OMM GR1605说明书英文20190122

GR1605MotorGrader
Operation and Maintenance Manual

Xuzhou Xugong Road Construction Machinery Co. Ltd
Important Safety Information
Illustration of safety warning mark
Safety warning mark Description
This mark confirms important safe information in the

manual. So when you see this mark, read the
following information carefully and abide it strictly.
Moreover tell it to other operators.
Warning
In the process of product operation, maintenance and repair, most accidents are caused by
not complying with basic safety rules or precautions. Be aware of all kinds of potential
hazards, accidents often can be avoided. Staff must to be vigilant against various potential
danger, shall also get necessary training to possess the right skills and tools required to
perform these functions correctly.
Incorrect operation, lubrication, maintenance or repair could cause danger, and it

may even cause casualties. Must first read and understand the product operation,
lubrication, maintenance and repair material, and then start the work.
The safety precautions and warnings are provided in this manual and on the products.
Ignore these dangerous warning may lead to one’s own or other’s casualty. XCMG has
limits to assume any possible danger of each case. Therefore, this manual and warning on
the product does not cover all cases.
XCMG has limits to assume any possible danger of each case. Therefore, this manual
and warning on the product does not cover all cases. Please be sure to first consider
all safety regulations and preventive measures that applied to the operation of this
product in working site, including the provisions for the specific location and
preventive measures, do not misuse this product beyond the scope of this manual.
Before using the tools, processes, methods, or operating technique that XCMG does
not recommend, must ensure that the tools, processes, work method, or operating
technique is safe for yourself and others. Ensure that you will use the operation,
lubrication, maintenance or repair procedures that do not cause damage or unsafety
to the product.
The information, technical parameters and charts in this manual are all based on the
existing data while writing the manual. The listed technical parameters, torque, pressure,
measured value, modifiers, charts and other items could change at any time, these changes
will affect the product maintenance. Before operation, please get the latest information.
This manual, which is translated by Chinese version, is the original manual. If there is any
objection, please subjecting to the Chinese version.
Operation and Maintenance Manual GR1605Motor Grader
Table of Contents
Important Safety Information....2
Table of Contents.......................3
1 Preface......................................1
2 Security Section......................3
2.1 Safety Sign.........................3
2.2 Additional Marking............6
2.3 General Hazard Information8
2.4 Prevent Compression and Cutting 9
2.5 Avoid Scalding................10
2.6 Fire Prevention and Anti-explosion 11
2.7 Fire Safety........................13
2.8 Tire Description...............13
2.9 Lightning Protection.......14
2.10 Before Starting Engine. 14
2.11 Engine Starting.............15
2.12 Before Operation...........15
2.13 Operation.......................15
2.14 Engine Shutdown..........17
2.15 Noise and Vibration......18
2.16 Cab.................................18
2.17 Protection Device..........18
3 Product Information..............19
3.1 General Information........19
3.2 Identification Information20
4 Operation................................22
4.1 Before Operation.............22
4.2 Machine Operation..........23
4.3 Engine Starting................38
4.4 Driving..............................39
4.5 Parking.............................41
4.6 Transport Information....42
4.7 Jacking Position Description 45
4.8 Towing Guidelines..........45
4.9 Engine Starting with Jumper Starting Cable 47
3
5 Maintenance...........................49
5.1 Tire Inflation.....................49
5.2 Lubricant Viscosity and Filling Capacity 49
5.3 Maintenance Channel.....52
5.4 Maintenance Services....52
5.5 Maintenance Interval......54
5.6 Maintenance Operation. .57
4
1 Preface table lists items that require maintenance

during the maintenance interval. Items
Document literature that do not have a specific maintenance
interval are listed under the headline “if
This manual should be stored in the file required”. The interval table can be used
storage area behind the cabin seat. as index of all maintenance steps.
This manual includes safety information,
control instructions, transport information, Maintenance interval
lubrication and maintenance information.
The maintenance interval is determined
The details or optional parts shown in this by the hours of operation. If the calendar
manual may differ from your machine. time can provide a more convenient
planning interval and is similar to the
This manual may not include
hours, the calendar time can be used to
modifications to the machine due to
replace the hours. The recommended
product improvements and upgrades.
maintenance work should be carried out
When you have any question about the in the first - to - term maintenance cycle,
machine or this manual, please contact whether it uses the hour or the calendar.
XCMG or its agent for the latest
In extremely harsh, dusty, wet conditions,
information.
it may be necessary to lubricate more
frequently than the provisions of the
Safety interval table.
The security section lists basic security In the case of maintenance, the
precautions, the contents and location of maintenance items of the previous level
various warning signs on the machine. should be done at the same time. For
example, when doing the maintenance for
Prior to operational maintenance, must items that shall be done every 500
read the basic grammatical measures in working hours or every 3 months, the
the security section. items of every 250 working hours or every
10 hours or daily maintenance shall also
Operation be done.
The operation section is available for

operator reference. This section
introduces various instruments, switches, Engine maintenance
machine manipulators, transportation and Maintain the machine according to the
traction data. <Operation and Maintenance Manual>
Photos and graphics show the operator and <Maintenance Manual>.
how to check, start, operate and stop the It is prohibited for anyone to remove,
machine according to the correct retrofit, or disable an emission related
procedure. device or component that installed on the
engine and machinery.
The basic operating techniques are

outlined in this manual. The technical and Machine capability
technical skills of the operator will be Additional optional parts or modifications
enhanced with the deepening of its may exceed the design capability of the
understanding of machine and machine machine, which can adversely affect the
performance. performance of the machine. Please
contact XCMG or its agent for details.
Maintenance
The maintenance section is a guide to the Product identification number
maintenance of the machine. The periodic XUG16005EDDB00021
5
1 2 3 4 5
Figure 1
XCMG global manufacturer code

(character 1-3)
Machine descriptor (character 4-8)
Check character (character 9)
Machine indicator (character 10-12)
Product serial number (characters 13-17)
2 Security Section
6
2.1 Safety Sign
Fig.2-1
There are some special safety symbols on the machine. Please read carefully and obey
all description about safety symbol on the machine, this chapter mainly introduces its
position and diagram description. Protect these safety symbols properly. If you find the
character or diagram is lost, damaged or unclear. Please replace with new one or get it
repaired in time.
If replacing the parts with safety sign, you should paste relevant symbol on the new part.
While scrubbing the safety symbol, please use cloth and soap rather than pharmaceutical
and oil liquid, etc.
No operation (1) Warning

Don’t operate the machine until you read
This sign is located in up front of the and understand instructions and
cab and the rear part inside the cab. warnings in the operation and
maintenance manual. Failure to comply
with these instructions or ignore these
warnings can lead to personal injury.
Maintenance warning signs (2)

The sign is located in front of the cab.
7
Warning
The electrolyte in the battery is acidic and
can cause personal injury. Do not allow
electrolytes to touch skin or eyes. Wear
goggles when maintaining the battery.
Avoid squeezing and bumping(5)

This sign is located on the left and
right sides of the blade, on the left and
Warning right sides of the front bulldozing plate
Please follow the manual to maintain the (if equipped), and on the left and right
rear axle, gearbox and engine regularly. side of the ripper (if equipped).
Control warning signs (3)

The sign is located in right side of the
cab. Warning
In operation, stay away from the area and
prevent the upper pressure from
squeezing the torso, otherwise there will
be serious injury and death.
Reverse warning signs (6)

This sign is located on the rear ballast
and ripper (if equipped).
Warning
The gear switch should be in N position
before starting!
No jump gear operation!
Stop the machine for steering!
Battery warning signs (4)

The sign is located on both sides of Warning
In reversing operation, stay away from
the rear frame.
the area, otherwise there will be serious
injury and death.
Fan protective safety signs (7)

The sign is located on both sides of
8
theframe rear part. Warning

Do not touch the engine to avoid
scalding. Before machine maintenance,
wait for machine temperature to drop to
normal temperature.
Description of danger zone (10)

The logo is located on the left and
right sides of the pendulum
Warning
When the engine is running, don’t open
or dismantle the safety hood, keep away
from the fan. Otherwise will lead to injury
or death.
Warning
It is prohibited to enter rotation area
Avoid squeezing (8) when grader is working.
The sign is located at the hinge
between front and rear frame
Warning
Articulated machine hinge joint area of
press danger, keep away from the
machine for a safe distance. Shall not
stand on machine when turning. May
occur serious casualties due to the
extruding.
Avoid scalding （9）

This sign is close to the muffler
exhaust of the hood.
9
2.2 Additional Marking
Fig.2-2
Hoisting fixed position (1)

The logo is located on the front and
rear part of the frame.
Fuel filling port (3)

This sign is located near the filler
connector of fuel tank.
Transport fixed position (2)
The logo is located on the front and
rear part of the frame.
10
Reserved port (4) drunk after taking the medicine, do not

operate the machine. In this case, you
The sign is located on the right door of will be harmed by your mistake.
the cab.
Wear hard hats and safety glasses for
the operation or maintenance of the
machine, wear safety shoes, reflective
vest, mask, earplugs and gloves.
Don’t wear loose-fitting clothes or
jewelry, or you may get into or get
If the main exit is blocked, leave the involved in moving parts, causing
machine from the right door of the serious injury or death.
machine.
Understand the width of the machine
so that it can be kept at an appropriate
Hydraulic system oil level (5) distance when operating near a fence
or boundary barrier.
The sign is located near the oil pointer
of the hydraulic oil tank. Beware of high-tension wires and
cables buried underground. If the
machine touches these dangerous
objects, it may cause serious damage
by electric shock.
All the shields and covers are fixed in
corresponding position on the device.
Take care of scattered items. Do not
stack items on the machine. Do not
leave any parts or tools around the
2.3 General Hazard operator’s seat. These things may fall
Information off, causing an accident, as the
machine vibrates during operation,
Only authorized personnel can
operate and maintain the machine. Be careful to use cleaning solvents,
Unauthorized persons cannot be do not put the maintenance solution in
allowed to board the machine. glass containers, and comply with
local regulations for dispose of liquids.
Be familiar with and follow all safety
regulations, precautions and Please do not smoke while
instructions when operating and maintaining the air conditioning and
maintaining the machine. with the presence of refrigerant gas.
Inhalation of inflamer smoke of air
A warning label of “no operation” on conditioning refrigerants can cause life
the starting switch or control device injury or death. Air conditioning
before maintenance and repair of the refrigerants produce gases that are
machine. inhaled by a lighted cigarette can
cause injury or death.Shall know the
specific signals used on the site and
Warning
The lack of concentration during the
the persons who give signal. Only
operation of the machine can lead to loss one person’s signal shall be accepted.
of control and personal injury to the
machine. Be careful to use any Shall know the specific signals used
equipment when operating the machine. on the site and the persons who give
signal. Only one person’s signal shall
be accepted.
Always adjust your body condition and
never operate the machine when you Use ladders or elevator when
are in poor health. If you are not maintenance is performed in the air.
comfortable, or if you feel sleepy or
11
the pinhole size can penetrate human

tissue and cause casualties.
Cleaning and washing
Clean the machine before
maintenance and repair. This ensures Disposal of wastes
that the dirt is not in the machine, and
that the maintenance work can be Discharge the oil in the container and
carried out safely. do not drain the oil directly onto the
ground. You can’t pour waste oil into
When cleaning the machine, wear sewers and rivers and so on.
skates to prevent slipping on wet
surfaces. Wear protective clothing and Comply with relevant laws and
goggles when using high pressure regulations when dealing with
water to flush the machine. hazardous substances such as
lubricants, fuel, coolant, solvents,
It is strictly forbidden to spray water filters, batteries and other substances.
directly on electrical system
components such as sensors and wire
plugs. If water enters the electrical Ventilation and exhaust
system, it may cause operational
failure. Please be careful. Exhaust fumes may
be harmful to your health. If the
It is strictly forbidden to spray water machine is operating in a closed area,
directly onto the engine, gearbox and must have adequate ventilation.
rear axle. If the water enters the
component, it can cause a serious 2.4 Prevent Compression
failure.
and Cutting
When cleaning the filter with
compressed air, wear protective Properly support the machine or
clothing and safety glasses. accessories when working under the
machine. Don’t rely on the hydraulic
cylinder to support it. If the control
mechanism moves or the hydraulic
Release system pressure pipeline leaks, the device or
The pressure may be stuck in the accessory will fall off.
hydraulic system. The machine or It is very dangerous to run the engine
attachment may suddenly move when for inspection, unless otherwise
the pressure is released in the specified, do not do any adjustment
system. Be careful when removing the when the machine
hydraulic pipe and connector, and
release the high pressure oil will Do not enter or place your hand, arm
cause the tubing to swing and eject. or any other part of body between
movable parts. For example, between
the working device and the oil
Oil penetration cylinder, between the machine and the
working device, and the front and rear
Oil penetrates the body can cause frame hinge. With the movement of
serious injury and death. Even if the the working device, the left and right
engine has been shut down, there is space of the blade will increase or
still pressure in the hydraulic circuit, decrease, which can lead to serious
and no hydraulic components can be accident or personnel injury. If you
removed before the pressure is need to enter the moving parts of the
released, otherwise it will cause machine, you must turn off the engine
personal injury. and lock the working device.
Don’t use bare hands to check for Stay away from all rotating and
leaks, use boards or cardboard to moving parts. Ensure that there is no
check for leaks. Even the pressure of clutter in fan blades. Fan blades will
12
throw or cut off the tools, debris that To prevent hot oil from ejecting, the
come inside. engine should be turned off to allow oil
to cool down. Slowly loosen the cover
When you hit an object, make sure no to release the pressure. When check
one is hurt by flying parts, debris, or whether the oil temperature has
other iron scraps. Wear protective decreased, you can check the air
glasses to avoid damage to your eyes temperature by putting hands near the
when tapping on an object. hydraulic oil and cooler of torque
After the maintenance is over, be sure converter. Be careful not to touch the
to reinstall the removable cover. radiator. The filler cap must be cold
enough to touch with bare hand.
2.5 Avoid Scalding Battery

Do not touch the engine body or Wear safety glasses and rubber
muffler, exhaust pipe, hydraulic gloves when maintaining batteries.
system, gearbox, electrical
components etc. to avoid scalding. The electrolyte of battery is acidic and
Before machine maintenance, wait for can cause personal injury. Don’t let
machine temperature to drop to the electrolyte touch the skin and
normal temperature. Release system eyes. If the electrolyte splashes into
pressure before disconnecting any your eyes and skin, rinse immediately
piping connection. with plenty of water and go to the
doctor immediately.
Coolant
When the engine is in working status, 2.6 Fire Prevention and
the engine’s coolant is hot and under Anti-explosion
pressure. All the pipes of the engine to
radiators has hot coolant inside. General description
The engine cooling system can be All fuel oil, lubricating oil, hydraulic oil,
checked only after the engine stops antifreeze liquid are flammable. In
and the cooling liquid cools down. order to reduce the risk of an
explosion, the following provisions
Before removing the filler cap, make should be observed:
sure the cap is cold. The filler cap is
cold enough to touch with bare It is important to perform a round trip
hand.Check the coolant slowly to check to help identify fire hazards.
release the water cover to release the When there is a hidden danger, do not
pressure. When checking if the water operate the machine.
temperature is decreasing, you can When you park the machine, pay
reach the front of the water radiator attention to the environment around
and check the air temperature. Be the machine, make sure that there is
careful not to touch the radiator. no dry grass, branches, paper, etc.,
Cooling system additives contain near the engine muffler.
alkaline substances, avoid contact Clean up combustible materials such
with your skin and eyes. as fuel, lubricants or other debris that
are stacked on the machine, make
sure there are no oil cloth or other
Oil flammable products.
Hot oil and parts can cause bodily It is forbidden to operate the machine
injury. Don’t let the hot oil and parts near the fire source. Keep oil,
touch the skin. lubricants or other combustibles away
from the open flame. Do not store
13
flammable oil in the cab. A metal object must not be cross-

connected to the terminal to check the
Do not operate the machine when fuel battery charging situation. The
leaks occur. Repair the leaking area charging condition of the battery
and clean up the oil, then restart the should be checked with a voltmeter.
machine.
Check the accumulator, battery cable,
Keep the inspection door of the main clamping, band and other fixed parts
compartment of the machine closed every day to replace all damaged
and operable, in order to use fire parts.
equipment in case of fire.
Avoid contact with metal objects that
Know how use the machine’s main may make the positive (+) terminals
export and emergency exits. and negative (-) terminals of the
Check all piping and hose for wear accumulator short-circuited.
and aging. Replace damaged piping If the battery cable is exposed to
and hose. Piping and hose shall be ground, can cause to the ground short
properly supported and fixed. circuit, causing fire hazards.
Do not make welding or flame cutting When cleaning the top surface of the
of pipes or cabinets containing battery, do not use gasoline, solvents,
combustible liquids. Before welding or or any other organic solvents.
cutting, apply non-combustible liquid
to clean or electric welding or cutting.
When checking fuel oil, lubricating oil, Wiring
battery electrolyte, use explosion-
proof lighting equipment. If such Check electrical wires daily, in case of
lighting equipment is not used, there is wear, tear, and other damage, replace
a danger of explosion. before operation. The electrical wires
shall not be installed in the hose or
Even in the dark, it is not possible to piping of flammable oil.
use a lighter or an open flame for
illumination, which is dangerous Ensure that all the clamps, shields,
because the gas emitted by a battery clips and bands are properly installed.
may explode. This will help prevent vibration, other
components grinding and overheating
during machine operation.
Battery and battery Cable
Do not operate the machine, if the Pipeline, channel and hose
battery cable and related parts show
wear and damage indication. Carefully check pipes, channel and
hoses. Don’t use bare hands to check
If the electrolyte of the battery is for leaks, use boards or cardboard to
frozen, do not charge the battery, and check for leaks. Even the pressure of
do not use other power to start the the pinhole size can penetrate human
engine. This is dangerous, and will tissue and cause casualties.
cause the battery to catch fire. When
charging or using other power source Please replace the affected parts if
to start the engine, melt the battery’s any of the following situations occur.
electrolyte before starting and check Displacement, damage or leakage of
for leakage. end connector.
The gas from the battery can cause Outer wear, cuts, expansion or
an explosion. Keep the fire or spark inflation.
away from the top of the battery. Do
not smoke in the battery charging Metal wire is exposed.
area.
Flexible piece of hose distorts.
14
Ensure that all the clamps, shields,

