cycles for the loader. Top up the bucket whenever possible, as a half-full bucket means low

productivity.

During the movement of load, tilt backward the bucket to a position capable of prevention

of leakage.

While loading a soft material pile, start from the bottom of the material and operate from

the front as per the figure to horizontally slide the bucket onto the ground towards the material

pile.

While loading a compact material, start from the top and handle downward.

To move away material from a stock pile, start from the position approximate one bucket

height above the bottom. Once the height of the stock pile is reduced, load from the bottom of

the pile.

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Loading to Truck

Park the truck at the position approximate 45º from the material pile, as shown in the figure.

This can save unnecessary movement. Guarantee a sufficient space to lift the bucket to the

dumping height, without slowing down the machine during driving.

Keep your position against the wind, in order to keep you and your machine away from the

dust.

Before dumping, drive your machine to be as close as possible to the truck.

If the truck body is approximately same with the bucket width, dump the load into the

center of the truck. If the truck body is two times of or longer than the bucket width, dump the

load to the front end of the truck.

Do not dump the load by sudden movement. Tilt forward the bucket step by step, till the

material is fully dumped. Shake the bucket by operating the operating lever back and forth to

shake off the adhered material.

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Operations of Machine on Slopes
Warning
Make sure that you are already trained, get familiar with the operations of machine on

slopes, and understand the possible adverse influences of the slopes and working environment on

the stability of the machine. If you don't understand these practices recommended for actual

applications, never operate the machine on slopes.

While operating the machine on slopes, there are many factors leading to adverse influences

on the stability of the machine and the safety of the machine and operator.

It’s really important and necessary to conduct the risk evaluation for the works to be

handled. Please refer to Risk Evaluation (Operation part). The operator shall abide by all safety

procedures specified and supported by the risk evaluation.

Driving up and down slopes

While driving on slopes, abide by the following requirements to guarantee the maximum

traction force.

Drive forward the unloaded machine to drive down a slope and drive backward to drive up

a slope.

Drive forward the loaded machine to drive up a slope and drive backward to drive down a

slope.

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Crossing over slopes

Before crossing over a slope, read and understand the instructions specified in this manual.

Operating the machine on a solid level ground can achieve the maximum stability.

Operating the machine on slopes will reduce the stability of the machine.

To cross over a slope, fully retract the boom and drive slowly at walking speed.

Unless it's really necessary, do not lift the attachment excessively high. When a load is

placed onto the forks, generally the lowest point of the load shall be no higher than 500mm

(20in) from the ground, as indicated by A in the figure. Some loads may hang beneath the forks,

as indicated by B in the figure. In such case, conduct the risk evaluation before suddenly lifting

the attachment to reach the ground clearance.

Bear in mind! Caution! Be careful! Taking unnecessary risks will probably endanger your

life and others.

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Lifting operations on slopes

The lifting operations on slopes can probably be dangerous. The failure to

understand and abide by the instructions of this part will probably make the machine
laterally unstable or even cause rollover. This will probably cause serious injuries or
even death to you or others. Make sure to fully understand and abide by the guidance
specified in this manual.

Unless the machine is level in width direction (for instance, laterally leveling of the

machine), do not conduct lifting operations on slopes.

Warning
Stop the machine and apply the parking brake before any lifting operation.

Lateral stability

To work on slopes, before any lifting operation, make sure that you have taken all factors

that may influence the stability of the machine into consideration. Please refer to Operations of

Machine on Slopes (Operation part) and ensure the lateral stability of the machine in width

direction.

The indicator A can be used to check the leveling of the machine.

Level the machine by one of the following methods, depending on the model and

specification of the machine.

For the machine with frame leveling (swing) function, level the machine in width direction

by swing control function, as indicated by B in the figure. Please refer to Frame Leveling

(Swing) Function (Operation part).

For the machine equipped with outriggers, level the machine in width direction by

outriggers, as indicated by C in the figure. Please refer to Outrigger Control Function (Operation

part).

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 To ensure maximum stability of the machine, it’s recommended to operate the machine on a

solid level ground whenever possible.

Important: If the machine can’t be leveled in width direction, before attempting any lifting
operation, make sure to conduct the risk evaluation. Please refer to Risk Evaluation
(Operation part).

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3.14. Operation at low and high temperatures
Low temperature

Take the following preventive measures at low temperature, thus it’s convenient for starting

the machine and avoiding its possible damages.

1. Apply the engine oil with correct viscosity.

2. If possible, apply the diesel oil with lower number.
3. Apply the correct coolant mixture.
4. Keep the full charge of battery.
5. Fill up the fuel after finishing each construction period, thus it’s convenient for
avoiding the formation of condensate on the wall of fuel tank.
6. Protect the machine during the misuse. Park the machine inside the room or cover it
with a waterproof canvas.
7. Install the cold starter. It’s possible to apply the additional cold-starting aid at very low
temperature,-18℃ (0°F) or lower temperature, e.g. fuel, oil and coolant heater. For
more advices, consult with your XCMG dealer.

Important: don’t start the engine via 24V voltage formed by connecting two batteries in
series, otherwise it will burn the induction multi-tube heater and starting motor.

8. Before starting the engine, first remove the snow from engine components, otherwise
the snow may enter into the air filter.

High temperature

Take the following preventive measures at high temperature to avoid the possible damages
of engine.

1. Apply the engine oil with correct viscosity.

2. Apply the correct coolant mixture.
3. Check the cooling system at regular intervals, keep the coolant level in appropriate
position, and ensure no leakage of coolant.
4. Keep the heat radiator/oil cooler clean, and remove the dust and debris, etc from the
heat radiator/oil cooler and engine periodically.
5. Check the engine fan belt periodically.
6. Check the air vent hole, and ensure no blockage of air inlets or outlets of engine
components.

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7. Check the engine pre-filter periodically (if installed).
8. Check the level of battery electrolyte.

Mechanical towing hook

Your machine may be equipped with a towing hook.

Before towing the machine, ensure that you follow the relevant laws and regulations

yourselves.

