Xda45u Articulated Dump Truck Operation and Maintenance Manual

ARTICULATED DUMPTRUCK
XDA45U
OPERATOR’S MANUAL
XUZHOU XUGONG EXCAVATOR MACHINERY CO., LTD

Contents
Introduction............................................................................................................................... 2
Safety labels ....................................................................................................................................... 2
Cab and control device ............................................................................................................ 10
Key switch ........................................................................................................................................ 26
Emergency stop button of engine................................................................................................... 26
Cigarette lighter .............................................................................................................................. 27
Loading and dumping brake button ............................................................................................. 27
Parking button ................................................................................................................................. 27
Bus keyboard ................................................................................................................................... 36
Steering column ............................................................................................................................... 39
Seats .................................................................................................................................................. 41
Operating instructions ............................................................................................................ 49
Safety operation rules ..................................................................................................................... 49
Measures before the operation ....................................................................................................... 51
Steering system ................................................................................................................................ 61
Brake system .................................................................................................................................... 61
Parking ............................................................................................................................................. 63
Measures to be taken when stuck .................................................................................................. 64
Salvage and hauling ........................................................................................................................ 65
Tipping ............................................................................................................................................. 66
Transport of machine ...................................................................................................................... 69
Operating technique................................................................................................................ 70
Fuel-efficient driving ....................................................................................................................... 70
Body vibration ................................................................................................................................. 71
Transport operation ........................................................................................................................ 71
Up or downhill operation ................................................................................................................ 72
Off-road operation .......................................................................................................................... 73
Operation in hazardous areas ........................................................................................................ 74
Loading ............................................................................................................................................ 76
Safety for the maintenance ..................................................................................................... 78
Please read before maintenance ..................................................................................................... 78
Preparing work before maintenance ............................................................................................. 80
Fire protection ................................................................................................................................. 83
Disposal with hazardous materials ................................................................................................ 84
Repair and maintenance ......................................................................................................... 86
Cleaning of engine compartment ................................................................................................... 87
Routine inspection of machine ....................................................................................................... 88
Electrical system ............................................................................................................................ 108
Gearbox .......................................................................................................................................... 111
Axle ................................................................................................................................................. 114
Brake system .................................................................................................................................. 116
Wheels ............................................................................................................................................ 117
Frame ............................................................................................................................................. 120
Body ................................................................................................................................................ 141
Concentrated lubricating system (optinal) ................................................................................. 146
Specifications ........................................................................................................................ 155
Oil quality and filter element ....................................................................................................... 155
Engine ............................................................................................................................................. 157
Power transmission ....................................................................................................................... 158
XDA45U Articulated Dump Truck Performance Parameters .................................................. 159
XDA45U shape diagram ............................................................................................................... 160
Introduction Transfer case: Kessler W4408
Brake system
Service brake
XDA45U uses full hydraulic oil cooled and wet
disc brake system, which ensures the vehicle with
the high braking performance and long service life.
Even on muddy road, it can provide the vehicle
XCMG XDA45U is a three-axle articulated dump with the good braking performance. The
truck with 6×6 drive. Its payload is 41t and the load decompression brake of strong engine is applied to
capacity 25m3. control steady speed on the downhill and slow
Design purposes down before the curve or crossroad. It reduced use
The machine is applied in principle under normal of service brake and ensured the low operating
conditions, i.e. outdoors, on the ground, off-road, cost and safe transport.
earth-moving as well as at the ambient temperature Parking brake: Spring loaded and pneumatic
between -25℃ (-13℃)- 40℃(113℃). The service released.
conditions, which are different from the above Frame
mentioned, are also described in the Operation The frame is composed of the articulated body,
Manual. When used on public roads, the front and rear frame.
corresponding measures must be taken, so that the The articulated body allows the free swinging and
machine can meet the local national regulations. In rotation of rear frame relative to the front frame
case of use for other purposes or in potential and ensures the good ground contact of all drive
hazardous cases, e.g. in explosive or inflammable wheels, whereby to provide the excellent mobility
environment or zones containing asbestos dust etc., and stable transport capacity at high-speed. The
the special safety regulations must be respected articulated body uses the casting.
and the machine must use and be equipped with Both front/rear frames are made by use of
the operating equipment applicable to these high-grade and low-alloy high-strength steel. The
conditions. main parts use the casting to increase the frame
Engine strength. Major weld seams have been subject of
Manufacturer: Germany-Benz 100% ultrasonic flaw detection.
Model: OM471 Suspension
Rated power: 390 kW/1600rpm The hydro-pneumatic suspension is combined with
Maximum torque: 2600 Nm/1300 rpm the A-frame, which ensures the vehicle with the
Type: In-line 6-cylinder diesel engine with engine good stability and off-road performance; the
electronic control system, a fixed geometry
suspension structure of articulated vehicle
supercharger, supercharged intercooler, EGR
and EGR cooler, multi-point electronic XDA45U can reduce the shock on the vehicle by
injection, DOC+DPF+SCR exhaust poor road conditions, increase the vehicle’s riding
aftertreatment technology comfort and steering stability.
Emission standards: Non-road EU Stage V (EU Stage
V) Steering
United States Stage IV (US Tier 4) The plunger pump with inlet variable displacement
Drive system provides the steering with oil sources. The flow
Gearbox amplification hydraulic steering gives a better road
Model: Allison 4800ORS feel of steering wheel, high steering responsively
Gears: 7 forward gears, 1 reverse gears and steering smoothness. It is equipped with
Maximum output torque: 20000Nm auxiliary steering.
Body alarm items use LCD.
The body uses all-welded construction and made Cooling system
of the high strength wear-resistant steel plate The Articulated Dump Truck XDA45U has the
HB400. It is solid and durable and has large outstanding cooling capacity and meets the
dumping angle, dumping ground clearance as well requirements of full load continuous operation by
as low loading height, thus very applicable to the dumping truck at the ambient temperature
quick dispatch of materials. 40℃.
Flat bottom, up-tail, rock type and installed with The engine uses the detachable corrugated fin type
rubber bumper block. radiator, which is convenient for maintenance and
Lifting system replacement.
The body lifting motion controls 2 single-stage, Lighting system
double-acting, and telescopic cylinders through a The lighting system is composed of the headlamp,
lifting valve bank. steering light, reversing light, brake light, cab light
Tires etc.,.
Tires: 29.5R25 tubeless all-steel radial tires The positions of illumination and warning light are
Rim:25-25.00/3.5 reasonable, and meet the lighting and warning
Cab requirements of operation in all kinds of weathers
In conformity with ISO standard, the FOPS/ROPS and environments.
cab is anti-rolling and possesses the large space Safety device
and wide vision, various display instruments, The cab is equipped with the rear windshield
alarms, lighting, control switch, radio etc., the protecting rack, 2-point seat safety belt, escape
driver seat is adjustable air-suspending with the hammer and emergency stop switch. The vehicle is
high back and the passenger seat equipped with outfitted with the rear view camera system,
the air-suspending device. It has the inclinable emergency lights, rotation alarm light, reversing
telescopic steering column, electric watch warning, steering locking rod, body strut, assisting
windshield wiper and washer, tinted glass and air steering and anti-slippery walking surface and
conditioner. The vehicle operational data and fault guardrail etc.,.
ARTICULATED DUMP TRUCK XDA45U
Safety labels
The machine uses the following warning, hazardous and safety labels.
● You have to fully understand the proper place and content of labels.
● To ensure that the label content is read; the label must be located at the proper place and often cleaned.
When cleaning the label, do not use the organic solution or gasoline, otherwise, it will result in the
peeling of label paint.
● Except for the warning, hazardous and safety labels, there are other labels. The same manner shall be
applied to handle these labels.
● When the label is damage, lost or unable to be read properly, it must be replaced by a new one.
Control console Hydraulic oil tank Fuel tank
Quality frame Battery box Rear side of cab
L/R sides of body