clips and bands are properly installed.
This will help prevent vibration, other Extinguisher
components grinding and overheating As an additional safety precaution,
during machine operation. keep a fire extinguisher above the
Do not operate machinery when there machine. Familiarize yourself with the
are fire hazards. fire extinguisher, regularly check and
maintain fire extinguishers, follow the
instruction of the signs.
Ether
The fire extinguisher is placed on the
Ethers (if equipped) are used for left side of the driver’s seat
starting engines during cold weather.
Ether is poisonous and inflammable. Follow the following procedures in
Inhaling its steam or skin touching case of machine catching fire:
ether will cause injury. 1) Stop the engine;
The ether is used in a place with a 2)Disconnect the power
good ventilation condition. Do not supply switch;
smoke while changing the ether jar. 3) Use fire extinguishers;
Shall pay attention to fire while using 4) Prevent fire spreading;
the ether. 5) Seek assistance.
Don’t store ether jar in living area or

inside the driver’s cab. Don’t put the Use of fire extinguishers:
ether jar in a place with direct solar 1) Take off the fire extinguisher from
radiation or above 39℃ (120ºF). Put the bracket;
the discarded ether jar in the safe
place, never make holes or burn it. 2) Remove safety pin;
Put the ether jar far away the non-
workers. 3) Grab the fire extinguisher hose to
make the nozzle to the ignition source;
4) Press the hand shank of fire
2.7 Fire Safety extinguishers, use fire extinguishing
agent, and stop using once the fire is
If you find yourself involved in a extinguished;
machine fire, the safety of you and the
other persons of the field is a top 5) After using, the fire extinguisher can
priority. The following actions can only only be maintained by the qualified
be taken if the action below does not department.
bring danger and risk to you and to 6) Remember to maintain a fire
anyone around you. extinguisher.
Remove the machine from the
flammable object, lower all the tools
and turn off the engine as soon as 2.8 Tire Description
possible. If the engine is still running,
the engine will continue to fire. Any Gas-filled tires explode when gas is
damage to the hose that connects to heated in a pneumatic tire. Special
the engine and pump can cause a fire. attention shall be paid to the possible
explosion of the tire when the welding
If possible, switch the battery cut-off operation is near the tire.
switch to the OFF position. Inform the
emergency personnel of the fire and In the driving of the machine, due to
your address. the heat generated by the high
traveling speed, the tire pressure will
If your machine is equipped with a fire be increased to a certain degree,
extinguishing system, follow the which is normal situation, do not try to
manufacturer steps of the system. reduce it; You shall slow down or stop
15
to cool your tires. But if the machine is 2.10 Before Starting

running at a high speed and the tires
are overheating, it may cause the tire Engine
to explode. Articulated machine
A tire explosion can push a tire, rim,
drive axle and other parts to a
distance of 500 meters or farther
away. The explosion and splashes
can cause serious injury and deaths,
so make sure the tire pressure is
normal and do not inflate over the
rated pressure. When adjusting the
pressure, stay away from the tire as
far as possible, and be sure to stand
behind the tire, do not charge Fig.2-3
inflammable gas.
Remove the pin (1), pull out the
Check the tire, rim, and prevent low- locking pin (2), and shift the fix lever
pressure operation, check the cracks (3) to the pin hole (4) position. Then
of the tire, gas bubble and so on. the locking pin (2) is inserted into the
Check whether the rim connecting pin hole (4), and the pin (1) is inserted
bolts and nuts are lost, and check into the hole in the end of the lock pin
whether the tightening torque of the (2).
rim connecting nut meets the
Only start the engine in the cab. Must
manufacturer’s recommended values.
not short start motor terminal or jump
When checking the tire, it is not
battery.
allowed to enter the front and back of
the wheel, and should be carried out Press the horn button to determine
on the side. If you want to remove the whether the machine horn is working
tire, you must fix the other tires with properly.
wedges.
Adjust the rearview mirror before
If the tires are to fall, escape as soon operating the machine to give the
as possible. The tires of engineering operator the best view.
machinery are very heavy, and if you
try to prop them up you can get Check seat belts and fasteners,
serious injuries. replace damaged and worn parts.
Adjust the seat and adjust the height
2.9 Lightning Protection and position of the control box to
When lightning strikes in the vicinity of achieve comfortable sitting position,
the machine, the operator will never so that the driver can still step on the
take the below operations: pedal completely while sitting in a tight
position.
1) Get on the machine or off
the machine. Ensure that the lighting system of the
2) If you are in the cab, do machine meet the requirements of
not leave the cab. If there is a working conditions and ensure that all
thunderbolt, you are on the lighting fixtures work properly.
ground, please stay away from
Before starting the engine, make sure
the adjacent area of the machine.
there are no people in the upper and
lower parts of the machine.
2.11 Engine Starting

Do not start the engine or move any
16
machine control device if the engine operator should make a tour to make
starting switch or machine lever is sure there is no danger around the
mounted with warning signs. machine.
Adjust the seat of the operator and When the machine is running, it is
fasten the seat safety belt. necessary to continuously inspect the
surrounding area of the machine and
Before the engine starts, check for to identify potential hazards when
any spectators and maintenance dangerous situations occur in the area
personnel to ensure that all personnel around the machine.
are away from the machine. Before
starting the engine, briefly whistle. Before operating the machine, ensure
that the visual field assist device is in
Combined with the parking brake, the good condition and clean.
gearbox from the control switch is
placed in the neutral. The specification and configuration of
the machine may result in a blind
Turn the engine starting switch key to area, which is not visible to the
the connecting position. Start to cycle operator after seating. Job site
all indicator light and meters, etc. organizations must be used to
Turn the engine starting switch key to minimize the hazards of these
the starting position and start the restricted horizons.
engine.
Release the starting key switch when
the engine starts. 2.13 Operation
Release the parking brake. The scope of the machine
Select the required forward or This machine is suitable for the

backward direction, and then select environmental temperature of -25 ℃ ~
the gear. 40℃.
Altitude≤3000mm
2.12 Before Operation
Wading Depth≤500mm
Get everyone out of the machine and
the surrounding area. It can only be used in a non-explosive
gas environment.
Remove all obstacles on the
machine’s route. Be careful of
dangerous obstacles such as cable
and ditches. Machine operation
Make sure all windows are clean. You can operate the machine only if
Doors should be fixed in open position you are sitting in your driving seat.
or closed position. You must fasten your seat belt when
operating the machine.
Adjust the rearview mirror before
operating the machine to give the Ensure that the frame lock pins are
operator the best view. not locked.
Ensure that the machine’s horn, Passengers are not allowed when the
reversing alarm and other alarm machine is operated.
devices work normally. When operating the machine slowly
on the open ground, check that all
control mechanisms and protection
Visibility information facilities are working correctly.
Before starting the machine, the When moving the blade, be sure not
17
to damage the frame ladder, wheel, emergency situation, shall quickly

and steering pull rod. lower the shovel down to the ground,
to help stop or prevent overturned
Before the machine turns and reverse, vehicles.
lift the rear scarifier up.
If the brake should be applied when
It is forbidden to stop or drop the downhill, do not operate the speed
working device rapidly; Otherwise, the shift lever or place the gearbox in
working device and hydraulic system neutral. If the speed exceeds the gear
will be damaged. speed, shall step the brake pedal to
When driving or steering in a narrow lower the speed.
area, notice the safety issues around When the machine walking on slopes,
you, reduce the speed, and confirm if the engine is off, should immediately
that there are no obstacles around applying brake, the brake pedal fully
you. Where there are obstacles, when stepped down to drop the blade to the
the vehicle is turning and walking, be ground, and then apply the parking
careful not to crash the vehicle and brake to keep the position of the
obstacles. machine fixed.
Work and drive in harsh environments To prevent injury or death, the
and be careful not to work alone in following rules must be observed
dangerous places. The condition of before moving the machine or working
the road surface, the strength of the device, even if the machine is
bridge, the topography of the job site equipped with a reversing alarm and a
and the state of geology shall be rear-view mirror.
investigated in advance.
1) Sound the horn to warn the
Avoid maneuvering the machine close personnel on the site.
to the suspension or deep gully. It is 2) Ensure that nobody near
possible that the machine’s weight or the machine. Pay special attention
vibration causes these places to to checking the rear direction of
collapse, causing the machine to the machine because the area is
collapse and causing casualties. not visible for the operator on the
The danger of rolling over may seat.
happen when crossing the ramp or 3) When working in areas
shifting direction on ramp. Do not where there is danger or poor
carry out such dangerous operation. visibility, assign a person to guide
traffic at the site.
Avoid steering on the ramp. Can steer 4) The unapproved personnel
the machine only when the machine is not allowed to enter the area of
reaches the flat ground. When the turning or walking direction.
operating on a bank or slope, speed 5) Do not change direction at
deceleration or small angle should be high speed.
adopted.
Do not exceed its carrying capacity
Choose the appropriate gear before when working, and the operation that
going downhill, do not shift gear in the exceeds the performance of the
downhill course. machine is extremely dangerous.
Therefore, the road condition should
When walking on the ramp, the center be confirmed in advance to avoid
of the machine moves to the front overload. The damage of machines or
wheel or rear wheel, which should be personnel caused by overloading.
carefully controlled and never apply
the brakes. When the machine is operating, be
careful to prevent the blade from
When driving on a slope, dam, or hitting the hard object to avoid
slope, the shovel blade is close to the damaging the blade. No personal
ground with distance of about 20-30 injury can be caused when a person is
cm (8-12 inch), in case of an
18
not standing in front of the frame. sure no people around the machine.
The steps taken are different
depending on the work device that
needs to be lowered. Wear proper
2.14 Engine Shutdown protective clothing. Follow the manual
The parking surface shall be as flat as instructions.
possible, and lower the working
device to the ground.
Do not park on a ramp. If you do need
to park, the slope must be less than 2.15 Noise and Vibration
15%, and the wedge should be placed Noise: External radiated noise of the
under the wheel to prevent the machine meets the limit requirement
machine from moving. Then drop the of 'outdoor noise instruction
work device to the ground. 2000/14/EC' and the weighted sound
When the machine has failure or need power level guarantee value of it, A is
parking in traffic congestion, set 106dB （ A ） . The sound pressure
fencing, signal, flags or warning lights, value nearby driver is 80dB （ A ） in
and place the other necessary signals drive cab.
in place to ensure that vehicles can
Vibration: The vibration value is less
see the machine clear. Also, make
than 2.5 m/s2 to operator's arm and
sure the machine, the fence, the flag
less than 0.5 m/s2 to body.
not obstruct the traffic.
When the machine is shut down, 2.16 Cab
lower the blade down to the ground.
No alteration of the operation console
Move the gear lever of gearbox to shall occupy the space of the
neutral position. operator’s operating space or the
seat. When installing radio equipment,
Set the parking brake switch in the fire extinguishers and other
braking position. equipment, you must ensure the
operating space of the prescribed
Turn the engine off, rotate the engine
driver or the space of the seat. Any
starting switch to off position, and pull
items brought into the cab may not
out the engine starting switch key.
encroach on the operator’s operating
When you get out of the machine, you space or the space of the seat.
must make sure that your body is in
contact with the armrest and climbing
stairs. 2.17 Protection Device
Be sure to switch the battery cut-off
Check the protective gear every day
switch to OFF position and then leave
to check if the structures are curved,
the machine.
cracked or loose. Do not operate the
Lock up all the equipment with the key machine in the event of damage to
and remove the key before leaving the these devices.
machine.
The operator is exposed to dangerous
Be sure to switch the battery cut-off situations if the machine is improperly
switch to OFF position and then leave used or in poor operation. This can
the machine. happen even if the machines are
equipped with proper protection.
Follow the normal operation steps
recommended for the machine.
Lower the working device when the
engine stops ROPS/FOPS
Before the engine flame out or put The ROPS/FOPS structure on the
down all work equipments, must make
19
machine (if equipped) is designed, and ROPS performance of the

tested and certified for the machine. machine. If ROPS/FOPS are
Any changes to the roll over protection structurally damaged, the protection
structure/falling off protection structure they provide will be weakened.
will weaken the structure. This will Tipping over, falling object and
make the operator under unprotected collision will cause damage to the
environment. Any modification or structure.
addition to the attachment, if the
weight of the machine is more than Do not weld support or holes in the
the weight specified on the ROPS/FOPS structure to install fire
certification plate, will also leave the extinguishers, emergency kits, work
operator in unprotected environment. lights, etc. Welding brackets or drilling
Being overweight can limit the braking holes in ROPS or FOPS will weaken
performance, steering performance the structure. Please consult XCMG
and agent for installation guidelines.
20
3 Product Information
3.1 General Information
Technical specification
Fig.3-1 Dimension unit: mm
The basic transportation specifications 1R 5 km/h

are listed below 2R 13 km/h
Table 3-2
3R 25 km/h
GR1605 Maximum crack depth 420mm
The lower limit of
CUMMINS-QSB5.9 engine reduction
3500m
Engine
diesel engine Maximum blade angle 90°
ZF158 （1）Gross Vehicle Weight is calculated
Transmission box 6 forward gears with full fuel tank, coolant, lubricants,
3 reverse gears
Gross Vehicle
operator, front counter weight and rear
Weight-Standard 15000kg counter weight.
Equipped（1）
Table 3-3
Turning radius 7.2m Name Mass kg
Travel speed 1F 5km/h Gross Vehicle Weight-
2F 8 km/h Standard Equipped
15000kg
3F 13 km/h Front bulldozer 1073kg
4F 18 km/h Rear ripper 1446kg
5F 30 km/h Fender 215kg
6F 47 km/h
21
Purpose information:
The moter grader is the earth moving Model number
machine, which belongs to the motor Rated power
Blade dimension
grader machine described in “ISO
Overall dimensions
6165:2001”. This is a self-propelled Total weight
wheeled machine with adjustable blade Year of manufacture
between front and rear axle. The grader PIN
can also be installed with front blade or a Manufacturer name and address
rear-mounted ripper. The motor grader
machine is used for leveling, slope
scraping, digging, and loosing materials
with the forward movement.
Application/configuration limitations
The maximum traction is 88kN.
The parking brake can function normally
on a slope of 20 %.
The servicing brake on the slope is 25% Fig.3-4
of the slope.
The GR1605 motor grader’s engine
nameplate is located at the top of the
3.2 Identification information engine.
The product identification number (PIN)

is used to identify the power machines
designed for operators to seat.
XCMG products designed not to be used
by operators, such as engines,
gearboxes and major attachments can be
identified by serial numbers.
Fig.3-5
The gearbox nameplate of GR1605 is

located atthefront of the gear box.
Fig.3-2
Fig.3-3
The product identification number (PIN)

is located at the bottom of the cab, on the
right side of the front frame. The
nameplate contains the following
22
4 Operation the steps and the handle.