Ensure that the towing hook of tractor is applicable for your machine, and keep sufficient

turning spacing to avoid any collision entanglement.

Warning
Check the towing hook and tractor hook ring for wears before each operation.
Any bad connection, worn hook or pull ring can lead to the loss of tractor, injury of
you and others.

During the traction, the machine must be at non-load (no ballast), while it drives with two

wheels.

Operate the hook by complying with the following procedure.

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 Warning
Don’t exceed the specified total weight of tractor or hook limit, otherwise the
machine will be unstable.

1. Check the tractor weight and tire pressure. Its maximum towing capacity is determined
by the type of installed brake system. Calibrate the tire pressure as per the requirements
shown on the cab odometer.
2. Put in the parking brake.
3. Adjust the rearview mirror to achieve the best visual effects of hook-towing area.
Warning
When the machine approaches the tractor, confirm no persons between the
machine and tractor.

4. Connect it to the tractor, and the steps for connecting the tractor to hook shall be
subject the tractor type, regardless of the following procedures to obey:

a. Before the machine approaches the tractor, first check and confirm whether the
positions of tractor and its hook are convenient for connection.

b. If any assistant is available, the assistant must stand near to the machine before
connecting the hook and tractor together.

c. If the machine fails to stop, the assistant can’t approach the tractor or machine, put
in the parking brake, and turn the engine switch to OFF position.

Warning
Before driving to leave, confirm that the tractor hook is correctly connected and
locked.

d. If the tractor has been connected, and Pin A is in correct reliable position, the
operator can’t start the engine before the assistant isn’t far away from the machine and
tractor.

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 Warning
Don’t use the rear attachment for towing and braking purpose. If no brake valve
of tractor is installed regardless of tractor braking demands, first contact with your
XCMG dealer.

1. For the operation of attachment, e.g. inclination of tractor, operate H/J as per the
installed machine tools and desired actions.
2. In order to avoid the pollution of machine hydraulic system, first make the tractor
horizontal in case of inclining the tractor before disconnecting the hydraulic working
equipment to drain the hydraulic cylinder oil of tractor.
3. In case of towing the tractor on the highway, select two-wheel drive. Check and
confirm that the indicator shows the activation of two-wheel drive.
Warning
Before driving to leave, confirm that the tractor hook is correctly connected and
locked.

3.15． Resetting the steering system

It’s only limited to four-wheel steering machine.

Warning

If the steering system isn’t reset at least once every day, it may lead to the
reduction of its steering effects.

The steering system must be reset:

1. At least once per day.

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2. If it’s difficult to steer
3. After driving for over 15 miles (24 kilometer) (two-wheel steering driving)
4. If the two-wheel steering indicator lamp flashes (about four times per second)
Reset the steering system as per the following steps:

1. In case of selecting two-wheel steering, the steering indicator lamp still indicates four-
wheel steering.
Since the sensor on drive axle stops the conversion of steering mode before the rear
wheel is not aligned or outside its normal position, the inconsistency of steering indicator
lamp and switch still keeps for a certain time.

2. Operate the machine until its rear wheels are aligned.

After converting rear-wheel alignment to two-wheel steering, the indicator lamp shows
two-wheel steering.

3. Select four-wheel steering again.

Front and rear wheels are reversely in the same phase now.

3.16. Transfer of faulty machine

Don’t tow the machine unless there are no other methods. Remember, it may cause
more damages of machine if it’s towed. Try to repair the machine in original position. If the
machine must be towed, read the following items for Caution and Warning, and apply the
given steps.

Caution
If its towed distance is too short or its speed is too high, it may damage the
transmission. Don’t tow the machine for over one mile. If a longer distance is required,
it’s best to apply the trailer. Its speed shall not exceed 15mph (25km/h) while it’s
towed.

Apply the rigid hook connection. If the towing chain must be applied, two towing
vehicles shall be applied, one is connected to the front of faulty machine, the other is
connected to the rear of faulty machine, thus its braking power can be supplied.

The towing vehicle must have sufficient tensile force and braking ability to pull
and stop the faulty machine.

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1. Put in the parking brake.
2. Turn the gearshift lever to neutral gear, or put forward/reversing lever in neutral gear.
3. Prepare for the machine driving. Observe the preparations for road driving.
If the engine can’t be started, it may be required to lift the boom up to the position
applicable for transportation and fix the boom. Take the operating steps as per the machine
conditions and different installed hydraulic pipes.

If so, it’s best to contact with your XCMG dealer for help and advices before
performing such work.

1. Install the hook in appropriate position.

2. Select the machine that can be towed, ensure that you know the actions of towing
vehicle driver, follow his instructions and all the relevant rules.

It’s required to observe that if the engine can’t be started, more effort will be required to
steer the machine.

3.17. Transportation of machine

Warning
The transportation contractor and driver are responsible for safety
transportation. Any machine, tool or part may move during the transportation, so it
needs to be fully fixed.

Note: before the transportation of machine, it’s required to follow all the regulations
and laws for the regions where you will pass.

Ensure the suitability of transported vehicle. Observe its fixed size (performance part),
and check the fixed size of your machine.

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 Warning
Before moving the machine on the trailer, first check the trailer and slope, and
ensure that no oil, grease or snow exists. Remove the oil, grease and snow from the
tires of machine. Ensure that nothing collides against the machine on the slope.
Observe the minimum ground clearance of machine in performance part fixed size.