Water tank
Accumulator Left and right suspension Right box
Rear of frame Left and right side of cargo box Engine
2
1 Lift Handle Caution Label

This sticker is located to the right of the cab lift handle.
The cab lift handle should be in the floating position while
the vehicle is in motion.
2 Lifting handle signs

This sticker is located behind the cab lift handle.
When the lifting handle is located at this position, the
body incidence increases, and the materials unloaded.
When the lifting handle is located at this position,

inclination angle of body remains unchanged.

body remains in suspending state.
When the vehicle is in parking or normal running state,
the handle should be set on this position.

body inclination angle decreases, and body retracted.
3 Apply parking brake warning sign

This sticker is located on the driver's right side of the cab.
Before leaving the truck, please apply the parking brake.
3
4 Logo marking of hydraulic oil

This identifier is located on the hydraulic tank.
It means that this oil tank contains the hydraulic oil,
whose level can be seen from the peep hole of hydraulic
oil.
5 Hydraulic oil refill warning mark

The patch is located on the hydraulic oil tank.
Indicates that before refueling, be sure to lower the cargo
compartment, turn off the key switch, and stop the engine.
4
6 Explaining identifiers of hydraulic oil refueling

This identifier is located on the hydraulic oil tank.
● Before refueling, please lower the body, turn off the
key switch and ensure that the engine is shut down.
Refuel the oil nearby the upper scale line of oil tank.
● Lift up and lower the body for 3 times.
● Repeat the steps 1 and 2, until the oil level reaches
again nearby the upper scale line.
● When the engine shut down, Make sure that the oil
level is nearby the upper scale line. After the engine
started and the body lifted, be sure that the oil level
is above the lower scale line.
● If necessary, please repeat the above steps for oil
refueling.
7. Vehicle welding warning sign
This identifier is located on the fuel tank at the left side
of walking board.
When the welding operation is conducted on truck,
please refer to the Maintenance part, Precautions for
Welding in Electrical System.
8. Hydraulic system high pressure hazard

This sign is located at the lift cylinder on the left side of the
rear frame.
Before loosening or opening the hydraulic system lines and
its components, be sure to turn off the key switch, make
sure the engine is stopped and relieve the hydraulic system
pressure.
9 Cargo compartment crush warning sign

This sticker is located at the front of the left and right
sides of the rear frame and at the rear of the rear frame,
respectively. When the cargo compartment is raised, it is
strictly forbidden to work under the cargo compartment
until a safety device is applied to prevent crush injuries.
5
10 Wheel deflection and squeezing warning sign

This identified is located in front, at both sides of rear
frame.
Please keep the distance. When the truck turns, the space
between the tire and frame decreases to prevent crushing.
11 Power switch warning sign

This sticker is located at the power switch on the left side of
the cab. It reminds the operator that there is power supply
here, and the power can be cut off in case of emergency.
12 Battery cable warning sign

This identifier is located on the top of battery box.
● Remove 2 negative cables from the wire clamp in
the battery box and insulate the cable socket.
● Remove 2 positive cables from the insulating busbar
post in battery box.
● Remove the jumper cable between the batteries.
● Replace the cable or battery, if necessary.
● Reconnect the cable in reverse order.
13 FOPS, ROPS warning sign
This identifier is located on the rear of driver seat in cab.

This cab meets the requirements of ISO3449, ISO3471.
Do not modify the cab frame without permission. Any
amendments will reduce the FOPS performances.
6
14 Accumulator High Voltage Warning Label
This identifier is located on the wall of energy

accumulator column.
High pressure! Before maintenance, pleas release gas in
the energy accumulator and fluid pressure. Proper
maintenance procedures -- the Maintenance part. The
operation requirements of pressure release from the
energy accumulator in hydraulic system.
15 Accumulator filling hazard label

This identifier is located on the wall of energy
accumulator column.
Only charge of dry nitrogen is allowed. Do not use
oxygen, because it may cause an explosion. Please refer
to the Maintenance part, the energy accumulator inflating
steps in Hydraulic System.
16 Suspension cylinder hazard signs

This identifier is located on the wall of suspension
cylinder column.
“Danger! High Pressure!” Before release of oil cylinder
pressure, don’t dismantle any metal parts like the plug
screw, pressure tap and charge valve etc.to prevent the
metal parts from bursting out from the oil cylinder and
causing casualties.
Please connect the charging device to the charge valve to
completely release the pressure in the oil cylinder.
Only dry nitrogen is allowed to be filled into the oil
cylinder. Please use the professional charging device and
strictly abide by the operation specification.
7
17 Falling prevention safety signs

This identifier is located sideway at left and right
walking boards.
When going or operating on the walking board after
gotten on board, you should keep away from the edge of
walking board to prevent from falling down.
When getting off, you should grasp firmly the handrail.
18 Reversing warning
This sign is located at the rear of the frame to warn the
operator to back up at any time, please stay away.
19 Lifting and tieing signs

There are 4 identifiers in total, two in front of vehicle
head and two at the tail of vehicle, which can be used for
towing and hoisting.
20 Hooking point sign

There are totally 4 hooking points on the truck, which are
respectively located at left and right side of the container
for the convenience of container montage and removal.
8
21 No-tread safety sign

This sticker is located on the engine.
It warns the operator not to step on the engine parts.
22 To avoid scalding injury warning sign

This identifier is located on the water tank.
To ensure the personnel safety, do not open the water
tank cap when it is in hot state, to avoid scalding injury.
9
Cab and control device
Warning
Before operating the machine, be sure that you understood the functions and positions of instrument
and operation controller. Please carefully read this Operation Manual, because your safety is
involved！
Always keep the Manual in cab for reference any time.
1 Blowing Air 8 Key Switch 15 Longitudinal 22 OBD

Outlet differential lock diagnostic
interface
2 Air conditioning 9 Rearview mirror 16 Parking brake
control panel power adjustment
3 Not used 10 Hood lift switch 17 Emergency stop
switch
4 Jogging pedal 11 Loading and 18 Cargo lift handle
dumping brakes
5 LCD display 12 Shifters 19 Cigarette lighter
6 Brake pedal 13 Bus keypad 20 12V power
outlet
7 Accelerator pedal 14 Engine cold start 21 Fuse box
10
ARTICULATED DUMP TRUCK XDA45U Cab and control device
LCD meter
Combination keyboard CAN failure
Engine
High and
Indicator and alarm Shortcut Cargo status coolant
1 low beam 6 11 16 21
lights keys indicator temperature
indicators
gauge
Engine oil
Width light Engine hour Engine
2 7 Right Turn Indicator 12 17 22 pressure
indicator meter tachometer
gauge
Longitudinal Cargo
Transverse
differential handle Transmission
3 8 differential lock 13 18 23 System time
lock action current gear
indicator
indicator indicator
Vehicle
Left steering Hazard warning Fuel level AdBlue level
4 9 14 horizontal 19 24
indicator light indicator gauge gauge
tilt angle
Alert and
System Vehicle
5 Speedometer 10 Cold Start Indicator 15 20 alarm 25
Voltage mileage
messages
11
1 High and low beam indicator
This green light is lit to indicate that the low beam headlights are on.
This blue indicator is lit to indicate that all headlights are on.
2 Wide-beam indicator
This green indicator light is lit to indicate that the wide lamps are on.
3 Longitudinal differential lock indicator
This yellow indicator light illuminates to indicate that the longitudinal differential lock is applied.
The differential lock can only be applied and released by the longitudinal differential lock switch when
the vehicle is stationary and the accelerator pedal is fully released, otherwise it will cause damage to
the vehicle drivetrain.
Warning
Do not use the differential lock on hard surfaces as this could cause serious damage to the
driveline.
The differential lock must not be activated when operating with anti-skid devices (e.g. snow
chains, etc.).
The differential lock must not be activated when a single tire is rotating.
12
Failure voltage, in which case