Note: Three-point contact can be two feet
4.1 Before Operation and one hand. A three-point touch can
also be one foot and two hands.
Key
Don’t get on the moving machine. It is
1) Door key
forbidden to come down from the moving
2) Start key switch
machine. Don’t jump off the machine. Do
3) Hood side door key
not carry tools or items when you are
4)Battery and starting motor circuit
getting on or off the machine. Use hand
breaker key
pull rope to pull the equipment onto the
5) Air filter key of oil tank
platform. When entering or going out of
the cab, the joystick should not be used
Door as an armrest.
Door open handle has lock, must turn the

door key counterclockwise to lock the
Daily check
door; If the door is locked with open
position, pull the inner handle behind the In order to obtain the maximum service
door to unlock the door. life of the machine, the machine should be
inspected thoroughly before starting the
engine.
Alternate exit
Check the machines around and under
The door on the left side of the machine is the machine. Check for loose bolts, piles
the main exit. The door on the right side of of garbage and oil stains, coolant leakage
the machine is a spare exit. and broken or worn parts.
Note: pay close attention to leakage. If a
leak is found, the source of the leak
Machine channel system should be found and fix the leakage. If a
The machine channel system is designed leak is detected or suspected, the liquid
for the purpose of fulfilling the technical level should be checked more frequently.
requirements of “GB/T17300 idt ISO 2867 Check the hydraulic parts of the machine.
earth moving machinery". The channel
system provides a channel for the Check the tire condition. When necessary,
operator to access the console and inflate the tire.
maintain the items described maintenance
Remove all accumulated waste and
section.
debris. Please make all necessary repairs
before operating the machine.
Make sure all covers and shields are
firmly installed.
Getting on and off the machine
Adjust the rear-view mirror to the
Only get on and off the machines with appropriate position.
stairs and/or handles. Sweep the steps
Ensure that the fault light on the
and handles before getting on the
dashboard panel does not shine.
machine. Check the steps and handles.
Carry out all necessary repairs. Face to Check all oil level, coolant liquid level and
the machine when getting on and off the fuel oil level. For all the grease nozzle
machine. Stay in three points contact with requires daily maintenance, should add
23
lubricant daily. Note: the seat should be adjusted at the

start of the operator or shift. The operator
Perform maintenance steps on your should sit close to the seat back. Adjust
machine every day: the seat so that the operator can step on
• reverse alarm - test the pedal.
• brake, indicator light and instrument- test
• rotary disc drive small gear tooth -
lubrication
• upper part of the rotary disc-lubrication
• liquid level of cooling system for cooling
system -check
• engine oil level -check
• oil and water separator in fuel system -
drainage
• seat belt -check
• transmission and differential oil level -check
Fig.4-3
Bogie lock 1. Seat back tilt adjusting handle 2. Front and
rear djusting handle 3. Weight control handle
Warning Tilt angle adjusting handle (1)

There are people around when the machine
turns. It can be squeezed, causing serious
injuries.
Pull up the adjusting handle
and adjust the angle of the seat back
to the required position; Then release
the adjusting handle and lock the
seat back.
Front and rear adjusting handle (2)
Lift the adjusting handle

Fig.4-1 upward, move the seat forward or
Remove the frame lock connecting rod (2) backward to the appropriate position;
and keep it to (UNLOCKED) position. Then release the adjusting handle
Frame lock connecting rod must be in and lock the seat.
(UNLOCKED) position, and then make Weight control handle (3)
the machine articulated.
Install the rack lock pin (2) to the
LOCKED position before proceeding any A weight indicator on the right
of the following operations. side of the handle, pull the weight
control handle (3), and rotate the
• Lift the machine. handle until the weight indicator
• Transport the machine.
reaches the appropriate value and
• Work near the center of the machine.
then push the handle back.
Upper and lower adjustment
4.2 Machine Operation
The adjustment method of upper and
Seat lower adjustment is to lift the upper
The seat can be adjusted in front and part of the seat, and then raise the
rearward, to left and right, back angle height of the seat; Lift the top of the
adjustment, seated depth adjustment, seat and press down to lower the
cushion and inclination adjustment seat height.
according to weight.
24
Seat safety belt （4）

The seat belt is configured before the
machine delivery. Check the seat belt
and install fasteners before operating
the machine; Adjust the seat belt and
fasten it to make the driver feel
comfortable.
Mirror
The mirror can expand the scope of
visibility around the machine. Ensure
the view mirror is in good condition
and clean. All mirrors should be Fig.4-4
adjusted at the start of each work 1.Left side rear mirror 2. Cab view mirror
shift or operator change. Retrofitting 3. Right rear view mirror
or adding additional equipment or
accessories may affect the view.
Operator’s control device

Note: your machine may not have all the controls described in this section.
25
Fig.4-5
1. Blade circle drive lever 2. Blade sideshift lever 3.Blade lift control for the left side 4. Ripper
control 5.Blade tip control lever 6.Control console 7.Displayer 8.Steering wheel 9.Right
combination switch 10. Centershift control 11. Articulationcontrol 12. Wheel lean control13.
Dozer lift control14. Blade lift control for the right side 15. Braking pedal 16. Accelerator pedal
17. Gear selector 18.Power light 19. Emergency stop button 20.Engine start switch 21. Full
automatic air conditioning controller 22.Energy-saving mode button 22. Gearbox control mode
switch 23. Interlock switch 24.Electrical socket 25.Tilt adjusting handle 26. Left combination
switch
3.Left blade lifting joystick 4. Rear ripper liftingjoystick 5.Blade angle change joystick 6.Control
console 7.Displayer 8.Steering wheel 9.Right combination switch 10. Blade swing joystick 11.
Frame articulated steering joystick 12. Front wheel inclination joystick 13. Front bulldozer lifting
joystick 14. Right side blade up-down control handle 15. Braking pedal 16. Accelerator pedal 17.
Gear selector 18.Power light 19. Emergency stop button 20.Engine start switch 21. Full automatic
air conditioning controller 22.Energy-saving mode button 22. Gearbox control mode switch 23.
Interlock switch 24.Charging port 25.Tilt adjusting handle 26. Left combination switch
Blade circle drive lever（1） to the hold position, and the blade will
Blade rotating joystick -- To remain in the selected position.
make the blade rotate
clockwise, pull the lever (1) Hold - After releasing the lever (1), the
back.After releasing the lever lever (1) will automatically return to the
(1), the lever (1) will automatically return hold position. The blade will remain in the
selected position.
26
The blade is rotated anticlockwise -- To before starting the engine, shall pull the
make the blade rotate anti-clockwise, pull lever (3) to the hold position.
the lever (1) back. After releasing the
lever (1), the lever (1) will automatically Ripper control (4) (if equipped)
return to the hold position, and the blade Rear ripper lift ---- The lever
will remain in the selected position. (4) is pulled backward and the
rear ripper can be lifted. After
Blade sideshift lever（2） releasing the lever (4),
The blade moves to the right - thelever (4) will automatically
The lever (2) is pulled back and return to the hold position, and the rear
the blade moves to the right. ripper will remain in the selected position.
After releasing the lever (2), the
lever (2) will automatically self return, and Hold - After releasing the joystick (4), the
the blade will remain in the selected joystick (4) will automatically return to the
position. hold position, and the rear ripper will
remain in the selected position.
Hold - After releasing the lever (2), the
lever (2) will automatically return to the Rear ripper lower---- To lower the ripper,
hold position. The blade will remain in the push thelever (4) forward. After releasing
selected position. the lever (4), the lever (4) will
automatically return to the hold position,
The blade moves to the left - The lever(2) and the rear ripper will remain in the
is pulled back and the blade moves to the selected position.
left. After releasing the lever (2),the
lever (2) will automatically self return,and Blade tip control lever (5)
the blade will remain in the selected The blade tip back–Pull lever (5)
position. backward. The top of the blade
will tip backward. After releasing
Blade lift control for the left side (3) the lever (5), the lever (5) will
automatically self return, and the blade
The blade left sidelift –Pull back will remain in the selected position.
on lever(3) in order to raise the
left side of the blade. After Hold - After releasing the lever (5), the
releasing the lever (3), the lever (3) will lever (5) will automatically return to the
automatically self return, and the blade hold position. The blade will remain in the
will remain in the selected position. selected position.
Hold - After releasing the lever (3), the The blade tip forward- Push the
lever (3) will automatically return to the lever(5)forward. After releasing the lever
hold position. The blade will remain in the (5), the lever (5) will automatically self
selected position. return, and the blade will remain in the
selected position.
The blade left sidelower - Push thelever
(3) forward on order to lower the left side Control console (6)
of the blade. After releasing the lever (3),
the lever (3) will automatically self return, Control console–Adjust the console to
and the blade will remain in the selected comfortable position according to the
position. driver’s comfort.
Blade float - Push the lever (3) to most Displayer(7)

forward detent position. Release the Displayer - Display engine gearbox oil
lever (3) and the lever (3) will remain in pressure water temperature, steering
the floating position. instructions, alarm instructions, gearbox
Note: it is possible to push the lever (3) gear and other information.
forward into a floating position with a Steering wheel (8)
greater force.
Steering wheel - Turn steering wheel to
Note: when the lever (3) is in the floating the direction required when traveling, the
position and the engine flames out, the machine can make a turn.
lever (3) will not return to hold position,
27
Right combination switch (9) in the selected position.

Used to control the speed of the front Hold - After releasing the lever (12), the
windscreen wiper and water spray. lever (12) will automatically return to the
hold position. The front wheel will remain
The front wiper has two gears, press the in the selected position.
right combination switch, the front
scraper is gear I, press again to lower Wheel leanleft - push the lever (12)
part, the front wiper is gear II. Press the forward and the front wheel lean to left.
right combination switch end button, then After releasing the lever (12), the lever
the front rain wiper glass sprays water. (12) will automatically return to the hold
position. The front wheel will remain in
Centershift control (10) the selected position.
Centershift right –Pull back the
lever(10) in order to move the Dozer lift control (13) (if equipped)
drawbar to the right. After The dozer raise – Pull back the
releasing the lever (10), the lever (10) will lever in order to raise the dozer
automatically return to the hold position, blade. After releasing the lever
and the rear ripper will remain in the (13), the lever (13) will automatically
selected position. return to the hold position. The dozer
blade will remain in the selected position.
Hold - After releasing the lever (10), the
lever (10) will automatically return to the Hold – After releasing the lever (13), the
hold position. The blade will remain in the lever (13) will automatically return to the
selected position. hold position. Thedozer blade will remain
in the selected position.
Centershift left–Push the lever (10) to
move the drawbar left. After releasing the The dozer lower – Push the lever (13)
lever (10), the lever (10) will forward in order to lower the dozer blade.
automatically return to the hold position, After releasing the lever (13), the lever
and the drawbar will remain in the (13) will automatically return to the hold
selected position. position. The dozer blade will remain in
the selected position.
Articulation control (11)
Blade lift control for the right side (14)
Articulation right – Pull the lever The blade right sidelift –Pull
(11) backward and move the back on lever(14) in order to
back of the machine to the right. raise the right side of the blade.
After releasing the lever (11), the lever After releasing the lever (14),
(11) will automatically return to the hold the lever (14) will automatically self
position. return, and the blade will remain in the
selected position.
Hold - After releasing the joystick (11), Hold - After releasing the lever (14), the
the joystick (11) will automatically return lever (14) will automatically return to the
to the hold position. The machine will
hold position. The blade will remain in the
remain in the selected position.
selected position.
Articulation left–Push the lever (11)
foreward and move the back of the Hold - After releasing the lever (14), the
machine to the left. After releasing the lever (14) will automatically return to the
lever (11), the lever (11) will automatically hold position. The blade will remain in the
return to the hold position. selected position.
Wheel lean control (12) The blade right sidelower - Push thelever
Wheel lean right –To lean the (14) forward on order to lower the right
wheels to the right, pull the side of the blade. After releasing the lever
lever (12) backward. After (14), the lever (14) will automatically self
releasing the lever (12), the return, and the blade will remain in the
lever (12) will automatically return to the selected position.
hold position. The front wheel will remain
28
Blade float - Push the lever (14) to most Engine starting switch - insert the starter
forward detent position. Release the key, rotate to ON position, connect the
lever (14) and the lever (14) will remain in circuit of whole machine; Turn to START
the floating position. position to start the engine. After the
engine starts, release the switch key in
Note: it is possible to push the lever (14) time so that it can bounce back to the ON
forward into a floating position with a position.
greater force.
Full automatic air conditioning
Note: when the lever (14) is in the controller (21)
floating position and the engine flames
out, the lever (14) will not return to hold
position, before starting the engine, shall
pull the lever (14) to the hold position.
Brake pedal (15)
The pedal stops the machine, and the
brake pressure depends on the the
pressure on the brake pedal.
Accelerator pedal (16)
Step on the accelerator pedal to control
the engine speed and output power. Fig4-5
Gear selector (17) Cooling - automatic mode
Forward - push the gear selector forward, 1) Close the hot water valve inside the
turn to right (+), one gear increases each hood;
time. Turn left (-), one gear reduces each 2) Start the engine
time.
3) Turn on the automatic mode setting
Neutral - when parking the machine, switch, the temperature display of the
place the gear selector in neutral liquid crystal display section, the air
position. output and the automatic switch, the light
Backward - pull the selector back, turn to on top of the air conditioner will all be
right (+), one gear increases each time. lightened.
Turn left (-), one gear reduces each time. 4) Adjust the temperature switch to set
Power light(18) the comfortable temperature. The
corresponding setting temperature air
Used to show whether the vehicle power conditioning automatically switches the
is connected. When the power indicator air volume, the outlet and the air inside
is on, it indicates that the whole vehicle and outside. Automatic operation for
power is in an on-state, and the power achieving the setting temperature.
indicator is out, indicating that the whole
vehicle power is in an off-state. 5) The stop of automatic operation -
press the OFF switch①, the setting
Emergency stop button (19) (if temperature and the air volume indication
equipped) on the LCD and the lamps above the
automatic switch and the air conditioner
Emergency stop button - Press the switch are off, then the operation stops.
button, the engine will be out of fire
immediately, and the whole vehicle Cooling - Manual mode
power will be off.
1) Close the hot water valve inside the
Note: Use this button in an emergency, hood;
and use the starter key to shut down in
normal state. 2) Start the engine
Engine starting switch (20) 3) Press the fan adjusting switch ② to

29
adjust the air volume. The setting the highest position of forward or reverse,
temperature and air volume are and the gear will be automatically
confirmed by LCD. switched according to the accelerator.
4) The on-off status of air conditioner Interlock switch (23)
switch⑧ can be judged by the light above
the switch. When the switch is in the locking
position, the locking clutch of the gearbox
5) Set the appropriate temperature by is in the allowable locking status; when
adjusting the temperature adjustment the gearbox detects that meets the lock
switch. condition, the lock clutch is automatically
locked. When the switch is in the
6) Adjust the blow mode switch to set the unlocking position, the locking clutch is
required blow outlet. prohibited to be locked.
7) Select the internal and external air Electrical socket (24)
mode with the button⑥.
The voltage of eletrical socket is 24V.
8) The stop of manual operation - press
the OFF switch①, the setting Tilt adjusting handle (25)
temperature and the air volume indication
on the LCD and the lamps above the air Tilt adjusting handle - counterclockwise
conditioner switch are off, then the turn the handle, adjust the position of the
operation stops. control console according to the driver,
and then tighten the handle.
Heating
Left combination switch(26)
1) Turn on the hot water valve inside the
hood; It is used to control the steering signal
and high beam.
2) Start the engine
Steering signal control - turn up the left
3) Press A/C button, the cooling indicator combination switch, the right steering
light is off, the cooling system stops light is on. Turn down the left
working; combination switch and the left steering
light is on.
4) Adjust the air volume button;
Turn the end of left combination switch
5) Adjust the temperature button; clockwise, switch the headlight to high
6) Press the MOOD button to change the beam, and turn the end side of the left
air outlet; Or press the AUTO button to combination switch side
select the outlet; counterclockwise, then switch the high
beam to the low beam.
7) Press the internal and external
circulation outlet buttons to select the High beam control - pull back the left
inner and outer circulation vents as combination switch and the high beam
required; lights up.
8) Press OFF button to stop the air- Control switch

conditioning system. Control switch - integrated assembly in
Note: when using the refrigeration the side wall of the cab, used to control
function, close the hot water valve and lights, alarm lights, emergency signals,
open the valve only when the heating etc.
function is used.
Manual/automatic shift switch (22)
The switch is in the manual position, and
the gear of gearbox should be manually
engaged. When the switch is in the
automatic position, the handle is put in
30
Rear worklamp switch of cab（33）

Press this rocker switch ， the
two worklights at the up rearof
the cab light up.
Front frame worklamp switch（34）
Press this rocker switch, the two
worklights on the front frame
light up.
Shovel blade worklamp switch（35）

Press this rocker switch, the
two work lighs down frontofthe
cab light up.
Reserved switch (36)
Fig4-6
energy-saving mode switch (27) Emergency light switch (37)
This switch has a mechanical lcok that Press the switch, the left and right
should be pushed when switch is on or turn signals on the front rack and
off.This switch is closed, the grader is in back of the hood sparkle.
the eco-mode.
Rear hood working light switch（38）
Engine flame-out switch (28)
Press the switch, and the left
Press the switch and the engine and right side of the rear hood
will stall immediately. After will light up.
released, the switch is reset
automatically. Rear screen wiper sprinkling
switch（39）
Parking switch (29)
When the switch is pressed, the
The switch with mechanical rear wiper sprays water. After
lock, press the switch, the released, the switch is reset
transmission brake disc the automatically.
vehicle function.
Rear screen wiper switch (40)
Worklight switch upfront of the
cab（30） The switch is three-position
switch, the wiper speed is two
Press this rocker switch, the gear. Press the lower end of the
two worklights up front of the switch to make the switch in the neutral
cab light up. position. At this time, the speed of the
wiper is gear I, and then press the lower
Headlamp switch（31）
end of the switch again, the wiper speed
Press this rocker switch,the is gear II .
headlamp is on, at this time it is
dipped headlight.
Rotating alarm light switch(42)
Press the switch and the
Clearance light switch (32)
rotation alarm light above the
Press the rocker switch, and the cab is on.
vehicle clearance light and
switch backlight are on.
31
Reserved switch (44) (49)