1. Put the blockages under front or rear wheels of trailer.

2. Move the machine on the trailer.
a. Ensure the correct or safe position of hydraulic cylinder.
b. Adjust the boom.
c. Move the machine on the trailer carefully.
d. Put in the parking brake, and put the drive in neutral position.
e. Lower the machine tool to trailer.
f. Lift the support leg to safe position.
g. Check whether the overall height is within the specified range. Adjust it if required.
h. Turn off the engine, and pull out its key.
i. Lock the cab.
j. Cover the exhaust chimney tightly.
3. Place the blockages under four front and rear wheels of machine. Anchor the machine
and trailer with lock chains.
4. Measure the height of machine from the ground. Before driving to leave, ensure that the
trailer driver knows the clearance height.
Lifting of machine

Follow the following steps while lifting the machine:

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1. Retract the boom, and lower it to ground.
2. Move away all the accessories.
3. Turn off the engine, pull out its key, close the windows, leave away from the cab, and
close the doors.
4. Remove all the infirm devices outside the machine.
5. Confirm the non-load weight of machine, and observe its fixed metrics.
Warning
Hoisting equipment

In case of applying the wrong hoisting equipment, you may be injured. Ensure the
good state of hoisting equipment. Ensure that the lifting tools conform to local
regulations, and they are applicable for lifting work, while ensuring the hoisting
equipment is competent for work.

1. Connect to the hoisting equipment in hoisted position.

2. Lift the machine. If the hoisting equipment bears down on the machine, avoid the
damages of machine with a spreader bar.
3. Check that the lifting point is just above the gravity center of machine, and observe its
fixed metrics.
Danger
During the lowering operation, don’t stand under the lifted load. Keep a certain
distance, and stand on one side, until the load safely falls. Ensure no one within the
area while lowering the load. If you fail to follow these provisions, you and others may
be seriously injured and even dead.

Warning
Communication

Any poor communication may lead to the accident. Let the persons around you
guide how to do it. If you and others work together, ensure that all the applied hand
signals can be understood by all the people. The working area is noisy, so it can’t rely
on language commands.

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121
3.18. Storage of machine
If the machine won’t be used for a longer time, you must store it properly and correctly
to avoid its deterioration.

1. Clean the machine fully, and remove the corrosive substances from it.
2. Fill up the fuel tank to avoid the formation of condensate on the wall of fuel tank.
3. Park the machine on the firm level ground (it’s best to store the machine under the
shed). Ensure that no machine parks in the position difficult to operate, thus it can avoid
the pull-out of machine in the later period of storage (in case the machine can’t be
started).
4. Stop the engine, retract the hydraulic cylinder, and lower the accessories to ground.
Open the filler cap of hydraulic oil tank, and operate the control lever to release the
residual pressure out of hydraulic pipe.
5. Apply a thin layer of grease or petroleum jelly to each exposed hydraulic cylinder lever.
6. Check the level of all the oil. Refill it if necessary.
7. Check the level and conditions of coolant. Refill it if necessary.
8. Remove or charge the battery, store the battery at warm and dry place, and charge it
periodically.
9. Check the tire pressure. Adjust it properly if necessary.
10. Check the machine for wears or damaged parts. Replace if necessary.
11. Turn the wheels periodically.

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4. Maintenance
4.1.Introduction
Note: please read and understand these operating instructions carefully so that you can
maintain this machine correctly. The correct maintenance is important for ensuring the
safety and extending the service life of machine.

In order to achieve the optimum performance, the design and manufacture of machine
can realize the comfortable work under all the complex operating conditions and
environments, and can save its operating energy. Before the transportation, the machine
must be checked at the factory and dealer’s shop to ensure the realization of the most
appropriate case in your hands. In order to keep such case, it’s very important that the
machine shall be periodically maintained by the recognized XCMG dealer as per the
requirements specified in this manual.

The full details of required maintenance items given in this section can make your
XCMG machine keep at peak efficiency.

The details of maintenance are described on the following pages, and many necessary
maintenance checks can be specially performed only by the trained XCMG persons. This
special work can be only performed by XCMG issuer and maintenance engineer who have
been trained by XCMG. The maintenance work can be fully, safely, correctly and efficiently
finished by them only with necessary special tools and testers.

XCMG often updates and inform all their product developments, performances and
changes of its issuer, so only XCMG issuer can be fully competent for maintenance and
repair of your machine.

Any list of maintenance records or notes can contain the maintenance records to make
a better plan for your maintenance demands. These records shall include the dates,
signatures and your issuer’s seals during each maintenance.

Please remember, if its maintenance is reasonable and correct, not only the stability of
machine but also its price can be increased during the resell.

Owner/operator’s support

123
 XCMG and dealer hope that you’re fully satisfied with new XCMG machine as well. If
you meet with any problem, you can contact with the maintenance points of your dealer, and
they will help you in time.

After setting the machine, you’re required to report the relevant maintenance names
during the contact with your dealer.

In order to achieve your maximum satisfaction, please let them know:

1. Your name, address and telephone.

2. Model and serial No. of your machine.
3. Purchase date and number of operating hours.
4. Problem characteristics.
Please remember that only XCMG dealer can obtain the rich and useful resources from
XCMG, and provide all kinds of items, including assurance certificate, maintenance prices,
lawful and required safety checks for weight tests.

Service/maintenance agreement

In order to make you plan and control the maintenance price of machine better, we
strongly recommend that you make full use of service and maintenance agreement supplied
by the issuers, thus you can make an appropriate adjustment as per the operating conditions
and schedule of your machine.

For more details, please contact with XCMG issuers.

Initial maintenance and check (100 hours)

In order to ensure the performance of machine in the later period, it’s very necessary
for the issuers to perform the initial maintenance and check of machine within one month
after purchasing the machine or 100 operating hours (whichever comes first). It should be
informed of the issuers, thus they can make the necessary arrangement.

Periodic lifting-checks and tests

Only XCMG issuers can meet the check demands fully, while reaching the test
parameters lawfully required by English Health and Safety Administrative Departments.

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Meanwhile, they can provide the annual check services as per the policy of insurance
company.

Only XCMG issuers can realize the definition of “competent person” through these
necessary tests and checks. It certifies that only the experienced modern engineers trained
by XCMG factory can ensure the considerations to attentive or reliable business level only
by providing the useful data and material support for XCMG issuers.

Replacement parts

We suggest that you supply only XCMG original parts. The parts manual can assist in
your confirmation of parts, which is convenient for purchasing them from XCMG issuers.

The processor is required to know the correct machine model or some serial Nos. of
machine. Observe “Familiar with your Machine” of Introduction.