the cause must be
4 Left turn indicator identified and
corrected or the
battery may be
damaged.
When the driver needs to turn left while Clogge Please clear the main
driving the truck, by wrenching the lever on d air air filter element or
the steering column in the driving direction, filter replace the element.
the corresponding turn indicator and left turn
signal light will flash simultaneously.
The light comes on
Joggin
when the vehicle
5 Speedometer g
jogging function is in
Brake
effect.
Engine
oil
level is
extrem
ely
Indicates the current ground speed.
high
The vehicle is on level
6 Indication and alarm light
ground and the oil
Engine level alarm will be
oil effective only when
Engine Please replenish
level is the engine is stopped
coolant coolant in time,
high and left for 5 to 10
level is otherwise, it will cause
low damage to the engine. minutes, otherwise, it
Engine will not alarm. This
This red parking brake
oil alarm is for reference,
indicator light will
level is please refer to the oil
illuminate when the
very dipstick for daily
Parkin parking brake is
low inspection.
g applied. Do not
Brake attempt to drive the
vehicle while the Engine
parking brake is oil
applied. level is
low
Battery The light comes on
Chargi when the AC motor is
ng not providing charging
13
When the transmission When the oil level is

oil temperature is lower than 60%, the
higher than 120 red light will come on.
degrees, the red light At this time, the driver
Trans
will come on. At this Hydrau should stop the car
missio
time, the driver should lic tank safely on a flat
n oil
immediately stop the oil surface, put it in
temper
car, put it in neutral, level is neutral, apply parking,
ature is
apply parking and low turn off the engine,
high
keep the engine check the oil level,
running until the oil and confirm whether
temperature drops to the oil level is in a
the normal level. reasonable range.
This light is When the hydraulic oil

illuminated when the temperature is higher
transmission is High than 95 degrees, the
malfunctioning. You oil red light will come on.
Trans should stop the car temper At this time, the driver
missio according to the ature should stop the car
n emergency stop of immediately, put it in
Failure procedure, put it in hydrau neutral, apply parking,
neutral, turn off the lic oil and keep the engine
engine and notify the tank running until the oil
service personnel temperature drops to
immediately. the normal level.
When the oil level is Hydrau

higher than 90%, the lic oil
red light is on. At this tank
High time, the driver should oil
hydrau stop the car safely on temper
lic oil level ground, put it in ature is
tank neutral, apply parking, low
oil turn off the engine,
level check the oil level,
Press the
and confirm whether Loadin loading/unloading
the oil level is in a g and brake button, the light
reasonable range. unloadi will come on. When
ng the cargo compartment
brake is lifted, apply the
loading/unloading
14
brake. Release the fluid red light will come on.

brake before driving. level At this time, the driver
should stop the car
safely on a flat
This red alarm
surface, put it in
indicates a serious
neutral, put it in park,
engine failure, so stop
turn off the engine,
the vehicle according
Engine check the oil level and
to the emergency stop
red make sure that the oil
procedure, put it in
light level is in a reasonable
neutral, apply parking,
alarm range.
shut down the engine,
and notify the service
personnel When the brake oil
immediately. temperature is higher
than 95 degrees, the
red light will come on.
This yellow alarm High
At this time, the driver
indicates that the brake
should immediately
engine is oil
stop the car, put it in
malfunctioning and temper
Engine neutral, apply parking,
needs to be checked. If ature
yellow and keep the engine
this light is
light running until the oil
illuminated, check the
alarm temperature drops to
engine promptly and
the normal level.
notify the maintenance
personnel as soon as
possible. Low
brake
fluid
When the oil level is
temper
higher than 90%, the
ature
red light will come on.
Brake At this time, the driver
oil should stop the car Unbuc
If the seat belt is not
tank safely on level ground, kled
fastened, the gear will
oil put it in neutral, apply seat
be restricted to below
level is parking to turn off the belt
2nd gear and cannot
high engine, check the oil remind
be reversed.
level and confirm er
whether the oil level is
in a reasonable range.
Door
left Please close the car
open door when driving.
Low When the oil level is
brake lower than 60%, the remind
15
er or engine torque <50%,

Light the light flashes at
1Hz.
The indicator light
comes on when the
engine stops or the DPF DPF (Diesel
main pump fails. If Indicat Particulate Filter)
this light appears or
while the vehicle is in Light
Main motion, stop the
pump vehicle according to
Exhaus Light comes on when
failure the emergency stop
t gas the exhaust gas
procedure, put it in
high treatment system
neutral, turn off the
temper performs automatic
engine, apply park,
ature regeneration or
and notify service
indicat manual regeneration
personnel
or
immediately.
DEF DEF (Diesel Exhaust

Torque Engine torque limit
indicat Fluid) indicator light
Limitin output. When engine
or specific role see the
g torque >50%, the light
subsequent table
Indicat is on long; when
When the AdBlue level is low, the vehicle system reacts as follows
AdBlue fluid level Indicator light

System response
(DEF)
AdBlue level
DEF indicator light is on.
below 10%
DEF indicator flashes at 1Hz.
Torque limiting indicator on for a long

AdBlue level 7.5%
time.
Torque is gradually reduced to 75%.
AdBlue level 5% DEF indicator flashes at 1Hz.
16
Torque limiting indicator changes from

long on to 1Hz flashing.
Torque reduced to 50%.
Maximum speed limited to 60% of rated

maximum speed.
DEF indicator 1Hz flashing.
Torque limiting indicator 1Hz flashing.
AdBlue level 2.5% Long red engine light.
Engine speed reduced to idle speed.
AdBlue level=0% Engine red light 1Hz flashing.
Engine idle speed.
Torque limiting at 20%.
When there is a problem with AdBlue quality, a fault in the metering process, or a fault in the
exhaust gas aftertreatment system, the vehicle system reacts as follows
Failure detection Indicator light

System response
(DEF)
Problem fault
DEF indicator light is on.
detected
Problem fault DEF indicator 1Hz flashing.

detected for 60
minutes Torque limiting indicator on for a long
17
time.
Torque gradually reduced to 75%.
Torque limiting indicator changes from

Problem fault long on to 1Hz flashing.
detected 180
minutes Torque reduced to 50%.
Maximum speed limited to 60% of rated

maximum speed.

Problem fault
detected 230 Long red engine light.
minutes
Engine speed reduced to idle speed.