This switch is a three-contact self-reset
Overload protection switch（45）(If switch, and it is not in the middle position
equipped) on time, the hydraulic pull pin has no
action. When the switch is pressed down
Press the switch, the blade lift oil or upward, the hydraulic pull pin will be
cylinder will generate a thrust to extended or contracted accordingly. The
prevent the hard object from switch is used in conjunction with the
hitting the blade, which is used in hydraulic pull pin lock switch (48).
conjunction with the floating switch.
Blade floating switch (46)(If equipped)
Press the switch and the blade
is working in a floating state.
Front bulldozer float switch
(47)(If equipped)
Press the switch, and front
bulldozer is in the float state.
Hydraulic pull pin lock switch (48)

This switch is the enable switch for
hydraulic pull pin, the switch is self-reset
switch, only the switch is in the closed
state and the hydraulic pull pin function
will work.
Hydraulic pull pin operation switch
Indicator and meter

Fig.4-7
No. Function No. Function

Oil temperature display of torque
(1) Left steering indicator lamp (17)
converter
(2) Hydraulic oil filter alarm light (18) Oil pressure indicator of torque converter
(3) Brake pressure alarm (19) Voltage indication
(4) Voltage indication (20) Engine hour indicator
(5) Charge indicator light (21) Machine oil pressure indication
(6) Preheat indicator light (22) Engine speed meter
(7) Stop fault indicator light (23) Date
(8) Engine fault indicator light (24) Fuel level indicator
(9) Wait for start indication (25) Water temperature indicator
Gear and manual, automatic
(10) (26) Articulated angle indication
instruction
(11) Lower beam indicator light (27) Mute
(12) High beam indicator light (28) Setting
(13) Clearance indicator light (29) Usage information inquiry
(14) Reverse indicator light (30) Reversing camera
32
(15) Right steering indication (31) Operation parameters quick query

(16) Speed indicator
Left steering indicator light (1) Gear and manual and automatic
indicator (10)
Turn the switch to the left, this
indicator is on. M-- Manual
A-- Automatic
Hydraulic oil filter alarm light (2)
F-- Forward
When the hydraulic system filter is
blocked, the indicator light is on. R-- Reverse
Number -- represents the selected gear
Brake pressure indicator light (3) Lower beam indicator light (11)
Brake pressure indicator - after Low beam indicator - when the
the engine starts, the indicator light is on, it indicates that the
lights up, and goes out after about 1 low beam has been turned on.
minute. If the indicator light is on when
machine operates, indicating that the High beam indicator light (12)
brake system fails; must stop the
machine for check. High beam indicator light - the
indicator light is on when the
Parking brake indicator light (4) combination switch is llocated
to the high - beam position.
The parking brake indicator light -
press the car button, the grader
is in the parking brake state and the Clearance indicator light (13)
indicator light is on.
Clearance indicator light - press the
Charging indicator light (5) rocker switch of the clearance indicator
light, and the indicator light is on.
Charging indicator - when the
key is switched on and the
engine is not started, the indicatoris Reverse indicator light (14)
on.The lamp went out about 1 minute
after the engine started. Indicating that Reverse indicator light - when the
the battery is in charge. gear selector is in reversing gear,
the light is on.
Preheat indicator light (6)
Right steering indicator light （15）
Preheat lamp - this indicator is
lit to indicate the engine’s inlet Right steering indicator light -
preheater opens. turn the left combination switch
upward. The indicator light is on.
Stop indicator light (7)
Stop failure indicator light - the

Oil temperature display of torque
indicator light is on, indicating
that the engine is in serious converter (17)
trouble and needs to be stopped Torque converter oil
immediately for maintenance. temperature indicator -
Engine failure alarm indicator (8) measuring range 60 ℃,
indicating that the torque converter oil
Engine failure alarm indicator - temperature.
indicator light is on, indicating that the
engine fails. Oil pressure indicator of torque
converter(18)
33
Oil pressure indicator of The system setting interface includes

torque converter - display the brightness setting, language setting and
oil pressure of torque time setting.
converte
Time setting
Working hours (20)
Working hours - display engine working

hours h.
Engine oil pressure indicator (21)
Engine oil pressure indicator - displays

engine oil pressure, measurement range.
Engine speed meter (22)
Fig.4-9
Engine speed meter - measuring range
Select the setting option through the
0-3000 rpm, indicating the rotation speed
upper and lower arrows, press the
of the engine.
confirm key to enter the corresponding
Oil level indication (24) setting interface, and return key to return
to the upper level menu: setting menu,
Oil level indication - and the “home” key return to the main
measurement range 0-100%, interface.
showing oil level in diesel tank.
Brightness setting
Coolant temperature indication (25)
Coolant thermometer - measurement

range of 40-120 ℃, indicating the engine
cooling water temperature.
Articulated angle indication (26)
Articulated angle indication - if equipped,

can display the hinged angle of the front
and rear frame. Fig.4-10
Setting (28)
Press the setting button to enter the Adjust the brightness through the upper
setting menu interface. and lower arrows, press the confirm key,
return key to return to the upper level
The interface includes: factory setting, menu: setting menu interface, and the
system setting, instrument setting. The “home” key return to the main interface.
factory and instrument setting requires
password, which is not open to users. Language setting
Fig.4-11
Fig.4-8
Use the up and down arrow to select the
System setting interface language, the return key to return to the
34
upper level menu: the system setup on the page and the confirm key for the
interface. fault information content query. Press the
return key to return to the previous menu:
Time setting usage information query interface.
Fig.4-12
Engine DM1 fault information
Through touch screen adjust the date
and time, turn the page through the left
and right arrows, select and adjust the
value by the touch screen, according to
the confirmation key, return key to return
to the backspace menu: the system
setup interface.
Using information inquiry (29)
By clicking on the main interface buttons,

Fig.4-15
direct enter information query interface,
this interface includes: running Use up and down arrows to move the
parameters, engine DM1 fault cursor, when more than one page fault
information, the gearbox fault page use the left and right key to turn
information, the main machine pages, use the confirm key for fault
information, instrument information, information content query, press the
variable power control information. return key to return to the previous
menu: usage information query interface.
DM1 - current fault code.
Gearbox fault information
Fig.4-13
In this interface select content up and

down arrows, through the confirm button
to enter the corresponding interface Fig.4-16
(variable power control information need
a password, it is not open to the user), Use up and down arrows to move the
click the “home” or return key to return to cursor, when more than one page fault
the main interface. page use the left and right key to turn
pages, use the confirm key for fault
Operation parameters information content query, press the
return key to return to the previous menu:
usage information query interface.
Main machine information
Fig.4-14
Use the upper and

lower arrows to turn Fig.4-17
35
Press the return key to return to the Do not start the engine if the engine starting
previous menu: usage information query switch or machine lever is mounted with
warning signs. Also do not move the
interface.
machine's control device
Instrument information Engine exhaust contains combustion
products, which are harmful to human
health. The engine must be started and
operated in a well-ventilated place. If the
engine is in a closed place, the exhaust gas
should be discharged outside.
1) Turn on the power supply switch.

2) Adjust the driver’s seat.
3) Fasten the seat belt and check the
Fig.4-18
condition of seat belt and installation
fasteners.
Press the return key to return to the 4) Check whether there are any
previous menu: usage information query bystanders and maintenance
interface. personnel to ensure that all
personnel are away from the
Reversing camera (30) machine and sound the horn briefly.
5) Engage the parking brake.
Click on the key of backup image of the 6) Place the gear selector in netural
main interface (30) and enter the reverse position.
image interface. At this time, there is no 7) Turn the key switch on the control
need to apply the reverse gear, when box to ON position and all the
applying the reverse gear, it will enter the indicator lights and instruments start
inverted reverse image interface. to circulate. The system check is
completed when the instruments
Operation parameters quick query (31)
stop moving.
Click the operation parameters quick 8) Turn key switch to START position,
query button (31) of the main interface, connect the starting motor and start
directly enter the operation parameter the engine.
quick query interface, turn pages through Note: the engine can be started only after
the up and down arrows, see other the engine preheating lamp is off. This
operating parameters; press the return indicator light indicates the engine intake
key to return to the main interface. heater is turned on.
9) When the engine starts, release the
key switch immediately, and the
switch will automatically reset to the
ON position.
10) After starting keep the engine idling
for 3 minutes, pay close attention to
the indication of dashboard.
11) If no abnormalities, and brake
indicator light is out, can release the
hand brake, ready to drive.
Fig.4-19 Note:
the starting time should not exceed 10 to
15 seconds, if need second start, the
interval time should not be less than 2
4.3 Engine Starting minute. In case of a secondary start, the
starting key will need to be rotated to
OFF place and then start. If it can’t be
started for three times, shall find the
Warning
36
reason to confirm the failure and restart. 3) Press the gear enabling button on
right handle, click the FNR on the
Engine and machinepreheating rocker switch and select the
Always run the engine at low idle speed forward/backward status;
for at least ten minutes before any 4) Automatic shift mode: when the gear
operation is performed under cold selection handle is pushed
conditions. forward/rearward, every time move
the handle to the right, one gear will
be increased, every time move the
Hydraulic system preheating handle to the left, one gear will be
reduced. Automatic shift mode: the
1) Place the gear selector in netural gear selection handle should be
position and then engage the pushed forward/backward.
parking brake.
5) Slowly press the throttle pedal to
2) Pull the blade sideshift lever forward slow the machine forward or
or backward, and move the blade backward;
sideways to right and left.
3) Test all engine oil cylinders and all
steering cylinders to make the hot oil
Warning
circulate in the cylinders.
It is forbidden to drive at high speed while
driving on the road with slope or poor road
conditions;
Transmissionpreheating
Choose the appropriate gear before going
1) Move the machine forward a few downhill, do not shift gear in the downhill
meters to test the gearbox and course;
power transmission system.
It is strictly forbidden to overspeed when
2) Operate the machine under light going downhill. Use the brake pedal to slow
down.
load until the system reaches normal
operating temperature.
3) Always pay attention to alarm
indicators and instruments during
machine operation. Shift between manual shift/automatic
shift
Note:
Through the gearbox control mode switch
Engine keeps running at low speed until (22), the gearbox will be converted
the engine oil pressure appears on the between manual shift and automatic shift.
dashboard, or the lamp on the engine oil
pressure indicator goes out. In 10 Speed change and gear shift should be
seconds, if the oil pressure indication in turn, scope of application of gear shift:
does not appear, the lamp on the oil
Ⅰ 、 gear Ⅱ ： leveling operation for large
pressure indicator does not go out, the
conditions such as uneven pavement and
engine will be shut down, check the
large shoveling amount, slope climbing;
reason, then start again. Otherwise could
cause engine damage. Ⅲ 、 gear Ⅳ ： fine leveling, surface dust
and snow, transition on uneven road;
Ⅴ、gear Ⅵ：driving in high speed
4.4 Driving
When changing gear, don’t accelerate in
Start order to avoid over impact on the
1) Lift the shovel blade and rotate it into transmission system.
the vehicle In order to improve the driver's comfort
2) Release the parking brake. and maximum extend the life of the
37
power components, please be sure to

slow down the brake when steering.
Warning
When shift during driving, loosen the
accelerator changing from low speed to When the speed is higher than 13km/h, the
steering lever cannot be used. Must use the
high speed and at the same time control steering wheel to steer.
variable speed control handle, and then
step on the accelerator; changing from High-speed steering is extremely dangerous
high speed to low speed, loosen the and is forbidden.
throttle first then slow down the speed for Steering on the ramp may easily lead to the
gear shift. machine tipping over, do not operate;
Notice: This gear selector has memory

function. In the automatic transmission
mode, the transmission gear selector
advances to the forward gear, and the Braking
forward speed can reach the maximum 1) Release the throttle pedal and step
speed of V1. Turn the handle to the left, down the brake pedal to stop the
and then decrement one gear for each machine.
shift. At this time, the maximum speed of
the automatic transmission can only 2) Do not put your foot on the brake
reach the selected gear speed. In the pedal when driving normally, unless
automatic transmission mode, the it is necessary.
backward transmission also has memory
function. Move the shift handle directly 3) Don’t step on the pedal repeatedly,
from the forward gear to the reverse unless it is necessary.
gear, and then to the forward gear, then 4) When driving downhill, use the
the forward speed can reach the engine as a brake, do not change
maximum speed of V1. gear or put the gearbox in neutral.
Notice: Reduce the speed when
downshifting, otherwise the machine will
not execute the downshift order to protect
the gearbox. Shovel blade adjustment
Notice: When braking downhill, you need Manipulate the control handals
to brake to reduce the speed, otherwise respectively to control the shovel blade,
the machine will automatically upshift to the shovel blade has all kinds of work
protect the gearbox. position to meet the needs of the working
Steering condition.
This machine is divided into steering

wheel and hinge steering.
4.5 Parking
Steering wheel: during traveling turn
steering wheel to the direction required Parking machine
when traveling, the machine can make a Park the machine on the flat road
turn. surface, without risks of falling stones,
Hinged steering: Pull the frame landslip or flood. If must park the
articulated steering control machine on the slope, should use the
handle(11)forward or backward, then the wedge to prevent the wheel from moving.
rear part of the machine turns to left or 1) Release the accelerator pedal and
right. Release the frame articulated step on the brake pedal to reduce the
steering control handleand the machine speed and adjust the gear and stop the
hinged will stay in the selected position. vehicle safely;
When steering in narrow site, can use the 2) Adjust the gear selector to neutral
hinged steering position.
3) Lower the blade down to the ground,
38
and slightly add downward pressure. please follow the following operation to
reduce the working device to the ground.
4) Press the parking brake button (29),
the roller is in the braking state.
5) In case of emergency, you need to
turn off the engine quickly and press the
emergency stop button.
Shut down engine
1) Don’t stop the engine immediately Fig.4-20
after stopping the machine, better make
the engine idling for 5 minutes until
engine cooling down.
2) Turn the engine starting key switch to
the OFF position so that the engine
flames out, then remove the key;
3) Turn the power main switch to the OFF
position.
Leave the motor grader Fig.4-21
1) use the climbing ladder and handrail 1) Screw the nut (1), (2) of the left multi-
when you get off, and face the grader. Do way valve and the nut (3) and (4) right
not jump. multi-way valve respectively, and slowly
loosen until the blade falls to the ground.
2) check and clean the debris
accumulation on the engine immediately, 2) Twist the nut (5) and (6) of the left
to prevent fire. multi-way valve respectively, and slowly
loosen it until the rear ripper falls to the
3) clean up all combustibles around the ground.
vehicle to prevent fire.
3) Twist the nut (7) and (8) of the right
4) lock the door and window and take the multi-way valve respectively, and
key off. gradually loosen it until the former
bulldozer falls to the ground.
Lower the working device when the Note: don’t lower the device too fast.
engine stops Remove the valve core assembly after
If the engine fails to work and the working the device has landed on the ground and
device is lowered to the ground, press check for damage. Reseal and reinstall to
the float button to bring the working valve group.
device down to the ground.
4.6 Transport Information