4.2.Health and safety

Grease

Introduction

Read and understand these data and relevant publications, which are very important.
Let all the colleagues contacting the grease read them, too.

Hygiene

It won’t create any endanger of grease against your health to apply the functions of
XCMG grease correctly and properly.

However, any excessive or long-time skin contact can consume the natural grease of
your skin, thus it will cause the dry skin or pain.

Low-viscosity oil is more likely so, so it’s required to pay special attention to it while
treating the used oil, because the used oil may be diluted by fuel pollutants.

125
 Keep the good protection and personal hygiene at any time for oil product treatment.
For more preventive measures, you’re recommended to read the relevant publications
published by local health agencies, while following the points below:

Storage

Don’t store the grease where the children can reach.

Don’t put the grease into any open or unsealed container without labels.

Waste treatment

Caution

It’s illegal to pollute the drain pipe, sewer or road surface. Remove all the
overflown liquid or grease.

The used liquid or grease, filters and polluted materials should be treated as per
local regulations. Adopt the approved waste treatment stations.

All the wastes must be treated as per the relevant regulations.

The used oil should be collected and treated as per any of local regulations. It’s never
allowed to pour the used engine oil into drain pipe, sewer or road surface.

New oil

Except for normal care and hygienic experiences, no other special preventive measures
are required for treatment or use of new oil.

Used oil

The used engine grease contains harmful pollutants.

In case of treating the used engine oil, the following preventive measures can assist in
protecting your health:

1. Avoid any long-time, large-area or repeated contact of skin with used oil.
2. Apply the barrier cream before treating the used oil. Pay attention to the following
items while removing the engine oil from the skin:
a. Clean the skin thoroughly with soap and water.

126
 b. Adopt the special brushes.
c. Apply the special liquid soap.
d. Don’t apply the gasoline, diesel or kerosene for cleaning.
3. Avoid any contact of skin with soaked clothes.
4. Don’t store the oily cloth waste in the pocket.
5. Re-apply it after cleaning the dirty clothes.
6. Discard the oil-soaked shoes.

First aid-oil

Eye

If your eyes contact it carelessly, clean it for 15 minutes with fresh water. If your eyes
are still in pain, seek for immediate medical treatment.

Swallow

If the oil is wrongly swallowed, don’t be lured for vomiting, and take the medical
advices immediately.

Skin

If the skin contacts a lot of oil, flush it immediately with soap and water.

Leakage

Apply the sands or locally approved small particles for absorption. Transfer the
accumulated sands or small particles to chemical treatment stations.

Fire

Warning

Don’t extinguish the fire with water when the oil’s fired, otherwise the fire will
extend more quickly, because the oil can float on the water.

The oil or grease can be fired. Extinguish the fire with carbon dioxide, dry
chemical agent or foam. Any firefighter should use the self-contained breathing
apparatus.

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Battery

Warning

The battery can emit the explosive gas. In case of treating or operating on the
battery, don’t smoke. Avoid any spark or flame produced by the battery.

The battery electrolyte contains sulfuric acid. If your skin or eyes contact it, it will
burn you. Please wear the safety glasses, and treat the battery carefully to avoid the
leakage. Any metal object (watch, finger ring, zipper, etc) shall keep away from the
electrode tip of battery. These objects may lead to short-circuit of its electrode and
burn.

After turning all the switches of cab to OFF position, disconnect or re-connect the
battery. In case of disconnecting the battery, first disconnect its ground electrode (-).

Charge the battery at well-ventilated place far away from the machine. Before
connecting or disconnecting the battery, first close its charging circuit. After installing
the battery on the machine, re-connect it by waiting for 5 minutes.

First connect its positive electrode (+) in case of re-connecting it.

First aid-electrolyte

Reference as below:

If your eyes contact the electrolyte, flush the eyes immediately for 15 minutes with fresh
water, and seek for medical treatment.

If it’s swallowed,

Don’t be lured for vomiting. Take a lot of water or milk, and then drink the milk magnesia,
beaten egg or vegetable oil. Seek for drug treatment.

If the skin contacts the electrolyte,

Clean with fresh water, and take off the electrolyte-soaked clothes. Cover the wound with
disinfected clothes, and then seek for drug treatment.

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Warning signs

The following Warning signs may be seen on the battery:

Sign Meaning

Keep away from children.

Safety glasses

No smoking, open fire or sparks.

Explosive gas

Battery acids

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 Pay attention to operating instructions

Caution

Don’t disconnect the battery while the engine is running, otherwise the electrical
circuits may be damaged.

Store the damaged, exhausted battery or fired residues and leaked materials in
the closed acidy box, and treat them as per local waste environmental protection
regulations.

Electrical circuit

Before connecting or disconnecting any electrical element, it’s required to understand

the electrical circuit. Its wrong connection may lead to personal injury or damages.

Danger

The battery electrolyte is toxic and corrosive. Don’t breathe the gas emitted by the
battery, and it shall keep away from your clothes, skin, mouth and eyes, etc. Wear the
safety glasses.

Caution

Store the damaged, exhausted battery or fired residues and leaked materials in the
closed acidy box, and treat them as per local waste environmental protection
regulations.

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 Warning

Battery gas

The battery can emit the explosive gas, so it’s required to keep away from open
fire or sparks. Don’t smoke near to the battery. When the battery is applied in the
closed area or charged, keep it well-ventilated. Don’t check the charging conditions of
battery by shorting its electrodes with metal, aerometer or voltmeter.

4.3. Guide for maintenance

4.3.1 Correct maintenance methods

Study how to maintain your machine correctly, and follow the correct maintenance and
check methods shown in these operating instructions. If any trouble occurs to your machine,
it must be repaired before the operation or contact with your retailer.

4.3.2 Check the machine before starting it per day.

a. Check the instruments;

b. Check the levels of coolant, fuel and oil;

c. Check the hose and steel pipe for oil leakage, twisted wears and damages;

d. Make the patrol inspection of general symptoms, sound and heat, etc of machine.

e. Check the loosed or missed parts.