Problem fault
detected for 240 Engine red light 1Hz flashing.
minutes
Engine idling.
Torque limiting at 20%.
When the detected fault is repeated, the system response time becomes shorter.
When the driver needs to turn right while

7 Right Turn Indicator Light driving the truck, by wrenching the lever on
the steering column in the driving direction, it
makes the corresponding turn indicator and
right turn signal flash simultaneously.
18
8 Transverse differential lock indicator of the instrument. (1) Shortcut key for prompt
and alarm, it means there is prompt or alarm
information, press F1 button, it will enter the
whole alarm information interface of the main
menu information query; (2) It means the
buzzer is sounding, press F2 button, the buzzer
This yellow indicator light is illuminated to
is forbidden to sound for 5 minutes. (3)
indicate that the transverse differential lock is
represents the transmission fault, press F3
applied.
button, it will enter the main menu information
The DA45U transverse differential lock is an
query transmission real-time fault information
automatic limited-slip differential lock and is
interface; (4) represents the engine fault, press
not equipped with this indicator.
F4 button, it will enter the main menu
information query engine real-time fault
9 Hazard warning light indicator
interface; press any no reminder button to
enter the main menu.
In the process of driving, if there is prompt and

alarm information and the buzzer 1Hz sounds,
This yellow indicator light is on to indicate the driver should immediately stop the car, cut
that the hazard warning light is on. to neutral, apply parking, check the fault
prompt information and solve the fault
10 Cold Start Indicator Light according to the operation specification.
If there is a prompt and alarm message and the

buzzer sounds for a long time, the driver
should stop the car according to the emergency
stop procedure, put it in neutral, apply parking,
This yellow indicator light illuminates to
turn off the engine, and notify the maintenance
indicate that the cold start switch is on.
personnel immediately.
11 Shortcut key
12 Engine Hour Meter
This number shows the number of hours the

engine is currently running on power.
13 cargo compartment handle action

There are shortcut keys on the rightmost side
indicator
19
The handle is Front vehicle

pushed to the cross slope
rear. Please angle
operate on level
ground when
Cargo Rear vehicle
lifting the cargo
compartment cross slope
compartment and
lift angle
apply the loading
and unloading
brake, and Vehicle
release the brake longitudinal
before driving. slope angle
When the cargo 15 System Voltage

compartment is
lifted, release the
handle, and the
Cargo hold
handle returns to
This number shows the current voltage of the
the neutral
power system.
position, it is
held
When the car

power down, 16 Cargo compartment status indicator
release the
Carriage handle, the
The light comes
floating handle back to
on when the
the center
cargo
position, then is
compartment is
floating
in place. If the
Cargo cargo
When the compartment compartment is
power of the drop in place not in place, the
Push the handle
cargo gear will be
to the front.
compartment limited to below
drops 2nd gear and
cannot be
reversed.
14 Vehicle horizontal inclination angle
20
Real time display

of the lift angle
Lift angle
of the cargo
compartment
19 Fuel level gauge
The light comes

on when the
cargo
Lift in place
compartment is
Indicates the current fuel level. When the fuel
lifted to the
level is below 20%, the fuel level indicator at
highest point.
the top of the chart turns red, at this time, the
fuel level can only maintain the work for a
When the van is lifted or dropped, the LCD short period of time, pay attention to refill the
meter will automatically cut out the rear fuel.
camera screen, at this time, press any key to
exit the image screen. 20 Alert and alarm information
The text cycle prompts the current vehicle

17 Engine tachometer
special status and fault alarm information.
21 Engine coolant temperature gauge
Note
When the engine overspeed warning light is
on, you must immediately apply slowing or
Indicates the current engine coolant
braking to reduce the speed, otherwise it
temperature. When the coolant temperature is
will cause serious damage to the engine and
higher than 110 degrees Celsius, the coolant
transmission.
indicator at the top right of the chart turns red.
If this happens, the operator should safely stop
When the engine speed is higher than
the truck, put it in neutral, and keep the engine
2270r/min, the engine overspeed warning light
running until the cooling temperature drops to
at the top left of the chart turns red, at which
a normal level and notify service personnel.
time the driver should apply slowing or
braking to reduce the engine speed.
22 Engine Oil Pressure Gauge
18 Transmission current gear
21
24 AdBlue level gauge
Indicates the current engine oil pressure. When

the oil pressure is too low, the oil pressure
indicator light at the top right of the chart turns
red, indicating low engine oil pressure. If this
occurs, the operator should safely park the
Indicates the current AdBlue level. When the
truck, put it in neutral, shut off the engine, and
AdBlue level is too low, the AdBlue level
notify service personnel immediately.
indicator turns red at the top right of the chart.
23 System Time
25Vehicle Mileage
22
26 LCD Gauge Menu
When the LCD meter is in the meter home page, press any button without prompt to enter the main
menu interface.
The main menu consists of three sub-menus: information inquiry, instrument setting and system
management.
Main menu
Information Service
Instrument settings
system management
The information inquiry interface contains information related to each system of the vehicle, they
are: whole vehicle alarm information, hydraulic and pneumatic system information, bus status, engine
information, engine real-time fault, transmission information, transmission real-time fault.
Main menu
Vehicle alarm information

Hydraulic and pneumatic system information
Bus status
Engine information
Engine real time fault
Transmission information
Transmission real time fault
The instrument setting interface can set backlight brightness, language, time, driver ID and
vehicle ID, update instrument program and query instrument information. Users can operate according
to each sub-menu.
Instrument settings
Backlight Setting
Language settings
Time setting
System update
Instrument information
Driver ID setting
Vehicle ID setting
The system management interface requires a password to enter and can view the controller I/O
status, controller version information, GPS information, and can calibrate the vehicle sensors. This
interface can be used as a troubleshooting aid for maintenance service personnel.
23
System management
Controller I / O port status
Controller version information
GPS information
Sensor calibration
If the vehicle is disassembled and installed (2) cab horizontal tilt sensor, (4) rear frame horizontal tilt
sensor, (1) jogging pedal, (3) steering (articulated body) angle sensor and (5) cargo compartment angle
sensor, please contact XCMG maintenance service personnel to re-calibrate the sensors.
27 Turbo Down and Delayed Cut-Off Interface

If equipped with a turbo delay-off device, when the engine is running and the engine is turned off using the key
switch, the turbo will be slowed down and the engine will be delayed off, and the driver is prohibited from
leaving the driver's seat during the turbo slow-down delay-off. The turbo speed down countdown prompt is as
follows
Turbine speed
reduction 0s
Main controller CAN fault

Attention
The driver is not allowed to leave the driver's seat during the turbo down delayed flameout.
The vehicle exhaust aftertreatment system still needs time to work and store information after the engine is
turned off, so after the engine is turned off, the prompt interface will end the countdown before disconnecting
the battery isolation switch, otherwise it will cause damage to the engine. The delayed power-off countdown
prompt interface is as follows
24
Turn off the battery

isolating switch after 0s
25
Key switch
The key switch is used to start and shut down the
engine.
“LOCK” position
You can insert the key switch to this position and turn
it. When the engine is running and the key switch is
reversed from the "ON" position to this position, the
engine is turned off, or if equipped with a turbo delay-off
device, the turbo is slowed down and the engine is delayed
off.
Attention
The driver is forbidden to leave the driver's seat
during the turbo-down delayed flameout
“ON” position
● When the key is located in this position, the PS
circuit of vehicle is powered on.
● When the engine started, the key switch is also
located in this position.
“START” position
This position is used to start up the engine. To start, the
key has to be held in this position. When the engine
started, release the key switch. Now, the key switch will
reset to the position “ON”. It is strictly to keep the
engine at the ignition position for longtime. The time
for each ignition shall not exceed 10s and the interval
no less than 2min. The overheating will cause serious
damage on the starter motor.
Emergency stop button of engine

Press this button, the engine will stop. On the left
walking board of truck inside the cab, there is an
emergency stop button of same function.
Attention
The motor can shut down only in case of an emergency.
Please use the key switch to shut down normally.
26
Hood Lift Switch
Press and hold the upper part of the switch to raise the
engine hood, and press and hold the lower part of the
switch to lower the engine hood.
Attention
Make sure the hood is free of snow, mud and other
debris before opening it.
Warning
Before closing the hood, make sure there are no people
around the hood and that all tools or debris have been
removed, otherwise, serious personal injury could
result!
Cigarette lighter
The cigarette lighter is used to light the cigarette.
Press the cigarette lighter, a few seconds later, the
cigarette lighter will bound to the original position. Pull
up the cap to ignite the cigarette.
The cigarette lighter socket can be used as the PS of
electrical equipment not higher than 240W (24V×10A).
Attention
The voltage of cigarette lighter is 24V.
Loading and dumping brake button

Please use the loading and unloading brake when loading
and dumping the machine. When the loading/unloading
brake is activated, unnecessary loading of the parking
brake can be avoided. Release the loading/unloading brake
before driving.
Parking button
Press the upper part of switch = Release parking brake.