Load and transport
Warning
Investigate the height limits of driving
When the equipment is put down, make sure
there is nobody around. routes. Make sure there is enough space
above the transport machine. This is
When the equipment is put down, if there are especially important for equipment with
people around, there may be a personnel roll-over protection structure (ROPS),
accident.
falling object protection structure (FOPS)
and cab.
Note: If the engine is unable to work, Remove ice, snow or other slipping
reduce the working device to the ground, materials from the loading platform and
39
carriage board before loading the Machine driving on road

machine to the transport machine
Removing ice, snow, or other smooth Inflate the tires to the correct pressure.
substances prevents the machine from When driving for long distances, shall
slipping in transit plan to stop and cool your tires and
Note: machine parts. For every 40 kilometers
(25 miles) or every driving hour the
Comply with all laws that specify the machine shall be stopped for 30 minutes.
characteristics of the goods (height,
weight, width and length). Obey all the Walk around and inspect the machine to
wide goods regulations on goods ensure safe operation.
management. Ensure that all required permits and
approvals are obtained according to local
regulations.
When the machine is moved to a cooler
area, ensure that its cooling system has Drive at a moderate speed. Obey various
adequate antifreeze. speed limits regulation while traveling on
public roads.
1) Hold the trailer wheel or train wheel
before loading the machine. Do not operate the machine when the
door is open at high speed.
2) After the machine is fixed, connect
the lock connecting rod. This will
secure the front and rear frames. Lifting and fixing of machine
Connect the front wheel tilt lock bolt.
This will keep the front wheel in a
vertical position.
3) Lower down the blade on the floor Warning
and move the gearbox operation
In case of incorrect lifting and binding and
switch to the neutral position.
improper equipment may misalign the
4) Engage the parking brake. machine during transport. When
transporting, make sure to use proper
5) Shut down the engine. procedures and proper equipment for lifting
and tying. If the machine is misaligned, may
6) Turn the starting switch to the OFF cause damage and serious injuries.
position. Remove the start key
switch
7) Switch the battery cut-off switch to
the OFF position. Remove the key of
the cut-off switch.
8) Lock the door and repair cover.
Install all anti-damage protection
facilities.
9) Fasten the machine with a fastening
rope.
Walk around the machine and check
liquid level in various boxes.
Drive at a moderate speed. Obey various
speed limits regulation while traveling on
public roads.
Fig.4-22
Note:
40
Incorrect lifting and tying may lead to 1) Engage the parking brake before
weight imbalance, causing personal using the lifting equipment and
injury and loss. fastening the machine.
The listed transport weight of the 2) Before lifting the machine, mount the
machine is indicating the most common frame lock pin first.
standard weight. If the machine has an
attachment, the weight of the machine 3) Tie 2 ropes in front of the machine.
and the center of gravity of the machine There is a ring on both sides of the
will change. Please refer to the operation machine. A mark showing a hook for
and maintenance manual for the machine identification of lifting ring.
mass. 4) Attach two ropes to the rear of the
machine. There is a ring on both
sides of the machine. A mark
showing a hook for identification of
Lifting points --- when lifting ring.
lifting machine, the lifting device
must beattached to the lifting point. 5) Attach 4 hanging ropes to the
hanger. The hanger must be in the
center of the machine.
Tie-down point- when
fixing a machine, the rigging must be 6) If there are tooling, it must be fixed.
fastened to the tie-down points. 7) lift the machine. Drive the machine
to where it needs to be.
Lifting machine 8) Fix the machine at the fastening
point. The fastening points on the
machine are marked with symbols.
Tie machine
Tie the machine with steel ropes and
sling bolts of appropriate ratings.
1) Fix the machine on the trailer.
2) Install the lock pin.
Fig.4-23
3) Engage the parking brake.
4) Llower the blade to the floor of the
transport machine. Drop all the
attachments on the floor of the
transport machine.
5) Turn the engine starting switch to the
OFF position.
Fig.4-24 6) Switch the battery cut-off switch to

the OFF position.
Use proper wire rope and sling to lift the
machine. 7) Tie a steel rope to the front of the
machine.
Place cranes or lift equipment to lift the
machine horizontally. 8) Connect the chain at the rear part of
the machine.
The width must be sufficient to avoid the
mechanical abrasion by the hoisting rope 9) If necessary, additional tie down
or sling. points can be added.
41
10) Block the wheels with a wedge Before lifting the rear part of the machine,
block. check the following conditions:
11) Comply with all regulations on the  The gearbox is located in the
loading of goods (height, weight, parking brake position.
width and length) and comply with all  Wheel tilt locking bolts are
the governing regulations for wide installed on the front axle.
goods.  The frame lock pin has been
installed.
 Front tires are wedged.
 The specification of the jack is
4.7 JackingPosition sufficient to support the mass of
Description the machine.
Position of jack lifting
Warning
Improper top lift and cushion

placement are not correct, and may cause
casualties.
When lifting a machine with a jack,

keep away from it. The jack shall have the
correct rated capacity required for the Fig.4-26
jacking machine and must place the pad
or support frame before any work is done It is used to hold therear of the machine
on the machine. at the bottom of the rear axle.
The front part of the machine

4.8 Towing Guidelines
Before lifting the front part of the
machine, check the following conditions: Towing machine
 The gearbox is located in the

parking brake position.
 Wheel tilt locking bolts are Warning
installed on the front axle. Incorrect towing of untraveling machinery
 The frame lock pin has been can cause casualties.
installed.
Before loosening the brake, block the
 Rear tires are wedged. machine with wedge to prevent movement.
 The specification of the jack is If not, the machine may roll freely.
sufficient to support the mass of
the machine.
To do the right towing procedures, follow
these suggestions.
The machine is equipped with spring joint
and oil pressure released brake. If the
engine or pressure system does not
work, the brake is engaged. The machine
cannot move.
Fig.4-25 This traction specification is applicable to
a short distance from a moving machine
It is used to hold the front of the machine
at low speed. The speed of the machine
at the bottom of the front axle.
cannot exceed 2 km/h (1.2 MPH). Move
The rear part of the machine the machine to a convenient place for
repairs. The following guidelines are for
42
emergency purposes only. Must transport information about the towing of the
the machine for long distance moving. unmoving machine.
The machine must be equipped with a
protective plate to avoid breaking of a Running engine
rope or towbar hurting the driver in the
process. If the engine is still running, you can tow
the machine for short distances under
No operator is allowed to stay on the certain conditions. Power transmission
towed machine unless the operator can and steering systems must be able to
operate the steering and/or braking. work. Tow the machine only in short
distance. For example, drag the machine
Check the condition of the towing rope or out of the mud, or pull the machine to the
the tow bar before towing operation. curb.
Make sure the rope or bar strong enough
for a machine that cannot move. The The driver on the tow machine must drive
strength of a tow rope or drag bar shall along the towing rope.
not be less than 1.5 times the total mass
of the towed machine. Drag out a
machine that stuck in the mud with such Engine failure
rope or a drag bar. In addition, use the
towing rope or drag bar to tow the Before you drag the machine, you must
machine upslope. do the following points:
The tow rope should be kept to a 1) If the fault is suspected to be caused
minimum angle. And the front position by the internal gearbox or the driving
shall not exceed 30°. system, remove the axle shaft.
The sudden motion of the machine will 2) Release the parking brake, use the
overload the tow cable or the draw bar. manual pump to connect the disc
The rapid movement of the machine can brake, and set the pump pressure to
break a traction rope or draw bar. The be 150 bar, which will release the
machine can be better towed when it brake completely.
moves slowly and smoothly.
3) Tighten the pull rod.
Normally, a traction machine should be
the same size as the towed machine. 4) Remove the wedge under the wheel.
The towed machine must have enough Tow the machine slowly the speed of
braking capacity, enough weight and the machine cannot exceed 2 km/h.
enough power to cope with the incline
and drag distance during towing.
Machines that can’t move may need to
4.9 Engine Starting with
towed by larger or multi machine. The Jumper StartingCable
larger machine can provide adequate
control and enough braking for the
downhill of an unmoving machine. Larger Warning
Do not use “hot line” connections or short
machines can prevent the unmoving connection posts. A short connection
machine from running out of control. between the starter terminal post may
bypass the engine neutral starting system,
Different situations have different needs. damage the electrical system, and cause an
In flat ground, the traction machine with unexpected movement of the machine. This
smaller capacity is required. A larger can result in personal injuries.
towing machine is required for slope or No proper maintenance of the battery can
poor ground conditions. cause personal injury.
Prevent spark generated from the battery. A
If the machine has a load on it, its spark can cause a gas explosion. Do not
braking system must be operated in the allow the ends of the jumper cables to
contact each other or contact with the
cab. machine.
Please consult XCMG or agent for more Electrolyte is an acid that causes bodily
43
harm if it contacts the skin or eyes. 1) For the machine that flames out,
When starting the machine with a jumper place the gearbox control switch in
cable, you must wear goggles.
the neutral position. On the stalling
Incorrect jumper cable connections can
cause an explosion that can cause personal machine, the parking brake is closely
injury. engaged. Lower the equipment
When using a jumper cable, be sure to down to the ground.
connect the positive pole (+) of jumper cable 2) 2Switch the engine starting
to the positive terminal (+) of the battery. switch to the OFF position on the
Next, connect the negative pole (1) to the
stalling machine. Turn off all
frame away from the battery. Follow the
operation procedures in the operation and attachments.
maintenance manual. 3) Switch the battery break switch
You can only use the power supply with to the ON position on the stalling
same voltage as the stopped machine to machine.
jump start. 4) Drive the machine that is used
Shut off all lights and electricity on the
machine. Otherwise, they will run when the
as a power supply next to the stalling
power is connected. machine, so that the cable can reach
the stalling machine. Never allow
two machines touch each other.
5) Shut down the engine of the
Note: machine used as a power supply. If
the auxiliary power source is used,
Ensure that the machine used as a turn off the charging system.
power supply does not touch the stopped 6) Make sure that the batteries on
machine which can prevent damage to both machines are properly placed
engine bearings and circuits. and well covered. Ensure that the
battery on the machine is not frozen.
7) The positive pole of the cross-
Turn off the shutdown switch on the wire starting cable is red. Connect a
power supply. This helps to avoid positive electrode of the jumper
damage to electrical parts on the cable to the anode cable terminal of
machine. the discharged battery. Some
machines use storage batteries.
The machine is a 24 volt start-up system.
8) Connect the other positive
Jump starting only allows the same
electrode of the jumper cable to the
voltage to be used. Using higher voltage
positive cable terminal of the power
can damage electrical systems.
supply.
The overdischarged maintenance-free 9) Connect a negative pole of the
battery, after jump connecting the cable connected starting cable to the
from other machines, can only be negative terminal of the power
charged by ac alternator and cannot be supply.
charged fully. These batteries must be 10) Finally, connect the other
charged to the appropriate voltage with a negative pole of the jump starting
battery charger. Many of the batteries cable to the frame of the stopped
that have been considered unusable can machine. Do not connect the jumper
be recharged. cable to the battery terminal. It is
prohibited to contact the jump
When starting the stalling machine with a starting cable with battery cable, fuel
cross-connect starting cable or auxiliary line, hydraulic line or any moving
power supply, do not engage the positive parts.
pole on the alternator B terminal. 11) Start the engine of the machine
Otherwise, the ac alternator could be that acts as a power supply, or
damaged. Be sure to connect the cable power the charging system of the
to the corresponding battery terminal. auxiliary power source.
12) Wait at least two minutes before
In the absence of an auxiliary starting
attempting to start the stopped
socket, the following procedure shall be
machine. This will allow the battery
performed:
on the stopped machine to recharge
44
partially. The maximum load of the tire should be

13) Try to start the stopped engine. used. The maximum load of the tire
14) Disconnect the starting cable in should consider the attachment. The
reverse order immediately after the pneumatic pressure of the tire shown is
engine is started. the cold air pressure during
transportation.
Level or strength Shipment
Size
index pressure kPa
14.00-
12 260
24
Tire Inflation pressure - adjustment

5 Maintenance
Must obtain correct tire pressure and
5.1 Tire Inflation maintenance advice from the tire
supplier. Driving the machine from the 18
Tires Inflated with Nitrogen ℃ to 21 ℃ warm workshop to the
It is recommended that the tire be filled freezing temperature, tire pressure will
with dry nitrogen and add pressure to change significantly. The tire pressure is
adjust the tire. This includes all the correct in the warm workshop, but will be
machines with tires. Nitrogen is an inert less in the freezing temperature.
gas that does not burn in the tires. Insufficient inflation will shorten the life of
the tire.
It has many other benefits besides
reducing the risk of an explosion. The
tyre is inflated with nitrogen to slow the
oxidation of rubber. The use of nitrogen
5.2 Lubricant Viscosity and
can also slow down the gradual Filling Capacity
deterioration of tires. This is more
Lubricant viscosity
important for a tyre that is expected to
have more than four years and longer Select viscosity
service life. Nitrogen can reduce rust of
wheel rim parts. Nitrogen also reduces To select the correct oil for each
the problem of disassembly. compartment, please refer to the table of
“lubricant viscosity at ambient
temperature”. Please select the oil type
and oil viscosity for the specific
compartment at the appropriate ambient
Warning
temperature.
Proper nitrogen inflation equipment and
equipment training are needed to prevent The appropriate lubricant viscosity level
overinflation. The failure of the tire and the depends on the minimum ambient
damage of the ring may be caused by temperature of the starting machine. The
incorrect use of the equipment, which can degree of lubricant viscosity is also
cause injury or death. dependent on the highest ambient
A broken tire or damage may result in temperature during the operation of the
injuries. machine. When cold starting machines
and cold machines are operated, the
required lubricant viscosity grade should
be determined according to the data
Tire pressure during transportation indicated in the list as “lowest”. When
operating the machine at the highest
The pressures of each application may expected temperature, use the “highest”
differ from the pressure shown. The column specified in the table to select the
pressure value should always be lubricant viscosity level. When starting
obtained from the tire supplier. the machine, use the maximum lubricant
viscosity under temperature.
45
When the machine works continuously, maximum oil film thickness.

high viscosity oil should be used in the
final drive and differential to maintain the
Table 3
Lubricant viscosity at different ambient temperatures
Ambient
Application part Oil type and performance Viscosity temperature
Min. Max.
API CH-4 engine oil SAE 15W/40 -15 50
Engine
API CH-4 engine oil SAE 5W/30 -35 40
Transmission box CH-4/SH SAE 15W-40 -15 40
L-HV46 hydraulic oil SAE 10W -15 50

Hydraulic system
L-HS46 hydraulic oil SAE 0W/20 -40 40
Main reducer of rear axle GL-5 Gear oil SAE 85W/90 -15 50
Brake GL-5 Gear oil SAE 75W/90 -35 40
Balance box GL-5 Gear oil SAE 85W/90 -15 50
Turbine box GL-5 Gear oil SAE 75W/90 -35 40
Lubrication parts such as
articulated bearing, pin,
GB7323 EP
cylinder seat, sleeves, 2# -20 50
lithium lubricating grease
bearing, spline, transmission
shaft etc.
Automatic lubrication GB7323 EP
2# -20 50
system lithium lubricating grease
Coolingfluid  increase corrosion.

 increase sediment.
Preferred to use GB2974 standard  reduce fuel economy.
stipulated HEC - Ⅱ - 20 coolant; In  shorten the time interval
cold area shall use the HEC - Ⅱ - 45 between oil change cycles (more
coolant in accordance with GB2974 frequent oil change intervals).
standard.  • increase overall operating
costs.
 • negative impact on engine
Caution: use only water as a coolant. emissions.
Only using water can cause corrosion
in the engine’s working temperature. The fault caused by using the wrong
In addition, it cannot provide sufficient fuel is not the responsibility of XCMG.
anti-boiling and anti-freeze protection. Capacity
Table 4
Diesel advice Application Capacity Filling Mark
part (L)
It is necessary to meet the technical Engine 24 Oil dipstick
parameters specified in GB19147- Transmissio 38 Oil dipstick
2013 to ensure the longest engine life n box
and the best engine performance. Hydraulic 190 Liquidometer
system
Mistakenly adding diesel with high
sulphur content will result in the Main 36 Oil level
following negative effects: reducer of screw
rear axle
 reduce engine efficiency and 30*2 Oil level
Balance box
durability. screw
 increase wear and tear. Turbine box 8 Oil dipstick
46
Cooling 50 Charging
system mouth
Fuel tank 380 Fuel meter
Note:
Observe the liquid level indicator to
ensure the injection system and/or
parts to the correct level.
Centralized lubrication system

operation（If equipped）
1） Ensure that the oil in the pump is

clean, and if the oil is not clean,
the electromagnetic valve is
blocked, the system cannot be
used normally and the service life
is badly influenced.
2） The observation pointer is used to
judge the action of the lubricator,
and adjust the oil volume. Through
the top plastic cover of the
lubricator, rotate the nut for
adjustment.
3） This lubrication system adopts
single line is centralized
lubrication system, driven by
electric pump, each lubricator
corresponds to a lubrication
points, controlled by PC,
according to the required number
the control the lubricating times,
interval, and also can set the
forced start button.
5.3 Maintenance Channel

Engine doors and covers
Fig.5-1
Open hood (1) to check the following

items:
 Related piping
47
 Engine supercharger Before unloading the machine and its oil

line, the machine must be put on the
 Scavenge filter of hydraulic tank ground first to allow the oil to cool before
work. The filler cap can only be removed
 Hydraulic pump when the engine is shut down, and the
filler cap is cooled enough that can be
 Fan touched by bare hand.
Open the access door (2) to check the

following items: Brake circuit
 Hydraulic oil tank To release the pressure on the brake
 Filter circuit, shut down the machine. Press
 Related piping the brake pedal repeatedly until the
 Battery main switch brake circuit pressure is released. Do
 Suction filter of hydraulic tank not assume that the pressure of the
 Silencer circuit will be released if the brake
pedal has no resistance. Pressure
5.4 Maintenance Services must be released when any part of the
brake circuit is checked.
Release system pressure
Steering circuit
cooling system
To release the pressure on the
steering circuit, shut down the
Warning machine. The steering valve has
Pressurized systems: Hot coolant can enough leakage to allow the oil to
cause severe scalding. Shall stop the return to the tank. Please wait ten
machine and wait for the radiator to cool minutes before turning on the steering
down, then open the cover. Then loosen system. This will allow all remaining
the cover slowly and release the
pressure to drain into the tank.
pressure.
Working devices circuit