4.3.3 Check of operating hour accumulation schedule

The operating hour accumulation schedule is used to determine the required

maintenance interval of your machine. The period shown in periodic maintenance schedule
shall be determined as per the operation under normal conditions. If you operate on the
machine under the harsh conditions, you must perform the short-time maintenance of
machine.

4.3.4 Machine maintenance at regular intervals

Carry out all the recommended maintenance methods in maintenance guide.

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4.2.5 Maintenance hints

a. Apply the recommended fuel and lubricating oil;

b. Don’t adjust the control throttle of engine and safety valve of hydraulic system;

c. Protect the electrical elements to avoid any contact with water or steam;

d. Don’t disassemble any electrical component, e.g. sensor, etc.

4.3.6 Windshield washing fluid

Apply the windshield washing fluid for machine, and ensure the entry of no dirt into it.

4.3.7 Clean oil and lubricating oil

Apply the clean oil and lubricating oil, keep the oil or grease container clean, and don’t
mix the sundries into oil or grease.

4.3.8 Check of drained oil or used filter cartridge

After changing the oil or replacing the filter cartridge, it’s required to check whether
metal filling or sundries exist in the used oil and filter cartridge. In case of finding out a lot
of metal fillings and sundries, report it to the supervisor, and take the appropriate measures.

4.3.9 Welding instructions

a. Turn off the engine;

b. Don’t apply the voltage over 200V continually;

c. Connect any ground cable within 1m away from its welded part. If the ground cable is
near to instrument or connector, etc, the faults will occur together;

d. Avoid any seal or bearing between the welded part and ground point;

e. Don’t use any working equipment pin shaft or area around the cylinder as a ground
point.

4.3.10 Prevent any thing from falling into the machine.

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a. When opening the access window or oil tank filler for check, it’s important to fall no
nut, bolt or tool into the machine. If any of above parts is fallen into the machine, take it
out immediately;

b. Any unnecessary article shall not be put into the clothes pocket, which can contain only
the articles required for check.

4.3.11 Dusty environment

During the operation in dusty environment, pay attention to the following points:

a. Check the dust indicator of air filter to confirm whether it’s blocked, and clean the air
filter at shorter specified intervals;

b. Clean the radiator core frequently to avoid its blockage. Clean the fuel filter frequently
and replace it;

c. Clean the electric appliance, especially starting motor and generator, to avoid the dust
accumulation.

4.3.12 Avoid the mixture of oil.

Don’t apply different brands of mixed oil. If it’s required to apply different brands of
oil, all the used oil must be removed from the machine.

4.3.13 Hydraulic system-exhaust

When the hydraulic unit is repaired or replaced, or the hydraulic pipe is removed or
installed, the air must be drained out of oil line.

4.3.14 Installation of hydraulic hose

When any O ring or sealed part of sealing gasket is removed, clean its mounting
surface and renew it. Remember to install O ring and sealing gasket;

During the installation of hose, don’t distort or bend the hose into a small-diameter
ring. Thus it can damage the hose and shorten its service life obviously.

4.3.15 Select the fuel and lubricating oil fitting the environment.

The fuel and lubricating oil applicable for ambient temperature must be applied.

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4.3.16 Check of electrical circuit

Warning: if the fuse is frequently burnt or the circuit is shorted, find out its causes and
repair it or contact with XCMG dealer.

a. Check the fuse for damages or capacity unconformity, check the circuit for open circuit
or short circuit, check the terminals for loosening, and tighten any loosened part;

b. Specially check the circuits of “battery”, “starting motor” and “alternator”;

c. For the survey and correction of causes, please contact with XCMG dealer.

4.3.17 Check of air conditioner

Check whether the air volume switch of air-conditioning system is in “Natural Wind”
position or its transfer switch is in “OFF” position. If not, please turn it to its corresponding
position.

4.3.18 Check of each instrument

Check whether each instrument runs well, and each illuminator, indicator lamp, horn or
wiper can operate normally. If abnormal, please contact with XCMG dealer.

Note: before starting the engine, ensure that any other person except for operator shall not
operate on or near to the machine. Keep the machine always under the control of operator.

4.3.19 Preparations before the maintenance

Before the maintenance, park the machine as described below:

a. Park the machine on level ground;

b. Lower the bucket to ground;

c. Reduce the speed of engine to idle speed, and run it for 3 minutes;

d. Turn the starting switch to OFF. Remove the key from the switch (if the maintenance
must be performed at the speed of engine, make someone always at the machine);

e. When no work is performed on the machine, hang a label of “No Operation” on right
control lever.

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4.4.Running-in of new vehicle
It’s important for extending the service life of machine, eliminating the possible

failure and avoiding significant faults to run-in the new vehicle. After the user purchased

this machine, operate on and maintain the machine as per the new vehicle running-in

provisions of these operating instructions, and then this machine can work normally.

4.4.1 Requirements for new vehicle running-in

a. The running-in period of new vehicle is 100 hours;

b. After each machine startup, first idle it for 5 minutes. The machine shall be started at

stable low-speed small throttle, and then its speed is gradually increased;

c. During the running-in period, make the uniform running-in arrangement by shifting

one gear forward or backward;

d. Unless in emergency, avoid any sudden start, acceleration, steering or braking action;

e. It’s best to load the bulky materials during the running-in period. Don’t work too hard

or urgently. During the running-in period, its loading weight shall not exceed 70% of its

rated weight, and its driving speed shall not exceed 70% of its rated maximum speed;

f. Pay attention to the lubrication of machine, and change or refill the lubricating oil and

grease at the specified intervals;

g. It’s required to observe the transmission, torque converter, front and rear axles, hub,

parking brake as well as temperatures of hydraulic oil, engine coolant and engine oil

frequently. If overheated, find out the causes and remove them;

h. Check the bolt or nut of each part for tightness.