Press the lower part of switch = Apply parking brake
27
Apply Release
1 Move the gear selector to the N-position. Slide down the latch on the switch and press the
2 Press the lower part of switch. upper part of switch.
3 Turn the start key to the position “Lock”.
If the switch is not pressed to apply the parking
brake before the engine is turned off, the truck
will apply the parking brake automatically after
flame out, but after the next ignition, the brake
will be automatically unlocked. To avoid the
accident by the movement of vehicle after stop
and ignition, please apply parking brake by use
of the parking button before flame out.
The use of parking brake in moving the machine
will result in abnormal wear of machine. When
the parking brake is use as the emergency brake,
it must be subject of the inspection afterwards.
Please contact the XCMG-authorized service
shop.
28
Warning
Applying the parking brake while the machine is moving can cause abnormal wear on the
machine. If the parking brake has been used as an emergency brake, the parking brake must be
checked afterwards by contacting an authorized XCMG workshop.
Warning
The parking brake must not be used as a loading and dumping brake!
Longitudinal differential lock switch
When the pneumatic system pressure is reasonable and the vehicle is stopped, press the longitudinal
differential lock switch, then the differential lock located in the transfer case is locked. The
longitudinal differential lock can only be applied or released when the vehicle is stopped. Release the
longitudinal differential lock in time after the vehicle is out of trouble.
Warning
Use of the differential lock on hard surfaces is prohibited, as it can cause serious damage to the
driveline.
The differential lock must not be activated when running with anti-skid devices (such as snow
chains, etc.).
The differential lock must not be activated when a single tire is rotated.
Attention
The longitudinal differential lock may only be applied or released when the vehicle is stationary
in place and the gas pedal is fully released. Release the longitudinal differential lock in time after
the vehicle is released.
Do not use the differential lock more than the number of wheels required by the road conditions.
Improper use of the differential lock can cause unnecessary tire wear, increase fuel consumption
and reduced maneuverability.
When the machine is operated with all differential locks combined, the steering capability of the
machine is reduced.
29
Mirror adjustment switch (optional)
Turn the upper knob to the side of the mirror you want to adjust to select the mirror to be adjusted.
Toggle the knob to the direction you want to adjust to adjust the corresponding mirror angle.
Engine cold start switch (optional)
Status indicator
Power
indicator
The indicators on the switch are power indicator (green) and status indicator (red), and the status
indicator indicates the working status of the heater and the fault code.
●Power on: Press the switch to (press the lower part of the switch, the switch is pressed to the
middle position for the first gear, the first gear for single open water circuit circulation; press the
lowermost position for the second gear, the second gear for the heater operation switch; the switch is
pressed to the second gear when the engine is turned on)
a. The heater begins to work, the power indicator light (green), the heater begins to carry out self-test
procedures.
b. If the self-test is normal and the heater starts to run normally, the status indicator light will be on at
this time (red).
c. If the status light is on (red) flashing, that is, the heater is working abnormally, please contact the
maintenance service personnel at this time.
●Shutdown: Just turn off the heater switch (press the upper part of the switch).
The power indicator light (green) goes off, the electromagnetic pump is disconnected, the fuel supply
stops, the heater stops burning, the main motor of the heater drives the combustion air wheel to
continue to work, so that the heater cools down, at this time the status indicator light (red) does not go
off immediately, it will delay about 3 minutes until the heater cools down, the main motor stops
working and then go off.
Warning
When the heater is working normally, it is strictly prohibited to use the vehicle main power
switch to turn off the heater. Before turning off the vehicle main power switch, please turn off
30
the heater more than three minutes in advance, otherwise the heat in the heater will not be
dissipated, damaging the heater and may cause a fire in serious cases.
Shifters
Service
indicator
Gear Current
range. gear
Mode
button
Up
button
Down
button
●Shift range: The highest gear that can be reached currently

●Service indicator: Only appears when gearbox TCM calibration is performed
●Current gear: The current gear of the gearbox
●R button：Selects reverse gear
●N position: select neutral
●D button: selects forward gear, shifts automatically between 1, 2, 3, 4, 5, 6 and 7
●Mode button: mode selection, does not have this function
●Up and down buttons: can be used to select the forward gear range. When in forward gear, pressing
the down button once will lock the gear range to the same gear as the current gear; each subsequent
press of the down button will shift the gear range down one gear; each press of the up button will shift
the gear range up one gear; a long press of the down and up button will continue to change gears until
the minimum or maximum gear is reached.
31
Press the down button

to select the gear
range
●Diagnostic function: When in neutral, press the Down and Up buttons at the same time to enter the
diagnostic function. Enter the diagnostic function to check the transmission oil temperature, oil level,
fault code and other information.
The specific method to view the transmission oil level from the shifter: stop the vehicle on level ground,
release the accelerator pedal engine idle, cut neutral, apply park, oil temperature between 40-104℃,
wait for 2-5 minutes, then press the down and up button at the same time to enter the diagnostic
function, press the down and up button at the same time to turn the page until the oil level page.
There are three kinds of prompt interface for successful oil level inquiry
TRANS OIL LEVEL OK oil level is normal
TRANS OIL [number of quarts or litres] LO oil level is low* pint or oil level is low* liter
TRANS OIL [number of quarts or litres] HI oil level high*pint or oil level high*liter
As shown in the figure, the oil level is normal and the oil level is 3 pints high respectively
Oil level query failure screen.

SETTLING waiting time is not enough, please continue to wait
ENG RPM TOO LO engine speed is too low
ENG RPM TOO HI engine speed is too high
MUST BE IN NEUTRAL not cutting neutral
OIL TEMP TOO LO Oil temperature is too low
OIL TEMP TOO HI Oil temperature too high
VEH SPD TOO HI Vehicle speed too high (vehicle not stopped)
SENSOR ERROR sensor failure (may be the speed sensor, oil temperature sensor, oil level sensor,
throttle sensor failure)
32
As shown in the figure, respectively, the engine speed is too high and oil temperature is too low tips
Transmission is equipped with oil dipstick, daily transmission oil level check please use oil dipstick as
the main.
Working Handle
Position 1
Position 2
Position 3
The working handle has 4 functions, corresponding to 3 positions, and the handle has the function of
automatic return to neutral position.
Cargo
Position Push the handle
compartment
1 forward
power down
Release the handle Float the
from position 1 carriage
Position
Cargo
2 Release the handle
compartment
from position 3
hold
Lifting on ramps is prohibited. The loading and
Position Push the handle
Lift unloading brakes should be applied when
3 backwards
lifting and released before driving.
33
Accelerator pedal
Depressing the accelerator pedal of the truck increases the traction of the truck. When the dump truck
is in rest mode, depressing the accelerator pedal can change the engine speed. The maximum speed of
a dump truck may be an unsafe speed on a haul road. Be sure to drive the dump truck at a safe speed
in accordance with mine safety regulations.
If the engine brake button is pressed, the engine brake is activated when the accelerator pedal is
released.
Ease pedal
When the jog pedal is depressed, the jog function is applied to the machine and the engine brake is
applied automatically.
Attention
Use the jog pedal for long downhill work.
Brake pedal
When the brake pedal is depressed, the brake function is applied to the machine while the engine
brake is automatically applied.
FU36 LCD instrumentation