Shut down the machine to release the
pressure of cooling system. The In order to release the pressure of the
cooling system pressure cap is working device circuit, lower the
cooled. Slowly remove the cooling working device to the ground, and the
system pressure cap to release the lifting lever of the left and right blade
pressure. will be pushed to the front end, and
then it will enter the floating position
and the blade will be in a floating
Fuel system
state.
To release fuel system pressure, shut
When the engine cannot start, the
down the machine.
blade floating can not work normally to
do the following operation.
Hydraulic system
Warning
Hot oil or hydraulic oil pressure can

cause injuries.
Fig.5-3
After shut down the engine, the pressure
of the hydraulic fluid will remain in the
hydraulic system. Prior to the
maintenance of the hydraulic system, it
can cause serious injury if the pressure
is not released beforehand.
48
2 ） Turn the battery cut-off switch to

the OFF position.
If there is no battery cut-off switch,
please remove the cathode cable of
the battery.
Note:
Do not use the electrical parts (ECM
electronic control module or electronic
Fig.5-4
control module sensor) or the ground
1) Screw the nut (1), (2) of the left point of the electronic parts for the
multi-way valve and the nut (3) and (4) welding machine.
right multi-way valve respectively and
slowly loosen until the blade falls to 3）Disconnect the main power switch
the ground. and the wiring harness connector on
the gearbox computer control box
2) Twist the nut (5) and (6) of the left (located in the lower right side of the
multi-way valve respectively, and cab), disconnect the wiring harness
slowly loosen it until the rear ripper connector on the engine ECU (on the
falls to the ground. rear hood at the right side of the door),
disconnect the control box wiring
3) Twist the nut (7) and (8) of the right harness connector (located in left side
multi-way valve respectively, and of the seat), in order to prevent the
gradually loosen it until the former control panel from burning out by the
bulldozer falls to the ground. current impact; After repair, must
restore the computer control panel
wire harness according to the
Engine oil system requirement, or the machine will not
start and drive.
To release the engine oil system
pressure, shut down the machine. 4) Fix the parts to be welded with the
grounding cable clamp of the welding
machine. Clip the clamp near the
Welding on machine welding point as much as possible.
Ensure that the grounding cable to the
Do not weld on any protective part of the circuit does not pass any
structure. Please contact your XCMG bearing. Using this program can
agent if you need to maintain the reduce the possibility of damage to
protection structure. the following parts:
Welding procedure must be correct in  transmission bearing
case of damage to electronic control
and bearing. If possible, remove the  hydraulic components
welding parts from the machine or  electrical components
engine before welding. If you must
weld near the electronic control device  other parts of the machine
of a machine or engine, remove the
electronic control device temporarily to 5) Avoid the debris and splashes from
prevent damage from heat. spattering into any wire harness and
parts.
The following steps should be
followed to weld a machine or engine 6) Weld the materials together
equipped with an electronic control referring to standard welding
device. procedure.
1 ） Shut down the engine. Turn the

engine start switch to the OFF
position.
49
5.5 Maintenance Interval Regular maintenance is divided into:

10, 100, 250, 500, 1 000, 2 000, 4
Ensure that all safety information, 000, 6 000, 12 000 hours
warnings and instructions are read
and understood before any operation
and maintenance is performed. Every 10 operating hours or every
The user is responsible for the Day
maintenance behavior. All  Reverse alarm ---- test
adjustments, proper use of lubricating  Brake, indicator light and
oil, oil liquid, filter and replace wear instrument---- test
and aging parts.  Rotary disc drive small gear
Failure to comply with correct periodic tooth ----lubrication
maintenance cycles and procedures  Liquid level of cooling system
can result in reduced product for cooling system -----check
performance or accelerated  Engine oil level ----check
component wear.  Oil and water separator in
fuel system ----- drainage
Make sure the interval is maintained  Seat belt ----check
according to mileage, fuel  Transmission and differential
consumption, hours of work or oil level - check
calendar time (whichever comes first).
Products that work under harsh
conditions may require more frequent First 100 operating hours
maintenance.  Gearbox oil - change
All maintenance of the previous cycle  Gearbox filter - replacement
must be performed before  Engine oil - change
maintenance of each subsequent  Oil filter - replacement
cycle.  Fuel filter – replacement
 Rear axle housing oil -
change
 Balance box oil - change
Maintenance if necessary  Rear axle braking oil –
 Detection/adjustment/ change
replacement
 Clearance of ball head and Every 100 operating hours
support clearance of traction
frame - detection/adjustment  Frame articulated bearing -
 Blade - check/replacement lubrication
 Scarifier teeth - check/replace  Front axle bearing -
 Engine air filter element - lubrication
detection/replacement  Bearing of working device -
 Engine belt replacement lubrication
 Fuel system - refueling  Ball rolling disc - lubrication
 Worm gearbox oil level check  Swing frame -lubrication
 Brake accumulator - check  Swing bolt - lubrication
 Reversing camera - adjustment  Scarifier bearing - lubrication
 Fuse - replacement  Rear axle bearing -
lubrication
 Blade lifting cylinder ball
hinge clearance - lubrication
Regular inspection and  Clearance of the ball hinge of
maintenance the tilting oil cylinder of the
Proper lubrication and maintenance traction frame - lubrication
can ensure the trouble-free operation  Clearance of ball head and
and long service life of the machine. support clearance of traction
frame - lubrication
50
 Pressurized air filter in cab -  Balance box lubrication oil-

cleaning/replacement sampling
 Water and sediment in the  Transmission box lubrication
fuel tank - discharging oil - sampling
 Hydraulic oil level - check  Gearbox filter - replacement
 Rear axle oil level - check  Worm tank oil sample -
 Balance tank oil level - check sampling
 Engine oil consumption -
check
 Tire inflating volume - Every 1000 operating hours or
detection Every Six Months
 Belt - check  Gearbox oil - replacement
 Front dozer bearing -  Gearbox filter - replacement
lubrication  Brake accumulator - detect
 External air filter -  ROPS - check
clean/replace  Rear axle housing oil -
First 250 operating hours change
 Balance box oil - change
Engine valve clearance - inspection  Rear axle braking oil –
change
Every 250operating hours
 Engine oil - change Every 2000 operating hours or
 Oil filter - replacement every year
 Fuel filter - replacement
 Coolant filter - replacement  Engine valve clearance -
 Cooling liquid sample - inspection
sampling  Hydraulic oil - replacement
 Air filter element -
cleaning/replacement
 Filter element in the air Every 2000 operating hours or
conditioner – every two years
cleaning/replacement  Battery or battery cable -
Fisrt 500 operating hours check/replace
 Lubricating oil of worm case -
 Battery or battery cable - replacement
check/replace  Condenser - cleaning
 Injection pump - check/adjust  Cooler pressure cap -
 Cooling liquid sample - clean/replace
sampling  Crankshaft shock absorber -
check
 Injection pump - check/adjust
Every 500 operating hours or  Engine camshaft - check
Quarterly  Evaporator - cleaning
 Braking system - test  Cooler - clean
 Engine oil sample - sampling  Rear axle housing - oil
 Engine stop - switch on/off replace
 Fuel system - refueling  Balance box - oil replace
 Fuel tank cover - cleaning
 Hydraulic system oil sample - Yearly maintenance
sampling
 Replacement of hydraulic oil  Cooling liquid sample -
filter - replacement sampling
 Rear axle vent valve -  Air filter element -
cleaning/replacement cleaning/replacement
 Balance box vent valve -  External air filter -
cleaning/replacement clean/replace
51
Every 3 years
 Seat belt - check
Every 4000 working hours

 Steering system pipeline -
check/replacement
Every 4000 operating hours or

every two years
 Hydraulic oil - replacement
Fig.5-5
every 3 years Lubricate the upper articulating
bearing by adding a proper amount of
 Cooling fluid - add
lubricating oil through the nozzle (1).
Lubricate the bottom articulating
bearing by adding a proper amount of
every 6 years
lubricating oil through the nozzle (2).
 Cooling fluid - replacement
Note:
according to the use environment of Front axle swing bearing -
the machine, such as high lubrication
temperature, high humidity, low
temperature, multi-dust, high altitude,
etc., make appropriate adjustments to
the time and content of regular
inspection and maintenance. You can
consult XCMG or its agent.
5.6 Maintenance Operation

Frame articulated bearing -
lubrication
Fig.5-6
Note:
The nozzle is located in the middle of
Wipe the oil mouth before adding oil to the front axle shaft.
the oil nozzle.
Wipe the oil mouth before adding oil to
the oil nozzle.
Lubricate the swing bearing of the
front axle by adding a proper amount
of lubricating oil through the nozzle.
52
Front wheel main pin bearing - Lubricate the front wheel hub bearing
lubrication of the machine by adding a proper
amount of lubricating oil through the
nozzle.
Front tilting rod bearing -
lubrication
Fig.5-7
Note: The front wheel main pin

bearings are symmetrical, with a total
of 6 lubrication points.
Fig.5-9
Lubricate the upper main pin bearing
on left side of the machine by adding Note: the front wheel hub bearings
a proper amount of lubricating oil are symmetrical, with a total of 2
through the nozzle (1). lubrication points.
Lubricate the tilt joint bearing of the Lubricate the front tilt rod bearing of
right side of the machine by adding a the machine by adding a proper
proper amount of lubricating oil amount of lubricating oil through the
through the nozzle (2). nozzle.
Lubricate the upper main pin bearing
on right side of the machine by adding
a proper amount of lubricating oil Front tilt cylinder bearing -
through the nozzle (3). lubrication
Front axle hub bearing - lubrication
Fig.5-10
Note: the front wheel cylinder

bearings have 2 lubrication points.
Fig.5-8
Lubricate the front wheel tilt cylinder
Note: the front wheel hub bearings bearing of the machine by adding a
are symmetrical, with a total of 2 proper amount of lubricating oil
lubrication points. through the nozzle(1)、(2).
53
Lifting cylinder ball hinge seat – Ball hinge seat of the tilting oil
lubrication cylinder - lubrication
Lubricate the lift cylinder ball hinge
seat by adding a proper amount of
lubricating oil through the nozzle(1) of
traction frame tilt cylinder.
Steering hydraulic cylinder end and

pull rod - lubrication
Fig.5-11
There are 2 shovel lift oil cylinder,

each blade lifting cylinder ball hinge
Fig.5-13
seat has 3 oil nozzles. Add a proper
amount of lubricating oil to the nozzle Lubricate the steering cylinder ball
(1) to lubricate the ball hinge of the oil hinge seat by adding a proper amount
cylinder, add a proper amount of of lubricating oil to the nozzle of
lubricating oil to the oil nozzle (2)(3), steering cylinder ball hinge seat.
and lubricate the installation seat of
the oil cylinder.
Steering track rod- lubrication
Tilt oil cylinder ball hinge seat -

detection/adjustment/replacement
Lubricate the swing cylinder ball hinge
seat by adding a proper amount of
lubricating oil through the nozzle(1) (2)
of traction frame swing cylinder.
Fig.5-14
Each steering track rod has 2 oil

nozzles. Add a proper amount of
lubricating oil to each nozzle to
lubricate the steering track rod.
Fig.5-12
54
Swing frame - lubrication Rotary drive pinion gear -

lubrication
Fig.5-15
Fig.5-17
The swing frame is symmetrical, with
a total of 6 lubrication points. 1) Remove the dirt and debris from
the pinion gear wheel teeth (1) and
Lubricate the swing frame sleeve by
the blade rotary disk (2).
applying a proper amount of
lubricating oil to the nozzle （ 1 ） 2) Apply proper amount of lubricant to
（2）（3）. pinion gear wheel teeth (1) and the
blade rotary disk (2).
Center misalignment lock
lever - cleaning/lubrication
Ball rotary disc - lubrication
Fig.5-16
The center misalignment locking lever

(1) is located below the front frame Fig.5-18
and above the turning circle.
1) Place the machine on a flat surface
1) Clean the debris, oil stains and rust and engage the parking brake.
points in the locking hole in the center
Park the shovel blade on the ground.
misalignment lock rod.
2) Apply proper amount of lubricant to
2) Add lubricating oil to the hole of
the ball rolling disc (1).
center misalignment lock rod.
There are 5 lubricating points of ball
rotary disc.
Pull rod ball head and support -

lubrication
Wipe the nozzle clean before
lubrication.
55
tractor backward or move the

machine forward.
Fig.5-19
The nozzle of the traction frame ball

head and socket is in the front of the
machine.
Add a proper amount of lubricating oil Fig.5-21
through the nozzle to lubricate the ball 3) Remove the screw (3) for fixing
head and socket. the traction frame and joint from
cover (2).
4) Remove the gasket (5) or install
Pulling rod ball hinge seat - the gasket (5) to keep the axial
detection/adjustment clearance at 0.6 士 0.2mm.
5) Install the cover (2) on the

Inspection
support seat. Rotate the cover (2)
1) Turn the blade and make the blade by hand. Cover (2) shall rotate
at a position of 90-degree with the freely on the traction frame ball
frame. Lower the blade down to the (4).
ground.
2) When the load of the drag bar ball 6) Check the torque used to hold the
and ball socket is still very light, move ball (4) to the anchor bolt (6). The
the machine backward slowly. Stop correct torque is 900 士 100Nm.
the machine and turn off the engine.
7) Put the pull rod on the frame
3) Measure the axial gap between the beam. Tighten the bolt (3) to the
ball (4) and the cover (3). The
torque of 1800 士 200 Nm.
clearance should be 0.6 士 0.2 mm.
Adjust clearance when needed.
Blade plate and side edge -
check/replace
Fig.5-20
Adjustment
1) Support the pull rod and the Fig.5-22
rotary disc with bearing. Side edges (1) and/or blade plate (2)
2) Remove the bolt(3) for the fixed may be damaged. The side edge
hitch frame and beam. Move the and/or blade plate may be severely
56
worn out. Replace the side edge 7) Stop the engine.

and/or blade plate when needed.
8) Tighten the adjusting bolt (1) to
1) Place a wooden block under
make the minimum clearance
the blade. Put the blade on the
between the blade rail and the anti-
block. Don’t set the blade too
wear pad 0.13mm to 0.90mm.
high. The block used is just
enough to remove the blade edge 9) Tighten the fixed nut on the
and blade plate. adjusting bolt.
2) Remove the side edge and/or
10) Install the top plate.
blade plate.
3) Install the edge and/or blade.
4) Lift the blade and remove the Angle device - lubrication
block.
Wipe the nozzle clean before
lubrication.
Anti-wear belt -
check/adjust/replace
Fig.5-24
Fig.5-23
There are two angle devices, each
has three oil nozzles.
1) Start the engine
Add a proper amount of lubricating oil
2) Turn the blade. Place the shovel in through the nozzle to lubricate the
a position with 90-degree with the angle device.
frame. Reduce the blade to 10 mm
from the ground. Engage the parking
brake. Stop the engine. Belt - check
3) Remove the top fixed plate (2) and
bottom plate (3). Visual check the
condition of anti-wear pad. If the anti-
wear pad is close to the shovel-wall,
replace the anti-wear pad.
4) Install the fixed plate.
5) Start the engine and lift up the
blade.
6) Make the blade move through
lateral stroke. Measure the clearance
between the shovel blade and the Fig.5-25
anti-wear pad. This makes it easier to
1) Make the engine stop.
find the smallest gap.
57
2) turn over hood. precharge pressure of nitrogen in the

accumulator (2) .
3) Check the condition of the belt.
Note: only dry nitrogen can be filled in
4) If there is one of the following the brake accumulator.
situations, the belt should be replaced.
Brake indicator and instrument - test
Excessive crack
Insert display chart
Excessive wear
Excessive damage
Braking indicator lights- test
5) Install the front cover (1) of the
hood. 1) Check for broken glass surfaces,
broken indicator lights or damaged
switches, etc.
Belt - adjustment and replacement 2) Start the engine idling until all the
Please refer to the belt adjustment instruments are in stable condition.
and replacement part of the engine 3) Look for instruments that don’t
operation and maintenance manual. work.
Brake accumulator - check 4) Turn on all the lights on the
machine. Check for normal work.
5) Sound the horn.
6) Move the machine forward and test
the driving brake. If the driving brake
does not function properly, refer to the
operating and maintenance manual -
brake system - test.
7) Shut down the engine.
8) Please make all necessary repairs
before operating the machine.
Fig.5-26
1) Turn the engine starting switch key

Braking system - test
to the connecting position.
Service brake force test
2) Brake pressure alarm light (1) on
display is about to be lightened. Make sure there are no people and
obstacles around the machine.
3) Start the engine and make it idle for
1 minute to increase the pressure of Test the service brake on dry and flat
the accumulator. Brake pressure ground.
alarm light (1) is about to goes off.
Shut down the engine. Note: 50m area is required for this
test. Fasten the safety seat belts
4) Step down and release the brake before testing the brake.
pedal to reduce the pressure of the
accumulator. Step down and release Use the following tests to identify the
the brake pedal at least 5 times until performance of the service brake. This
the brake pressure alarm indicator test is not to measure the maximum
light (1) is lightened. braking force of the brake.
5) If step the brake pedals down under 1) Start the engine Lift the blade
5 times, the brake pressure alarm slightly up. Step down the brake pedal
indicator (1) is on, then measure the to apply the service brake. Remove
the parking brake.
58
2) Place the gearbox in the third life. To prevent performance

forward gear position. degradation, clean air filter cartridges
according to needs.
3) Increase the engine speed to 1800
RPM, keep for 15 seconds. The
machine should not move.
4) Reduce engine speed to low idle
speed and engage the parking brake.
Lower the blade down to the ground.
The gearbox is placed in a neutral
position for two minutes to cool the
torque converter and gearbox oil. Stop
the engine.
Parking brake - braking force test
Fig.5-27
Warning
In the test, if the machine is still moving,
may cause an accident. Clean the filter
In the test, if the machine starts to move, The cab air filter is located in the lower
slow down the engine immediately and part of the right side of the cab.
close the parking brake control.
Clean filter
Note: in the case of dust environment,
Note: if the parking brake is tested, the air filter in the cab needs to be
the machine can still move, Must cleaned more oftenly.
repair the parking brake before the
machine engaged into work. 1) Disassemble the cover of the filter
Make sure there are no people and element of the air filter in the cab.
obstacles around the machine. 2) Remove the filter element (2).
Test a parking brake on a dry, hard
surface. 3) Clean the filter element with
compressed air.
Fasten your seat belts before you test
the parking brake. 4) Install filter element and install
Use the following procedures to filter cover.
identify the performance of the parking
brake. This test is not to measure the
maximum braking force of the parking Replace the filter
brake. Note: change the cab air filter
1) Place the machine on a slope of according to the requirement.
20% grade.
1) Disassemble the cover of the filter
2) Engage the parking brake. Loosen element of the air filter in the cab.
the parking brake pedal. The wheel
should not turn. If the wheel turns, 2) Remove the filter element (2).
step on the parking brake control
pedal. 3) Properly discard filter element of
filter.
4) Install the new filter element.
Cab air filter - cleaning/replacement
5) Install filter cover.
Note: the air recirculating filter
cartridge filter is blocked by dust, Lubricating oil of worm case –
which will reduce the performance of replacement
air conditioner or cab heating
equipment and shorten the service
59
Warning the oil level of the turbine tank. Keep

Hot oil and hot parts can cause injuries. the oil level in the middle of the oil
Do not allow hot hydraulic oil or hot parts window (3).
to contact with skin.
7) Install the plug.
Note:When testing, maintaining,

testing, adjusting and maintaining the Lubricating oil of worm case - level
engine, please be careful to ensure check
that the liquid is filled in the container.
Before opening or dismantling any of If there may be a leakage, check the
the components that have liquid, be oil level. Keep the oil level in the
prepared to collect the liquid. middle of the oil window (2).
Dispose of all liquids according to Condenser - cleaning

local laws and regulations.
Note:If the condenser is dirty, clean it
with a brush. In order to prevent the
condenser from damaging or bending,
the hard brush must not be used. If
the condenser radiator is defective,
repair it. Before cleaning the
condenser, the machine must meet
the following conditions:
The battery cut-off switch must be
located in the OFF position;
Fig.5-28
The interlock pin must be installed in
the position of LOCK.
Fig.5-29
Note: before removing the screw,

clean the area around each discharge
screw, and then clean the area around
each check/plug. Fig.5-30
1) Remove the discharge screw (l). The condenser is in front of the

Remove the plug (2). Drain the oil radiator.
into the proper container. 1) open the door on both sides of the
2) Clean and install the drain plug. hood.
3) Fill the turbine tank. 2) check for debris on the condenser.