4.4.2 Perform the following work after eight-hour new vehicle running-in period.

a. Fully check the bolt or nut of each part for tightness, especially the diesel engine

cylinder cover bolt, exhaust pipe bolt and front/rear axle fixing bolt, rim nut, drive shaft

coupling bolt, diesel engine fixing bolt, transmission fixing bolt, etc;

b. Check the tightness of fan belt, generator belt or A/C compressor belt;

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c. Check the level of transmission oil, drive axle oil or diesel engine oil;

d. Check the hydraulic system or braking system for leakage;

e. Check the fixed connection of each control operating rod or throttle link;

f. Check the temperature and connection of each part of electrical system, power supply

of generator, lighting and operation of steering signal lamp, etc;

g. Lubricate the pin shaft of working equipment once every 10 hours (within 100 hours

after starting its operation).

Note: during the check of oil level, check it as per the relevant operating instructions.

4.4.3 Work performed after the running-in period of new vehicle

a. Fully check the bolt or nut of each part for tightness, especially the diesel engine

cylinder cover bolt, exhaust pipe bolt and front/rear axle fixing bolt, rim nut, drive shaft

coupling bolt, diesel engine fixing bolt, transmission fixing bolt, etc, any of which shall be

once checked;

b. Check the tightness of generator belt and A/C compressor belt;

c. After the running-in period, check, adjust and lubricate each part of machine. Clean

the return filter cartridge of hydraulic oil tank, and check the cleanness of hydraulic oil. If

necessary, replace the return filter cartridge.

Note: during the change of transmission drive oil, drive axle lubricating oil or

transmission oil fine filter, it shall be performed as per the relevant operating instructions.

4.5.Details for maintenance

Note: before performing any control or maintenance step, be sure to read and understand all
the safety materials, Warning and guides.

It’s very dangerous for operator or staff around him to maintain the poor machine.
Please ensure that the regular maintenance and lubrication of machine are specified in the
details for maintenance, thus safe or effective operation of machine can be ensured.

Warning

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 The repair must be performed by the personnel with professional qualifications
and tools. After confirming the safety of machine, remind you of repair. The machine
shall be parked on firm level ground.

In order to prevent anyone from starting the machine, pull out its starter key.
Before operating under the machine, first disconnect the battery or block the tires.

If you fail to take these measures, you may be injured and even dead.

Except for daily work, the number of machine operating hours is considered in the
details for maintenance. Evaluate the correct maintenance intervals as per the readings of
chronograph, and perform the regular checks. Don’t use the machine required to maintain.
In case of finding out any problem during the regular maintenance check, correct it
immediately.

Corresponding to:

Every 10 hours= per day

Every 50 hours= per week

Every 500 hours=every six months

Every 1000 hours=per year

Every 2000 hours=every two years

Every 6000 hours=every six years

Note: the maintenance is subject to hour or calendar interval, whichever comes first.

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For the details for operation and maintenance

Important: the maintenance is subject to hour or calendar interval, whichever comes first.
Refer to the corresponding calendar.

Check, maintenance points and liquid level of engine before starting

600
Operation 10 50 100 500 1000 2000
0

Engine

Quality and level of coolant Check □ □ □ □ □

Cooling system Empty, refill. □ □

Oil level Check □ □

Oil and filter Replace □ □ □ □

Air straining valve Clean □ □ □ □

Internal elements of air filter Replace □ □

External elements of air

Replace □ □ □ □
filter

Pre-filter Check □

Water separator and fuel

Dirt check □ □ □ □ □ □
filter

Oil-water separator Replace □ □ □ □

Fuel filter Replace □ □ □

Front engine fitting belt Check □ □ □ □

Front engine fitting belt Replace □

Fixing of bolt on engine Check □ □ □ □ □

All the pipes Check □ □ □ □ □

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Heat radiator Clean □ □ □ □

Ventilation gauze Clean □ □

Valve clearance Check and adjust. □ □

Oil fillers, gauge sealing

Replace □ □
gum

Rocker cover, injector strip Replace □ □

High-pressure oil line Check □

Transmission, axle,
steering gear

Reliable drive connection Check □

Drive oil level Check □ □ □ □

Drive oil Replace □ □ □

Drive oil filter Replace □ □ □ □ □

Reliable axle connection Check □

Axle oil level Check □ □

Axle oil Replace □ □ □ □

Hub oil level Check □

Hub oil Change □ □ □

Hub oil (with an oil pressure

Change □ □ □ □ □
brake)

Axle vent hole Check □ □ □ □ □

Trunnion bearing Check/adjust □ □ □ □ □

Steering position limiter (if

Safety □ □ □ □ □
installed)

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Front hub bearing Check □ □ □ □ □

Safety of tire nut Check □ □ □ □ □ □ □

Tire pressure/fill port Check □ □ □ □ □ □ □

Location of front wheel Check □ □ □ □ □ □ □

Transmission filter Clean □ □ □

Drive shaft and universal Safety and

□ □ □ □ □
knuckle lubricate

Axle pivot and linkage Lubricate □ □ □ □ □ □

600
Operation 10 50 100 500 1000 2000
0

Hydraulic oil

Oil level Check □ □ □ □

Oil Check, replace □ □

Oil filter Replace □ □ □ □ □

Suction filter Clean □ □

Auxiliary filter (if installed) Replace □ □ □ □ □

Brake

Level of brake system fluid Check □ □ □ □ □

Brake fluid Replace □ □

Brake pedal Check □ □ □

Electrical appliance

Level of battery electrolyte Check □ □ □ □

Line Check □ □ □ □ □

Joint of battery Check □ □ □ □ □

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Body and cab

Lifting/unloading/
inclination/ steering cylinder Lubricate □ □ □ □ □
pin

Telescoping cylinder piston

Lubricate □ □ □
rod pin

All the other pins Lubricate □ □ □ □ □ □

Fire extinguisher (if

Check □ □ □ □ □ □
installed)