Fuse box FU01 Aftertreatment Controller ACM
SPARE Spare
A fuse with the correct calibrated current
FU08 Engine Emergency Stop
strength must be used.
FU12 Engine diagnostic connector 2
Icon on the fuse box FU13 Wiper
FU14 Radio
FU02 Key switch
FU15 Cigarette lighter
FU04 Engine controller MCM-11
FU16 Seat Inflator
FU05 Engine Controller MCM-12
FU17 Fuel pre-filter
FU18Centralized lubrication
FU19 Heated rear view mirror
FU10 Powertrain Controller CPC4
FU20Reverse light
FU11 Engine diagnostic connector 1
FU21 Working light
FU27 Hood lift
FU22Headlights
FU28 Flashing light
FU23Air dryer AIRDRY
FU29 Engine cold start
FU24Air-conditioning
FU30 Main controller KCA
FU25 Backlight
FU31 Main controller KCA
FU41 Cab Boost
FU32 Transmission controller TCM
FU33 Transmission Controller TCM
FU35 Positioning system GPS
34
FU34 Bus keypad EPAD

FU40 Positioning system GPS
FU38 Hydraulic controller KCB
FU39 Hydraulic controller KCB
SPARE Spare
Attention
Do not install a fuse higher than the amperage specified on the sticker. There is a risk of damage
or board misfire.
If the same fuse blows repeatedly, the cause must be identified.
To replace a fuse, disconnect power and use a fuse of the same capacity and type.
35
Bus keyboard
After powered on, the switch backlit will turn on
automatically. The lower LED indicator light will
go on after the corresponding button pressed.
1 Engine brake 8 Hazard warning lamp
2 Headlamp 9 Not used
Rearview mirror
3 Not used 10
heating (Optional)
Outline marker
4 11 Not used
lamps
Cab supercharge
5 Front work lamp 12
switch
6 Rear work lamp 13 Manual regeneration
7 Flashing light
1 Brake switch of engine

When the accelerator pedal is lifted, the limited
engine brake will be activated automatically.
2 Headlamp switch
Press the switch, the PS of headlamp (low
beam/high beam) will put through, the low/high
beam combination switch takes effect. Press the
switch again, the PS of headlamp (Low beam
/high beam) will shut down and the low/high beam
combination switch becomes invalid.
3 Not used
4 Outline marker lamps switch

Press the switch, the front/rear outline marker
lamps will go on. Press it again, the front/rear
outline marker lamps will go off.
5 Front work lamp switch

Press the switch, the headlamp will go on. Press it
again, the headlamp will go off.
36
6 Rear work lamp switch

Press the switch, the rear lamp will go on. Press it
again; the rear lamp will go off.
7 Flashing light switch

When the switch is pressed, the cab top blinker lights
illuminate, and when the switch is pressed again, the
blinker lights turn off.
8 Hazard warning lamp switch

Press the switch, the hazard warning lamp will go
on. Press it again, the hazard warning lamp will go
off.
9 Not used
10 Rearview mirror heating switch (Optional)

If the heated rearview mirror function is optional, the
heated rearview mirror turns on when the switch is
pressed. Press the switch again and the heated
mirrors turn off.
11 Not used
12 cab supercharge switch(Optional)

Press the switch, the cab supercharge will activate.
Press it again, cab supercharge will deactivate.
37
12 Manual regeneration switch

With the vehicle parked on level ground, release
the gas pedal, shift to neutral, apply the parking
brake, keep the engine idling, press the switch, and
after 5 seconds, the manual regeneration function
turns on. Once the function is on, pressing the
switch again does not turn off this regeneration
process.
Stage 0 No operation
Stage 1 is required.
Regenerate Keep the
manually switch in the
Stage 2
for the next open state
1-2 hours. for at least 5
Regenerate seconds. The
manually engine idle
Stage 3 within the speed will
next 30 increase
minutes. during the
regeneration
Manual
Stage 4 process. The
regeneratio
/Carbo regeneration
n is
n process takes
performed
Burnin approximatel
immediatel
g y 30-60
y.
minutes.
Immediatel
y stop and
contact
Stage 5
maintenanc
e service
personnel.
38
After adjusting the tilt angle of the steering

Steering column
column, push the handle downward to lock the
Length and angle of inclination of a steering steering column to the desired position.
column can be adjusted to provide comfortable

operating position for the driver. Multi-function combination switch
A multi-function combined switch is used
for controlling turn signals, high beam/low
beam headlamps, front windshield wipers, and
horn.
Turn signals operation

1. Steering wheel Right
2. Telescopic knob The handle is pushed forward to the
3. Tilting/telescopic handle maximum angle (8°), and performs automatic
4. Multi-function combination switch boxout, and sends right turn signals.
. Left
The handle is pushed backward to the
Tilting handle maximum angle (8°), and performs automatic
The tilting handle of the steering column boxout, and sends left turn signals.
can be used to adjust the tilt angle of the Note: An indicator light corresponding to
steering column. a combination instrument will be lit to indicate

the selected direction. See an assembly
Tilt adjustment instrument section in the maintenance manual.

Pull the tilting handle upward so that the Note: When turning ends, the handle will
steering column can be released from the lock be reset automatically and the turn signals will
position. After adjusting the tilt angle of the
be canceled.
steering column, push the handle downward to
lock the steering column to the desired High beam/low beam operation
position.
High beam/low beam switch
Telescopic adjustment Lift up the handle to the maximum angle
Pull the tilt handle upward to release the (8°) and then release it, so the handle will
steering column from the locked position.
automatically move down to its original
39
position and the high (low) beam will be A windscreen wiper rotary knob has 4
switched to low (high) beam; each time of positions. Turn the knob clockwise or
handle operation enables one high beam/low counterclockwise to the corresponding
beam switch. position to control the swing speed of the
Note: When the headlamp switch of the wiper.
bus keyboard is turned on (the headlamp Position 0 - wiper stops running
power supply is connected), the control Position J - wiper intermittent swing
function works. When the headlamp switch of Position Ⅰ -Wiper swings
the bus keyboard is turned off, the control continuously at a low speed.
function does not work. See the bus keyboard Position Ⅱ -Wiper swings
section in Operator’s Manual. continuously at a high speed.
Note: When the control function works,
an indicator light corresponding to a Windscreen wiper button
combination instrument will be lit to indicate
the selected high/low beam. See an assembly
instrument section in the maintenance manual.
Horn Button
Pressing the wiper button (below the

horn button), so the front windshield wiper is
started to clean the pump.
Note: When the wiper cleans the pump,
the wiper cannot be turned on
Press the button at the end of the
automatically. It must be turned on
combination switch to sound the horn. You
must verify that the horn is functioning manually.
properly before moving the vehicle. When
starting the engine and driving the vehicle, all
local safety rules regarding the use of the horn
as a warning signal device must be observed.
Windscreen wiper operation

A windshield wiper control device has 1
rotary knob and 1 button.
Windscreen wiper rotary knob
40
Seats
1. Body weight adjustment 2. Height adjustment 3. Seat cushion angle adjustment

4. Cushion depth adjustment 5. Shock absorber 6. Armrest adjustment
7. Armrest 8. Headrest 9. Backrest adjustment
10. Backrest adjustment 11. Seat belt 12. Front/back adjustment
41
Body weight adjustment Seat cushion angle adjustment