Clean the condenser when necessary.
4) Clean and install the plug.
3) wash away all dust and dirt in the
5) Start the engine and run the condenser with clean water.
machine for several minutes to check
if the turbine tank leaks oil. Note: you may need to add additives
with oil removal function. Additives
6) Shut down the engine and check must not contain ammonia.
60
4) Close the door of the hood.
Cooling system coolant -

check/replace
Warning
Hot coolant, steam and alkali can cause
personal injury.
In the working temperature, the engine
coolant is hot and under pressure. The
radiator and all piping or engines have Fig.5-33
hot coolant or steam inside. Any contact
with them can cause severe burns. 1)The engine stops and cools down.
Only when the engine stops and the 2) Open the door(1) of the hood.
cooling system pressure cover is cooled
enough to be touched by hand, slowly 3) Remove all dust or debris from the
remove the cooling system pressure cap
surrounding area of the pressure cap
to release the pressure. Do not try to
touch the hose connector when the (2) of the cooling system. Cleaning
coolant is still hot. The hose will fall off must be done before the cooling
and cause burns. system pressure cap can be removed.
4) gently lift the pressure cap of the
cooling system to release internal
pressure.
5) open the drain valve (3). The drain
valve is located on the water pipe
below the rear right side of the
machine. Drain the coolant into the
proper container.
6) Flush the cooling system with clean
water until the drainage is clear.
Fig.5-31
7) Close the drain valve.
8) Add the coolant.
9) Install cooling system pressure cap.
10) Start the engine and make it run
for 2 minutes, stop the engine.
11) Open the cooling system pressure
cap.
12) Check the radiator liquid level and
add enough liquid.
Fig.5-32 13) Check whether the radiator leaks.

14) Install cooling system pressure
cap.
61
Cooling system pressure cap - to restore the initial condition. The

cleaning/replacement alarm is located on the air filter. The
alarm will start when the intake
1) Remove any dust or debris from the resistance reaches 25 inches.
surrounding area. This work must be
done before the cooling system
pressure is removed.
2) Slowly remove the pressure cap to
release the pressure.
3) Check the cover and cover seal for
damage, sediment and foreign
impurities. Wipe the lid off with a clean
cloth. If the cover is damaged, replace
it.
4) Install the cover.
Fig.5--35
1) Open the access door to maintain

the air filter housing.
2) Loosen the butterfly nut to remove
the back cover and remove the ash
from the housing.
3) Remove the air filter element from
the air filter housing and use the
compressed air to maintain from the
inside of the filter to the outside. Do
Fig.5-34
not wash with oil or water.
Engine air filter - clean/replace 4) After the main filter element is

maintained, the main filter should be
Note: the air filter can only be checked carefully, if find the damage
maintained when the engine stops. filter paper, degumming filter cartridge
Otherwise, the engine may be cover and other defects, or after 5 or 6
damaged. times maintenance, the new filter
should be replaced.
Be careful when removing and
installing air filters. Make sure not to 5) The safety filter element should not
damage the inner tube inside the air be maintained, if the main filter
filter housing. Make sure the air filter element leaks, the dusty safety filter or
is installed properly so that the air filter after 500 hours, should replace the
can work properly. safety filter core.
It is recommended that the air filter 6) After the main filter is maintained,
should be maintained for every 3 you shall pay attention to the correct
months, 250 hours or when the intake installation, do not leave out the parts,
resistance indicator shows that the and not knock the housing of the filter,
intake resistance is too high. This is otherwise, the filter element cannot be
different depending on your particular removed and replaced. The back
engine, and small interval should be cover and the butterfly nuts on each
taken in more dusty area. filter shall be tightened to ensure
sealing. And should make the dust
When the air filter alarm becomes red, bag vertical downward.
the filter element of air filter should be
maintained. After the maintenance, 7) Check all sealing rings during
press the air filter to reset the button assembly to ensure good condition,
62
otherwise replacement should be 250 hours interval can be used, or oil

carried out. sample analysis determines the
acceptable oil change interval.
If your selected interval is too long, the
Oil level of engine - check engine may be damaged.
Use the oil type recommended in table
Warning 3. Do not use single - stage oil.
Hot oil and hot parts can cause injuries.
Do not allow hot hydraulic oil or hot parts An unusually harsh operating cycle or
to contact with skin. harsh environment can shorten the
service life of engine oil. Cold
Note: oil should not be too less or too weather, corrosive environment or
much when filling the crankcase. Any extremely dusty conditions may need
one case can cause engine damage. to shorten the time interval
recommended by table 3 for engine oil
change. Improper maintenance of air
filter or fuel filter may also shorten the
oil change cycle. If the machine will be
used in an unusually harsh operating
cycle or harsh environment, please
contact XCMG or the agent.
Contact us for more information.
Replace oil and filter
Warning
Do not allow hot hydraulic oil or hot parts
Fig.5-36
1) The engine must be in a horizontal When testing, maintaining, testing,

position at least 15 minutes after the adjusting and maintaining the engine,
engine stops. please be careful to ensure that the
liquid is filled in the container. Before
2) Open the access door and pull out opening or dismantling any of the
the oil level gauge (1). components that have liquid, be
prepared to collect the liquid. Dispose
3) Check whether the oil level is of all liquids according to local laws
between the “L” low and “H” height of and regulations.
the oil gauge.
Oil should not be too less or too much
4) when necessary, remove the oil when filling the crankcase. Any one
filler cap (2) and add oil. case can cause engine damage.
5) clean and install oil filler cap. Place the machine on a flat surface
6) close the access door. and engage the parking brake. Stop
the engine.
Note: When the oil is still hot,
Engine oil and filter —replacement discharge the oil from the crankcase.
This will remove waste particles
Selection of oil replacement suspended in the oil. Because when
interval the oil cools, the waste particles will
settle to the bottom of the crankcase.
These particles will not be removed
63
during discharging oil and they will contact the base, then tighten the fuel
recirculate with the new oil in the filter with the coil wrench. Make sure
engine lubrication system. the installation tool does not damage
the filter.
7) Clean and install oil filler cap.
8) Remove the oil filler cap (2) and
add oil.
9) Check whether the oil level is
between the “L” low and “H” height of
the oil gauge.
10) Install oil filler cap (2).
11) Start the engine and stop it after 2
minutes.
Fig.5-37 12) Check the engine for leaks. Check
whether the oil level is between the “L”
low and “H” height of the oil gauge.
13) Close the access door.
Engine oil filter - check
Fig.5-38 Cut the filter element with a filter

cutter. Expand the fold to check if
there is any metal or other debris in
the filter. The filter element of the filter
cartridge contains an excess of debris
indicating that it may fail.
If there are metal fragments found in
the filter element of the filter, a magnet
can be used to distinguish ferrous and
nonferrous metals.
Ferrous metal indicates wear and tear
Fig.5-39 on steel and cast iron parts.
1) Open the crankcase release screw Nonferrous metals indicate that the
(4), drain the oil into the proper aluminum parts of the engine are
container. worn, such as main shaft bush,
2) Install crankcase discharge valve connecting rod bearing bush, or
(4). turbocharger bearing bush.
3) Clean the engine oil filter (3) before

removing engine oil filter. Remove oil A small amount of debris may be
filter with coil wrench. found in the filter element of the filter.
4) Clean the seat of engine oil filter This can be caused by friction and
housing. Make sure all the old filters normal wear and tear.
are removed.
5) Apply a thin layer of engine oil on Engine valve clearance— check
the new filter seal gasket.
6) Install the new filter, tighten the
sealing ring of the filter with hand to Warning
64
Ensure that the engine cannot be started maintenance manual “capacity” to

when the maintenance is carried out. Do understand the fuel tank capacity of
not use the starting motor to drive the
your machine.
flywheel to avoid personal injury.
Hot engine parts can cause burns. Wait a
certain amount of time before
measuring/adjusting valve clearance to
cool off the engine.
Only qualified maintenance personnel

can carry out the work.
Ensure that the valve clearance is
measured after the engine stops. In
Fig.5-40
order to get the accurate
measurement results, the valve is 1) Clean the filler cap (1) and
cooled before the maintenance is surrounding area.
carried out. 2) Remove the filler cap.
3) Fill fuel into the fuel tank.
Remove the hood, air filter and muffler
to check clearance of engine valve. 4) Install filler cap.
For the correct adjustment

procedures, please refer to the engine Fuel system- refueling
operation and maintenance manual of
CUMMINS. Note:
Don’t let the dirt get into the fuel
system. Thoroughly clean the
surrounding area of the fuel system
Fuel system- refueling components that will be
disassembled.
Warning Place the appropriate cover on the

Failure to comply with the following disassembled fuel system parts.
procedures may result in personal injury
or death.
Leakage or spillage of fuel on hot
surfaces or electrical components can
cause fire.
Wipe out all the leaking or splashing fuel.
Do not smoke when working on fuel
systems.
When replacing the fuel filter, switch the
battery cut-off switch to the “OFF”
position.
Note:
When testing, maintaining, testing, Fig.5-41
adjusting and maintaining the
machine, be sure to prepare a 1)Check whether the oil and water
container for the discharged liquid. separator is full.
Before opening or dismantling any of
the components that have liquid, be 2）If the oil-water separator is not full
prepared to collect the liquid. of oil, press the oil pump on the
separator repeatedly until the oil and
Dispose of all liquids according to water separator is filled with oil.
local laws and regulations.
3）When the oil water separator is full
Please refer to the operation and of oil, try to start the engine. If the
65
engine starts up, but the engine oil and water separator cup (2) to
doesn’t run smoothly or the engine is discharge the water and sediment
not ignited, let the engine run at low from the fuel oil strainer. The oil and
idle speed until the engine turns water separator cup is below the fuel
smoothly. oil filter (1). Get the fuel into the
proper container.
2) Remove fuel oil strainer (1) and oil
and water separator cup (2). Clean
Fuel oil strainer filter core - filter housing base.
dischargement/replacement 3) Remove the oil and water separator
from the fuel oil filter.
Warning Note: Check the oil and water
Leakage or spillage of fuel on hot separator cup for damage. If it is not
surfaces or electrical components can damaged, the oil and water separator
cause fire. cup can be reused.
When discharging and/or removing any
part of the fuel system, turn off the switch 4) Clean the oil and water separator
to the closed position. cup and clean the groove of the O
sealing ring. Clean oil and water
Note: separator cups in clean, non-
flammable solvents. Use the
When testing, maintaining, testing, pressurized air to dry water separator
adjusting and maintaining the engine, cup.
please be careful to ensure that the
liquid is filled in the container. Before 5) Use clean diesel oil or clean
opening or dismantling any of the lubricating oil to lubricate O ring seals.
components that have liquid, be Place o-ring seal on groove of oil
prepared to collect the liquid. water separator.
Dispose of all liquids according to 6) Install the clean oil and water
local laws and regulations. separator cup on the new filter.
Do not fill fuel into the fuel filter before 7) Apply clean diesel oil to the sealing
installing the fuel filter. Otherwise the ring of the new filter.
fuel will not be filtered and may be 8) Tighten the new filter by hand until
contaminated. The contaminated fuel the filter seal is in contact with the
will accelerate the wear and tear of filter mounting base. Note that the
the fuel system parts. indicator on the filter is positioned
relative to the fixed base of the filter.
9) Tighten the filter according to the
instructions in the filter printing.
Note: Ensure that the installation tool
does not damage the filter during
installation.
10) Fill the fuel system with oil.
11) Start the engine and check for
leakage.
Fig.5-42 12) Close the access door.
The fuel oil strainer is located in the
engine compartment, on the left side
of the machine. Coarse fuel filter – replacement
1) Open the discharge valve (3) on the The coarse fuel filter is located in the
66

of the machine.
Fig.5-43 Fig.5-44
1) Remove secondary fuel filter (1). 1) Remove secondary fuel filter (1).
2) Drain the oil from the secondary 2) Drain the oil from the secondary
fuel filter to the appropriate container. fuel filter to the appropriate container.
3) Clean the fixed seat of the fuel oil 3) Clean the fixed seat of the fuel oil
filter. Make sure all the old seals are filter. Make sure all the old seals are
removed. removed.
4) Apply clean diesel oil to the sealing 4) Apply clean diesel oil to the sealing
ring of the new filter. ring of the new filter.
5) Install the new filter, tighten the 5) Install the new filter, tighten the
sealing ring of the filter with hand to sealing ring of the filter with hand to
contact the base, then tighten the fuel contact the base, then tighten the fuel
filter with the special wrench. filter with the special wrench.
Note: ensure that the installation tool Note: ensure that the installation tool
does not damage the filter during does not damage the filter during
installation. installation.
6) Fill the fuel system with oil. 6) Fill the fuel system with oil.
7) Start the engine and check for 7) Start the engine and check for
leakage. leakage.
8) Close the access door. 8) Close the access door.
Fine fuel filter - replacement Fuel tank cover - cleaning