Reflector Check □ □ □ □ □ □

ROPS/FOPS structure Check □ □ □ □ □ □ □

Door and hinge Lubricate □ □ □ □ □

Control lever connection Lubricate □ □ □ □ □

Water hyacinth level Check □ □ □ □ □ □ □

Cab heating air freshener Replace □ □ □ □

Cab heating recirculation

Replace □ □ □ □
filter

Boom slider slideway Check □ □ □ □

Inner arm hose Lubricate □ □ □ □

Boom slider clearance Check/adjust □ □ □ □

Boom slider conditions and

Check/adjust □ □ □ □ □
safety (replaced if necessary)

Accessory

Accessory lock pin Lubricate □ □ □ □ □

Hydraulic towing hook inner

Lubricate □ □ □ □
leg (if installed)

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 Hydraulic towing hook pin
Lubricate □ □ □ □
(if installed)

Register/certify

Safety working load signs

Update □ □ □ □ □ □ □
and flipcharts

1. The initial 100-hour maintenance can be finished only by your XCMG issuers.
2. If the machine works in the hard and severe environment, change the engine oil and
filter every 250 hours.
3. If the fuel contains high-concentration sulfur, the maintenance period of engine oil will
be influenced. For more information, observe the fuel system.
4. In case of frequent operations in the dusty environment, more frequent maintenance is
required.
5. If the engine is difficult to start or its performance deteriorates, the filter will be
renewed.
6. This work should be performed by the professional personnel.
7. After a large drive repair, the temperature of new oil should be near to its normal
operating temperature, the new oil shall be re-changed at this time, thus the dirt entered
during the repair can be taken away. If the dirt still exists in the oil, the oil and filter
shall be re-changed after the next 100 hours.
8. After the repair of hub, the temperature of new oil should be near to its normal
operating temperature, and it shall be re-changed, thus the dirt entered during the repair
can be taken away. In order to remove any impurity, change the new oil again after 100
operating hours. If a new brake plate is installed, it will become especially important.
9. The axle and drive shaft have been lubricated with high-performance grease before
leaving the factory. If the standard grease is applied during the maintenance, its
lubrication period shall be reduced to 50-hour interval, and contact with your XCMG
issuer for more advices.
10. If the option of variable volume pump is available, the machine will be equipped with a
filter. Then you must replace two filters at the same time as per the maintenance detail
period.
11. If the machine operates under the hard severe conditions, check the arm gasket for

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wears every 250 hours.

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Note:

1. Don’t apply any common engine oil.

2. It’s prohibited to apply the oil changed by friction.
3. The machine must be properly applied, thus the oil can soak into the brake, and limited
oil can flow to different areas.
4. Don’t apply any common brake fluid.
5. The capacity of oil tank is limited, and the total capacity of hydraulic system is
determined by the equipment being used. Make all the cylinders full of oil, and observe
the oil level in case of filling the oil.
6. It’s recommended to apply XCMG HP grease. In case of applying XCMG MPL grease,
the machine must be lubricated every 10 hours for the work requiring 50 hours totally,
and it must be lubricated every 50 hours for the work requiring 500 hours.
7. The additive with optimum performance is included.
Coolant mixture

Check the concentration of coolant at least once every year, and it’s best to do before
the cold start.

Change the coolant as per the intervals of machine maintenance details.

Warning
The anti-freezing agent may lead to personal injury, and follow the manufacturer’s
instructions while handling the anti-freezing agent.

First dilute the overrich anti-freezing agent before the operation. Apply the fresh water
with its PH value not more than 8.5. If no, apply the deionized water. For more information
on water hardness, please contact with local water suppliers.

The antifreezing agent with correct concentration can prevent the engine from freezing
in winter, and provide the whole-year corrosion protection.

Its protection functions are supplied by XCMG high-performance antifreezing agent

and inhibitor as below:

50% concentration (standard)

At least -40℃ protection

144
60% concentration (applied under the extreme conditions)

At least -56℃ protection

Important: don’t exceed 60% concentration. In case of exceeding this percentage, its
protection functions will be reduced.

4.6 Washing machine

Introduction

Use water or steam cleaning machine, does not allow mud, debris and other loom.

Before cleaning, remove the sections:

1. In the device will be out of place must be cleaned, as the main job, or a job, the engine
and the whole machine around on the fuel system must be cleaned.

2. When the cleaning is completed, the machine away from the wash area, wash down or
remove something from the machine.
Important: after removing components, there will be exposed to dirt and debris. Cover all
openings before continue cleaning first, and remove the dirt.

Detergent

Avoid the use of high concentrations of detergent - always be diluted detergent according to
the manufacturer's recommendations, otherwise it will lead to damage to the paint.

Always follow local regulations deal with recommendations on the machine to clean dirt
off.

Pressure washing and steam cleaning

Caution

Do not use water or steam cleaning inside the cab. Because the water or the steam can
damage the plug-in unit type computer, causes the loom not to be able to operate. Use the
brush or the wet cloth for dusting.

Engines and some components may be high-pressure washing system damage, if you want
to use high-pressure washing system to clean the engine, you must take special precautions.

145
Ensure alternator, starter motor and all electrical components have shields, not direct high-
pressure cleaning system for cleaning.

Important: Do not put the gun aligning bearings, oil pads, and electricity -related electrical
components, such as engine control units, alternator, and fuel injectors.

Use a low-pressure water gun, foam brush off caking mud and dirt.

Note: the machine after each pressure washing or steam cleaning, need to re- lubrication.

Before prepare cleaning:

1. The machine parked on a firm, level ground, hang up the parking brake, set the drive in
space, reduce equipment to the ground, and stop the engine.

Important: Stop the engine and wait at least one hour with the engine cooling. While the
engine is running do not try to clean engine parts.

2. Make sure all electrical systems have been disconnected.

3. Ensure that all electrical connections are properly connected.

Warning

To avoid burns, dealing with the scorching element is wearing protective gloves. In order to
protect your eyes, use a steel wire brush cleaning element of time wear protective goggles.

Air suspended in the fire flammable particles, such as grass, wood chips, and so on, does not
allow the engine components or support shaft shield buildup. Always check the area, each
time the work shift when the Clean, if needed, more clean-up. To open the engine hood, the
top is free of debris.