Body weight adjustment must be A seat cushion angle can be adjusted
performed when the vehicle is parked and the separately.
driver is on the seat by pushing up and down Pull the left handle up to adjust the seat
the weight and height adjustment handle angle. Adjust the seat cushion to a desired
(arrow) slightly. position by applying pressure to the front or
In the whole process, the driver must sit rear part of the basin.
on the seat.
Attention
Before weight adjustment being performed,
a shock absorber is adjusted to a "soft"
position.
To avoid endangering a driver, each driver
must check and adjust the body weight
adjustment settings separately before
driving the vehicle.
Height adjustment
Seat height is set through compressed air
and can be continuously adjusted.
Seat weight is adjusted by pushing up
and down the weight and height adjustment
handle (arrow) drastically. If the seat is
adjusted to the top or bottom end, the seat will
be adjusted automatically to ensure a
minimum elastic stroke.
Attention
Before height adjustment being performed,
a shock absorber is adjusted to a "soft"
position.
In order to avoid damage, keep the air
compressor running continuously (the seat
height is continuously adjusted) for 1
minute at most.
42
Cushion depth adjustment

A seat cushion depth can be adjusted
separately.
Pull the right handle up to adjust the seat
depth. Adjust the seat cushion to a desired
position by moving the cushion forwards or
backwards.
Shock absorber
A seat shock absorber device can be

adapted to a variety of road and non-road
driving conditions. The shock absorption
effect can be adjusted individually for this
purpose.
Rotate the handle to a desired position
and release the adjustment handle.
1- hard
2- middle
3- soft
Position 2 is basic setting recommended
for general driver weight.
Armrest adjustment
An armrest tilt can be changed by

rotating adjustment knobs.
When a rotary knob is rotated outwards,
a front part of the armrest rises; when a rotary
knob is rotated inwards, a front part of the
armrest falls;
43
Armrest
If necessary, the armrest can be folded up

and its height can be adjusted separately.
Adjust handrail height: Remove a round
cap from the cover (arrow), unscrew hex nuts
(size: 13mm), adjust the handrail to a desired
position (5 spacing), tighten nuts (torque: 25
Nm), and then install the round cap. 
Headrest
Headrest height can be adjusted
separately: Pull a headrest up to the end
position gradually.
A headrest angle can be individually
adjusted by pushing the headrest forward or
backward.
A headrest can be removed by pulling the
headrest to exceed the end position.
Backrest adjustment
A locking mechanism is loosened by

pulling up the locking handle up to the top.
When a locking mechanism is loosened, do
not apply pressure load on the backrest.
Move the backrest to a desired position
by applying or releasing pressure on or from
front or back of the cushion.
When a backrest mechanism is locked (a
lock handle is loosened), a backrest will not
move.
Seat belt
A seat belt and fastener installation must be
checked before you drive the vehicle.
44
Seat belt fastening

Pull a seat belt out from a contractor
continuously.
Lock a seat belt with lock tongue and lock.
Make sure a seat belt is surrounded by a lower
part of the driver's waist.
The contractor automatically adjusts length
of the seat belt and locks it in place. A
comfortable cushion allows the driver to have a
certain range of space.
Seat belt loosening

Press a release button on the buckle to
loosen the seat belt. A seat belt cushion retracts
to the contractor.
Front/back adjustment
Front/rear adjustment is performed by
pulling up the locking rod.
Warning
It is forbidden to operate the locking rod
when driving the vehicle.
Attention
After seat front/rear position adjustment is
completed, a locking rod must be stuck in the
locking position. "Clicking" may be heard
when a locking rod is locked. When a locking
rod is locked, a driver's seat will not move
forward/backward.
Do not use your leg to operate the locking rod.
45
Air Conditioner
Blowing surface Blowing surface/defrost Internal circulation / fresh air switch ON/OFF switch
Defrost Temperature adjustment Wind Boy Adjustment A/C button
Button Disengage function

Function System operation and display
operation button
ON when.
*Blower: OFF before state to drive
*Mode damper: OFF before state to drive
*Electric water valve: Pre-OFF status to
drive
ON/OFF *A/C: Pre-OFF status to actuate
Air conditioning *LCD: Light up *Power switch can
ON/OFF When OFF disable this function
*Blower: OFF
*Mode damper: Current state to fix
*Electric water valve: Fixed by current
status
*A/C: OFF
*LCD: OFF
A/C *Power switch, OFF

*A/C indicator on/off
Compressor button, A/C button,
*A/C cycle ON-OFF-ON each time the
Start/off can release A/C
A/C button is operated
function
Airflow *The display shows the air speed level

*Blower cannot be turned off by button
operation
*Power switch, OFF
Air volume *Manual adjustment of blower speed from
button turns off
adjustment 1 to 7 speeds
blower operation
*Blower operation status increases or
decreases by 1 speed for each ▼ or ▲
operation
TEMP *The set temperature (17℃℃32℃) is
*The power switch
displayed on the display.
button can release this
*The set temperature can be changed by
function
Set temperature 0.5℃ when operated by ▼ or ▲.
-System stop
Adjustment *The maximum setting temperature is 32℃
operation
and the minimum is 17℃.
-Electric water valve
*According to the set temperature, the
is now fixed
electric water valve is controlled
46
Blowing *Blow face/defrost

surface *The blowing surface button indicator
button, defrost button,
Blowing lights up
power switch button
function *MODE function is fixed to blowing mode
can release the blow
face function
Blowing *Blow face/defrost button indicator lights *Blow face button,

face / defrost Blow up defrost button, power
face/defrost *MODE function is fixed to blowing switch button can be
function surface/defrost mode released from the
blow face function
Defrost *Blow face/defrost

*Defrost button indicator light is on button, blow face
Defrost function *MODE function is fixed to defrost mode button, power switch
button can release the
blow face function
Internal
circulation Internal * This function can be
* In the state of internal circulation, the
/Fresh air circulation / deactivated by the
operation is changed to fresh air intake
switch fresh air power switch and
* In the state of fresh air, the operation is
switching fixed to the internal
changed to internal circulation inlet air
function circulation state.
Precautions on use of air conditioning

During the running of air conditioning, the engine must start at low running speed. When the engine runs at
high speed, do not start the air conditioning. Otherwise, it will cause the fault of air conditioning fault.
Ventilation
When the air conditioning is turned on, the ventilation is also activated.
Temperature control
At the temperature where you feel cooler when entered into the cab: 5-6℃ (9-10.8℃) lower than the
outdoor temperature. This temperature difference is normally considered as the most suitable to human
health. Therefore, you must pay attention to adjust the temperature correctly.
Requirements when the air conditioning is not in use
To lubricate all parts of compressor, operate the cooling and dehumidification functions. Heat at low idle
for 3-5mins once every month. Check the coolant capacity twice every year.
Condenser cleaning
The condenser should be cleaned once every 500hrs or as necessary.
1 Park the truck at the maintenance position.
2 Open the engine hood
3 Use the compressed air to blow clean the condenser.
Attention
Please pay attention to the hoses among the compressor, condenser and evaporator. There is always
47
some redundant pressure in the system.