The fine fuel filter is located in the
of the machine.
Fig.5-45
The fuel tank cover is on the left side

of the machine.
67
1) Clean fuel tank cover (1) and Dispose of all liquids according to
surrounding area. local laws and regulations.
2) Remove the fuel tank cover and Note: the normal hydraulic oil
disassemble it. replacement interval is 2000 hours or
1 year. Through oil analysis, the
3) Check whether the fuel tank cover hydraulic oil replacement interval may
is damaged. If the cover is damaged, be extended to 4000 hours or 2 years.
replace the cover. The oil analysis must be conducted
4) Clean the fuel tank cover with every 500 hours or 3 months, which
clean, non-flammable solution. can prolong the replacement interval
of the hydraulic oil. The oil liquid
5) Assemble the fuel tank cover and analysis results can be determined
install it. whether the hydraulic oil replacement
interval can be prolonged. If the oil
hydraulic analysis is not performed,
Water and sediment in the fuel tank the hydraulic oil replacement interval
- discharge must be maintained every 2000 hours
or 1 year.
Start the machine until the oil is warm.
Stop the machine on a flat surface,
front wheel in front. Bring all
attachments to the ground. Press the
attachment slightly downward. Make
the machine articulated part straight
and install the frame lock connecting
rod. The frame lock connecting rod
must be free to move within the frame.
Fig.5-46
Place the front wheel to the vertical
position, and then install the front
The outlet is at the bottom of the fuel wheel tilt bolt. Engage the parking
tank. brake. Stop the engine.
1) Open the drain valve (1). Drain
water and sediment into proper
containers.
2) Tighten the vent.
Hydraulic oil - replacement
Warning
Fig.5-47
When testing, maintaining, testing,

adjusting and maintaining the engine,
please be careful to ensure that the
liquid is filled in the container. Before
opening or dismantling any of the
components that have liquid, be
prepared to collect the liquid.
68
11) Start the engine. Let the engine

run for a few minutes.
12) Keep the oil level between L and
H of oil level meter (2). When
necessary, add hydraulic oil by filling
port.
Note: No bubbles in oil. The bubbles
in the oil indicate that the air goes into
the hydraulic system.
13) Make the engine stop.
Fig.5-48 14) Tighten any loose clamp and any
loose joints when necessary. Replace
all damaged hoses.
Hydraulic level - check
Fig.5-49
The hydraulic system tank is located

in the back of the cab.
1) Remove all dust or debris around Fig.5-50
the filler (1) of hydraulic oil. This work
must be completed before the The hydraulic tank gauge is located in
hydraulic oil filler is removed. the right front of the hydraulic oil tank,
on the right side of the machine.
2) Slowly open the hydraulic oil tank
filler to release the pressure. 1)Start the machine until the oil is
warm.
3) Open oil screw plug (3) (4) to
discharge oil. 2) Stop the machine on a flat surface,
front wheel in front.
4) Install the oil screw plug and clean
the area around the discharge valve. 3) Bring all attachments to the ground.
Press the attachment slightly
5) Replace the hydraulic system oil downward.
return and suction filter.
4) Make the machine articulated part
6) Remove the hydraulic oil tank and straight and install the frame lock
add the filter screen. Wash and dry connecting rod. The frame lock
the filter in clean, non-flammable connecting rod must be free to move
solvents. within the frame.
7) Install a filler screen. 5) Place the front wheel to the vertical
position.
8) Add hydraulic oil.
6) Engage the parking brake. Stop the
9) Check the sealing of filler cap. If the engine.
filler is defective, replace the filler cap.
7) The oil level shall be between the L
10) Install the filler cap of the hydraulic and H of the oil level indicator.
tank.
69
8) Refuel when necessary. 1) Remove

any dust or debris from the
surrounding area of the filler cap of
hydraulic oil. This work must be
completed before the hydraulic oil filler
is removed.
Note: Confirm that the oil type added
is the same as the oil type hydraulic
system.
9)Slowly open the hydraulic oil tank
filler cap to release the pressure.
10) Add oil through the filler pipe.
Fig.5-51
11) Clean and install hydraulic oil filler
cap. 1) Remove any dust or debris from the
surrounding area of the filler cap (3) of
hydraulic oil. This work must be
Hydraulic oil filter - replacement completed before the hydraulic
system oil filler is removed.
Warning
2) Slowly open the hydraulic tank
cover and release the pressure.
Do not allow hot hydraulic oil or hot parts 3) Open oil screw and drain oil.
Note: during the inspection, 4) Install the oil screw plug and clean
maintenance, testing, adjustment and the area around the discharge valve.
maintenance of the product, you must
be careful to ensure the discharged oil 5) Clean surrounding area of filter (5)
properly collected. Before opening or (6).
dismantling any of the components 6) Remove the filter with the wrench.
that have liquid, be prepared to collect
the liquid. 7) Clean the base of the filter. Check
for old seal rings in filter. Remove the
Dispose of all liquids according to old sealing ring from the filter.
local regulations and requirements.
8) Apply a thin layer of clean hydraulic
Stop the machine on a flat surface, oil to the new filter oil seal.
front wheel in front. Bring all optional
parts to the ground. Press the 9) Install a new filter.
attachment slightly downward. Make
10) Add hydraulic oil.
the machine articulated part straight
and install the frame lock connecting 11) Install the filler cap of the hydraulic
rod. The frame lock connecting rod tank.
must be free to move within the frame.
Place the front wheel to the vertical 12) Start the engine. Let the engine
position, and then install the front run for a few minutes.
wheel tilt bolt. Engage the parking
13) Keep the oil level between L and
brake. Stop the engine.
H of oil level meter (2). When
necessary, add hydraulic oil by filling
port.
Note: No bubbles in oil. The bubbles
in the oil indicate that the air goes into
the hydraulic system.
14)Make the engine stop.
70
15) Tighten any loose clamp and any The fall of scarifier can cause bodily
loose joints when necessary. Replace injury or death.
all damaged hoses. Before replacing the gear teeth, the
scarifier should be held up by convex
piece.
When a fixed pin hits, it may be thrown
Radiator - cleaning and injure the persons nearby.
When you hit a pin out, make sure there
1) Open the repair door on both sides is nobody around.
of the engine hood.
Wear protective glasses to avoid damage
2) Remove dust from the surrounding to your eyes when tapping the locating
pin.
area of the radiator. Remove debris
from the surrounding area of the
radiator.
3) Close the access door.
Radiator core - cleaning

You can use compressed air
(maximum pressure of 30 psi, high
pressure water or water vapor to
remove dust and other debris from the Fig.5-53
radiator core). But it’s best to use 1) Check the tip of the scarifier. If the
compressed air. tip of the tooth is damaged or
overworn, replace the tip of the
scarifier.
Oil cylinder bearing of scarifier - 2) The cushion is high enough to
lubrication remove the tip.
Wipe the oil mouth clean before using 3) Overshot the positioning pin from
the grease to fill the lubricant. the fixed side of the tooth tip. Remove
the tip of the scarifier.
4) Install the new tooth tip on the rake
teeth.
5) Push the positioning pin through
the tooth tip and rake tooth.
6) Repeat step 2 to step 5 to replace
the tip of the other splitter.
7) Improve the scarifier. Remove the
cushion. Bring the scarifier down to
the ground.
Seat belt - check

Before operating the machine, you
must check the condition of the seat
Fig.5-52
belt and seat belt fasteners. Replace
Lubricate the cylinder bearing by all damaged or worn parts before
adding a proper amount of lubricating operating the machine.
oil through the nozzle.
Tooth tip - check/replace
Warning
71
The used oil products must be

processed according to the
regulations and must not be directly
discharged into the environment.
Differential and axle - oil change

Fig.5-54
1) Check the buckle (1) for wear or

damage. Replace the seat belt if it is
worn or damaged.
2) Check the woven belt of seat belt
(2) for wear or damage.
If woven belt wears or tears, replace
seat belt.
3) Check all seat belt fasteners for
wear or damage. Replace any worn
or damaged mounting fasteners.
Ensure that the fixing bolts are Fig.5-55
tightened
The differential and axle shell share
4) If the machine is equipped with a an oil chamber. The arrows below are
lengthening belt of seat belt, the seat the differential and axle shell oil level.
belt lengthening band should also be
inspected according to the procedure. 1）Clean the filling port, oil discharge
outlet and porthole area.
2) Open the oil inlet bolt (1) and the oil
Seat belt - change outlet bolt (3) and clean the internal
1) Seat belts shall be replaced within oil.
3 years after the installation date. 3) Tighten the drain bolt (3) again
2) Confirm the service life of the new 4) Refuel the differential from the
seat belt before it is installed in the filling port
seat. Install seat belt system with new
mounting fasteners. 5) Observe the oil level from the
observation port (2)
3) If the machine is equipped with a
lengthening belt of seat belt, the seat
belt lengthening band should also be
inspected according to the procedure. Balance box -oil change
Drive axle - check/maintenance
Warning
Note:
Oil must be lubricated and changed
Fig.5-56
with the oil specified in the manual.
Check the oil level regularly.
72
The diagram arrow shows the oil level Rotary bearing - lubrication
observation port.
1）Clean the filling port, oil discharge
2) Loosen filler bolt (1) and drain bolt
(3) to completely clean the internal oil.
3) Tighten the drain bolt (3) again.
4) Lubricate the balance box by
Fig.5-58
balancing the tank.
The rotary bearing lubrication points of
5) Observe the oil level from the the rear axle are located at the front
observation port (2). and rear ends of the balance box, and
are symmetrical arranged with a total
of 4 positions.
Rim oil - oil change（option the wet
brake） Wipe the oil mouth clean before using
the grease to fill the lubricant.
Tire inflating volume - detection
Fig.5-57
Fig.5-59
1）Clean the filling port, oil discharge
1) Measure the pressure of each tire.
2) Inflate the tyre when needed.
2)Unscrew bolts (1) and (2) side by
side and clean the internal oil. 3) Consult an agent to understand the
correct bearing capacity and correct
3) Tighten the drain bolt (3) again.
work pressure.
4) Lubricate the balance box by
4) Please refer to the following
balancing the tank.
additional instructions for inflating the
5) Observe the oil level from the tire.
observation port (2).
Operation and maintenance manual,
6）Tjghten the bolt（1）. “air inflation of tyres”
“tire pressure during transportation”
“adjustment of tire inflation pressure”
Gear box - oil level inspection
73
Warning
to contact with skin. Fig.5-60
Gearbox - oil filter replacement

1) Park the vehicle in a flat place
Note:
2) Gearbox changing handle in neutral
position “N” During the inspection, maintenance,
testing, adjustment and maintenance
3) The gearbox is in the working of the product, you must be careful to
temperature range ensure the discharged oil properly
collected. Before opening or
4) The engine is idling dismantling any of the components
5) Unscrew the oil ruler (1) that have liquid, be prepared to collect
counterclockwise, remove and wipe the liquid.
clean The machine has reached 100 hours
6) Insert the oil ruler (1) into the oil for the first time, must be changed for
pipe and tighten it, then take it out (at the first time. Thereafter, oil will be
least twice). replaced at least once every 1,000
hours or at least once a year! If you
7) The oil temperature is about 40 ℃, have a filter alarm on the dashboard,
the oil level should be between scale you should replace the filter
in the “cold” and middle scale immediately.
8) Oil temperature is about 80 ℃, the
oil level should be between the middle
and “hot” of the scale and check cold
oil level is only to ensure the torque
converter and gearbox has plenty of
circulation flow rate, the final criterion
for determining the oil level is to
satisfy the hot oil level.
Fig.5-61
Note:
Check the oil level (every week).
Vehicles will be parked on a flat place,
“N” transmission shift lever in the
neutral position, parking brake is in
braking position, engine idle running
(about 1000 r/min), the oil temperature
of 40º Ｃ , the oil level should be
between the middle scale and lower Fig.5-62
scale. When the oil temperature is 80º
Ｃ, the oil level should be between the
middle scale and the upper scale line.
Due to the influence of the installation
state, the actual oil level of the
gearbox will rise when the engine
stops. The increase is related to the
installation conditions of the gearbox.
If the oil gauge can be pulled out at
Fig.5-63
this time, the oil will be exposed.
Please do not pull out the travel ruler.
74
Window cleaner - refill

The storage tank of the windscreen
cleaner is placed in the rear end of the
cab.
图 5-64
1) Park the vehicle in a flat place, the

gearbox is at work temperature,
remove the drain plug (2), drain the
old oil and drain the oil into the proper Fig.5-65
container.
1) Open windscreen cleaning agent’s
Note: In order to replace the filter protective cover(1).
easily,it is necessary to turn the hinge
to the left to the limit,and remove four 2) Take down the filling coverof the
bolt and the right cover plate. storage tank.
2) Clean the drain plug and the cover 3) Add the cleaning agent for the
of the shell, then tighten the drain plug storage tank.
(2) clockwise.
4) Install the filler cap.
3) Turn the filter (3) into two
counterclockwise direction, and turn
the new filter clockwise into the filter Windscreen wiper - check/replace
holder and tighten it.
Check the front and rear windshield
Note: when oil is released, not only wiper blade, and change the wiper
should drain the gearbox oil, but also blade if the wiper blade makes strips.
the torque and radiator oil
4) Turn out the vernier gauge(1), fill in
the oil according to the regulations, Window - cleaning
and add the oil from the mouth of the
vernier gauge (1), and fill the oil until Shall stand on the ground to clean the
reach the “cold” scale of the vernier windows. Use the appropriate
gauge. equipment to reach the window and
use the provided handle to keep the
5) The gearbox control handle is in the position stable.
neutral position “N”.
Use the window cleaner to clean up
6) Start the engine and run at idle the windows.
speed.
7) Continue refueling to the upper Camera - adjustment
scale of the “cold” oil area.
8) All gear options are selected once.
9) Parking brake is in safe position.
10) Check the oil level again and
refuel to the upper scale of the “cold”
oil area when necessary.
Fig.5-66
1） Park the machine on the
75
horizontal ground. parking brake. Move the gearbox

2） Turn the engine starting switch to switch to REVERSE position.
OFF position and pull out the The reversing alarm should ring
engine starting switch key. immediately. The alarm warns the
3） Transfer the Xu electromagnetic people behind the machine that the
cut-off switch to the OFF position. machine is backing up. The reversing
4） Loosen the bolt (1) and point the alarm should continue ringing until the
camera to the area you want to gearbox is switched to NEUTRAL or
observe. any FORWARD position.
5） Tighten the bolt (1).
Accumulator recycling
Fuse - replacement
Be sure to recycle the battery. Never
Fuse - protect circuit system to avoid dispose of a battery.
damage caused by overloads.
Replace the fuse if the element is Be sure to send the used batteries
separated. Use the new fuse to back to one of the following
separate the components and check departments:
the circuit. Repair the circuit.  Battery supplier
 Designated battery recycling
Note:
point
The fuse can only be replaced with
 Recycling points
the same type and capacity of fuse.
If you need to change the fuse
frequently, the circuit system may fail. Battery or battery cable -
inspection/replacement
1) Turn the engine starting switch to
Stop the engine - emergency stop
OFF position. Turn all switches to
Engine stop switches are located on OFF position.
the control box inside of the cab.
2) The key of the battery cut-off switch
1) When the engine is running, press is placed in the OFF position. Pull out
the emergency STOP switch to STOP the key.
position. The engine will be shut
3) Disassemble the battery negative
down.
cable in the battery. The battery break
2) Switch the engine starting switch to switch is connected to the machine
the OFF position frame.
3) Move the engine stop switch to Note: don’t let disconnected battery
RUN. wire touch the battery’s disconnecting
switch or the machine.
4) Restart the engine.
4) Disassemble the battery negative
cable in the battery.
Reverse alarm -- test 5) Disassemble the battery positive
The reversing alarm is located at the cable in the battery.
back of the machine. 6) Check whether the terminal of the
To test whether the alarm is working battery is corroded. Check whether
properly, switch the engine starting the gasket is worn or damaged.
switch to the (ON) position. 7) Repair when necessary. When
Apply the service brake. Release the necessary, replace the battery or
battery cable.
76
8) Connect the battery anode cable.

9) Connect the battery cathode cable.
10) Connect the battery cable to the
battery cut-off switch.
11) Install the main battery disconnect
switch key. Switch the battery
disconnect switch to the connected
position.
77
Electrical schematic diagram1
78
79
Electrical schematic
diagram4
80
81
82
83
Hydraulic schematic diagram 1
84
地址：中国江苏省徐州市经济开发区工业一区
Add：NO.1 Industry District, Jinshanqiao Developing zone, Xuzhou, Jiangsu, China
电话（Tel）：+86-516-87738058
传真（Fax）：+86-516-87738068
邮编（Post Code）：221004
服务电话（Service Tel）：+86-516-87735101
服务传真（Service Fax）：+86-516-87738154
质量监督电话（Quality Inquiry Tel）：+86-516-87738137
备件电话（Spare Parts Tel）：+86-516-87738105 87738170
版权所有侵权必究
（All rights reserved，Violators will surely be prosecuted）

OMM GR1605说明书 英文20190122

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GR1605MotorGrader

Operation and Maintenance Manual

Safety warning mark Description

This mark confirms important safe information in the

Incorrect operation, lubrication, maintenance or repair could cause danger, and it

1 Preface table lists items that require maintenance

The operation section is available for

The basic operating techniques are

XCMG global manufacturer code

2.1 Safety Sign

No operation (1) Warning

Maintenance warning signs (2)

Avoid squeezing and bumping(5)

Control warning signs (3)

Reverse warning signs (6)

Battery warning signs (4)

Fan protective safety signs (7)

theframe rear part. Warning

Description of danger zone (10)

Avoid scalding （9）

2.2 Additional Marking

Hoisting fixed position (1)

Fuel filling port (3)

Reserved port (4) drunk after taking the medicine, do not

the pinhole size can penetrate human

2.5 Avoid Scalding Battery

flammable oil in the cab. A metal object must not be cross-

Ensure that all the clamps, shields,

Don’t store ether jar in living area or

to cool your tires. But if the machine is 2.10 Before Starting

2.11 Engine Starting

Select the required forward or This machine is suitable for the

to damage the frame ladder, wheel, emergency situation, shall quickly

machine (if equipped) is designed, and ROPS performance of the

Fig.3-1 Dimension unit: mm

The basic transportation specifications 1R 5 km/h

The product identification number (PIN)

The gearbox nameplate of GR1605 is

The product identification number (PIN)

4 Operation the steps and the handle.

Door open handle has lock, must turn the

lubricant daily. Note: the seat should be adjusted at the

Warning Tilt angle adjusting handle (1)

Front and rear adjusting handle (2)

Lift the adjusting handle

Seat safety belt （4）

Operator’s control device

Blade float - Push the lever (3) to most Displayer(7)

Right combination switch (9) in the selected position.

Engine starting switch (20) 3) Press the fan adjusting switch ② to

8) Press OFF button to stop the air- Control switch

Rear worklamp switch of cab（33）

Shovel blade worklamp switch（35）

Reserved switch (44) (49)

Hydraulic pull pin lock switch (48)

Hydraulic pull pin operation switch

Indicator and meter

No. Function No. Function

(15) Right steering indication (31) Operation parameters quick query

Stop failure indicator light - the

Oil pressure indicator of The system setting interface includes

Working hours - display engine working

Engine oil pressure indicator - displays

OMM GR1605说明书英文20190122

OMM GR1605说明书英文20190122