Require special attention:

When the engine is running; do not clean the engine components. Stop the engine and wait
at least one hour to let the engine cool down.

a. Disconnect the battery.

146
b. Do not put directly at the fuel injector nozzle directly cleaning.

c. Do not wash any of the following components:

d. Fuel injection pump.

e. Cold start device .

f. Electric closed solenoid

g. Electrical connector

h. Ensure alternator, starter motor and all the electrical components have been protected, and
not directly with the high-pressure cleaning system for cleaning.

4.7 Check the damage

1. Check the steel structure is damaged, write down the paint is damaged, so that the next
maintenance.

2. Check all the pins are in the correct position, check that they are safe fastening
positioning element.

3. Ensure that all the steps and hand is not broken, solid and reliable.

4. Check the broken windows and cracked glass.

5. Check fighting tooth damage and secure situation.

6. Check for damage lamp.

7. Check the tires for damage and sharp objects that might have been stabbed in the case.

8. Check the security identity in the correct position, without damage.

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 Seat belts

Check the seat belts and reliability.

Warning

If the machine equipped with seat belts, if damaged or belt worn, or the machine has just
had an accident, then replaced with new. Every three years for a new one.

Check the seat belt signs of worn and stretched. Check the stitch width and no pine damage;
check the buckle assemblies are not damaged, works fine.

Check the seat belt mounting bolts without damage, properly installed and tightened.

Jib safety lever

Warning

When working in a boom, boom could suddenly fall, resulting in serious injury or death.
Arising before any maintenance work is undertaken under the boom, jib safety rod is
installed.

When mount or remove safety bar to wean people off.

You must climb up to the machine to install or remove the safety bar. Be careful, especially
machine wet slippery. Before try to climb out the dirt and oil. Do not bleed when the arm, it
will burn you.

Safety pole position differs from the machine.

148
Installation

Before installing, first remove the load on the forks, and empty bucket or equipment.

1. Completely recovered arms (unless extended arm when the need for maintenance).

2. Stop the engine, make sure the parking brake mount, transmission in neutral, pull out the
ignition key.

3. The safety lever out from the stowed position A.

4. Put the safety lever into the hydraulic lifting cylinder rod around B. Put to the safe
position.

5. In order to prevent the boom slowly slide your finger to pinch the boom to fall on the
safety lever.

149
Attention: Careful reduces moves the arm, prevented harms the safety lever. The safety
lever supports to moves the arm weight stops immediately.

Detachment

1. Raises moves the arm, the safety lever does not support the weight.

2. Stops the engine, guarantees the parking brake to hang up, the gear box in the neutral
gear, draws out starts the key.

3. Detachment safety lever.

4. Puts the safety lever to deposits position A.

4.8 Change the diesel filter

Change the Filter Element of the Oil-water Separator

1. Place the engine on the solid and level ground, making sure the occlusion of the

parking brake and that the transmission is on neutral position. Lower down the accessories

to the ground, turn off the engine and pull out the start key.

2. Uncover the housing of the engine.

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3. Dismantle the hollow bolt connecting the fuel filter and the low pressure oil pipe.

4. Dismantle the bolt connecting the fuel filter and the fixing bracket.

5. Dismantle the fuel filter element and filter base.

6. To fill to the new filter with clean diesel when replace the filter element, while keep the

filter base clean and apply lubricating oil in the rubber pad.

7. After the rubber pad contact to the base, and then tighten the 3/4 ~ 1 laps, so that it is

sealed.

8. Need to remove the exhaust screw on the filter base, press the hand pump on the

strainer to exhaust the filter air.

Explosion view for fuel filter assembly

151
Change the Element of Fuel Filter of the Engine

1. Place the engine on the solid and level ground, making sure the occlusion of the

parking brake and that the transmission is on neutral position. Lower down the

accessories to the ground, turn off the engine and pull out the start key.

Caution

Do not let the dirt into the fuel system. Perform thoroughly cleaning to the
connection before disconnecting the connection of any part of the fuel system. If some
element is disassembled, for instance the fuel pipe, it is required to equip with the
protective cap and the plug to avoid the entering of dirt. Non-compliance of these
explanations will lead to the entering of dirt into the fuel system. The dirt in the fuel
system will severely damage the fuel injection bubbler and lead to expensive
rehabilitation expense.

2. Uncover the housing of the engine.

3. Turn off the valve on the fuel pipe line.

4. Use the special wrench of the fuel filter counter clockwise to remove the fuel filter.

5. Before install the new fuel filter, apply the oil evenly to the rubber seals.

6. Tighten the new fuel filter with hand.

7. Open the valve on the fuel pipe line.

8. Exhaust air for the fuel system.

9. Check the sealing of the fuel filter installation.

152
 Fuel filter

Fuel filter

4.9 Lubrication
In order to guarantee the loom high efficiency the work, must to the loom regular
lubrication. The regular lubrication may enhance the loom the working life.

The loom must carry on the lubrication after the pressure clean and the steam clean.

Warning

Carries on these work time you need to approach the loom. If possible to reduce moves
the arm, draws out starts the key, separates the accumulator cell. This may prevent the
engine sudden start. Guarantee the parking brake already to hang up.

If it must enter under the loom, stops up four wheels first.

Arm safety lever

The raised arm possibly suddenly falls down, and causes the serious injury. Before
work under the raised arm, install well the arm safety lever. Refer to the maintenance
chapter Arm Safety Lever.

153
 It must be finished with an injection gun. Two-stroke injection gun is commonly
effective. When new grease escapes out of the joint, stop lubricating.

Each lubricated point is numbered in the illustration below. Report each number during
the lubrication. Reinstall the dust cover after finishing the lubrication.

Note: it may be required to lubricate some optional tools more frequently. Refer to the
option of optional tools.

In case of applying XCMG MPL grease, it’s required to lubricate every 10 hours for
50-hour operation.

In case of applying XCMG MPL grease, it’s required to lubricate every 50 hours for
500-hour operation.

154