Do absolutely not open the system, where a certain surplus pressure is contained. Have the
authorized maintenance shop do this job.
48
Operating instructions
Safety operation rules
The drivers must have a driver’s license B2 and above (other countries refer to implementation).
Warning
Withdraw all outsiders from the machine workspace. Attentions should be paid from all directions, so to
avoid crashes on the personnel or objects. During the start process, do not touch the control level or switch.
Before the operation, you have to honk the horn.
1 To guaranty the safety of yours and other road users and personnel in working site,
2 Before the operation, the machine operator should try everything possible to reduce the accident risk.
3 The machine operator must be very familiar with how to operate and maintain the machine, and have
received the necessary machine operation training.
4 The machine operator must conduct the operation in compliance with the provisions and instructions
in the Operation Manual and respect all national regulations or special requirements relevant to the
working site and risks.
5 The machine operator must have a full rest. It is prohibited to operate the machine after drunk and
taken drugs.
6 Regardless of operating on public roads or on the operating site, the machine operator must be
responsible for the machine load.
● In operation, no risk of load falling is allowed.
● Do not take any load, which visibly endangers the safety.
● Comply with the provisions relevant to the maximum rated load of machine. Pay attention to the impacts
from the distance variation between the load and gravity and additional device.
7 When lifting the body on abrupt slope or spongy ground, do not operate the machine to avoid the risk
of overturn.
8 The machine operator must be responsible for the working area of machine.
● Prevent personnel from getting access into the hazardous area, i.e. park at least in 7m away from the
machine. The operator may allow a working staff to enter into this area, but must be very careful
afterwards. He is allowed to operate the machine only when seen clearly the opposite side or received the
clear signal indicating its position.
● When there is risk of being struck by apparatus or dropped objects (e.g. stones or logs) in the parking
position, no persons are allowed to stay in cab, unless the cab is strong enough or protected to withstand
this kind of object impacts.
The dangerous area around the static and

running machine should be at least 7m away
from the machine.
49
Accident ● Adjust the seat.

1 After the occurrence of accident, it should be ● Select the flattest terrain.
reported immediately to the Local Emergency ● the machine speed should be adaptive.
Management Agency. 10 The cab is a protecting facility for the
2 If possible, the machine should stay put. machine operator. It meets the test standard
3 Only take the necessary measures to reduce requirements (ROPS) on the rolling
loss, especially the casualty. Avoid the protection structure. Therefore, in case of
motions which make the investigation of tipping of machine, hold firmly the steering
accident more difficult. wheel and do not jump from the truck！
4 Wait for the further instruction from the Local 11 The cab also meets the requirements of
Emergency Management Agency. dropping object protection and has the lighter
weight as described in the testing of Falling
Safety of operator Object Protective Structures (FOPS).
12 In a thunderstorm, do not climb, enter or
1 Be sure to fasten the diagonal safety belt. leave the machine.
2 Be sure to start up the machine (engine) on ● When you are outside the machine, a certain
the operator seat. distance with the machine should be held before
3 Check and confirm whether the overlapping the storm has passed.
seat safety belt has any wears or damages. ● When staying in cab, you have to stop the truck
4 The machine must be fully operational, i.e. and sit motionless until the storm stopped. Do not
before use of machine, any faults which can touch any controllers or metal product.
cause accident, must be troubleshot. 13 The cab has three emergency outlets, i.e.
5 Wear the work suit and hard hat suitable for doors, RH window and LH window.
safe operation.
6 In running of machine, do not use the mobile
phone. In operation, use of the mobile phone
should comply with all national provisions！
7 When entered into an exit from the machine,
please use the tread and handle. Use
three-point standing, i.e. two hands and one
foot, or one hand and two feet. Be sure to
face the machine – do not jump down！
8 When the machine is moving, the doors must
be closed.
9 The vibration during the operation is harmful
to the machine operator. The following
measures can be taken to reduce the adverse
effect of vibration:
50
Driving on public roads 2 Activate the parking brake.

In comparison with other means of transport, the 3 Turn off the engine using the ignition key or by
articulated vehicle is a type of slowly moving and pressing the emergency stop button in the cab or
on the frame near the left armrest rail.
large vehicle. It can cause the traffic jam. You
4 Leave the cab.
should pay attention to the vehicles at the back.
5 Use the battery at the cab entrance to cut off
Provide others with the convenience of overtaking.
the switch and shut down the main PS.
In operation on public roads, do not use the work
6 Try to put out the fire.
lamp, rotation alarm signal light or hazard
7 Call the fire department as necessary.
flashlight, unless otherwise stipulated in local
regulations. Measures before the operation
In consideration of the traffic flow and density or 1 Carry out the routine maintenance.
the necessity of other local conditions, the road 2 Clean/deice the windows and rearview
signs must be used and the barricade and other mirrors.
safety device set. 3 Check and confirm if the backup camera (if
In the following cases, the rotating alarm lamp can installed) clean and intact.
be used: 4 Check and confirm that all lights are clean
● When the machine obstructs or poses risk to the and intact.
traffic stream; 5 Check and confirm if it is possible to cause
● In operation on road or roadside. damaged, fault/loose parts or leakage.
6 Confirm that the battery disconnecting switch
is put through.
Fire-safety procedure 7 Confirm that the connecting lock of steering
When your own safety will be not exposed to the frame has been disconnected.
direct hazard, please take the following measures. 8 Confirm that he wheel stop dogs have been
When the working site is on fire removed.
1 If possible, drive the machine off the 9 Confirm that the engine hood and guard plate
hazardous area. are closed.
2 Activate the parking brake. 10 Adjust the operator seat.
3 Turn off the engine using the ignition key or by 11 Check and confirm if the diagonal safety can
pressing the emergency stop button in the cab or be fastened without damage.
on the frame near the left handrail. 12 fasten the diagonal safety belt.
4 Leave the cab. 13 Confirm the sufficient fuel in the oil tank.
5 Use the battery at the cab entrance to cut off 14 Check and confirm if there are persons
the switch and shut down the main PS. nearby the machine.
6 If possible, put out a fire quickly and call the
fire department as necessary.
When the inner machine is on fire After the operation
When the machine is under operation: Top up the fuel tank and prevent form the
1 Try to park the machine on a place of fire formation of condensed water.
prevention.
51
Start the engine 5 Continue to turn the key to the "START"

position (starting position) until the desired
There are three ways to start the engine: key switch engine speed is reached.
start, external engine start/stop button start and The engine starts and runs at idle speed. After
approx. 3 seconds, the engine speed increases
jumper start. In general, use the key switch to start; and the engine continues to run at the current set
when it is convenient to operate the external engine speed after the key is turned back to the "ON"
position. The engine speed can be increased to
start/stop button, use the external engine start/stop the maximum speed limit. The "START"
button to start; jump start is a temporary emergency position (starting position) is held for no more
than 10s.
start solution, which is applied when the car battery
If the engine does not start immediately:
runs out of power. interrupt the starting procedure within 10
After starting, run the engine at low idle speed for at seconds. Turn the key back to the "ON" position
and try to restart again.
least half a minute. This is to ensure lubrication of After 3 attempts to start, wait about 3 minutes
the turbocharger. and try again.
Immediately after starting the engine, observe
the oil pressure gauge.
Preparation of engine start
1 Before the engine start, it should be filled
with oil, coolant and fuel as specified;
2 Be sure that the battery is plenty of
electricity;
3 When the fuel system was allowed to
continuously run until the fuel run out. When
the engine restarts after the refueling, it is
necessary to bleed off the fuel system, which Key switch
enables the Mefformin to continue in filter;
4 Pre-setting the engine idle speed value.
5 Securing the vehicle to prevent skidding.
6 Turn on the operating power. Warning
Start with the key switch
It is strictly prohibited to let the engine in the
1 Set the operating handle in the N-position
ignition position for long time. Each ignition
(N-position of gearbox);
time shall not exceed 10s and the interval no
2 Insert the key into the key switch. Now, the
less than 3min. The overheating will cause the
key is set in the "LOCK”position;
serious damage on the starter motor.
3 Turn the key to the“ON”position; the PS
circuit of vehicle is electrified;
4 At the meantime check and confirm that all
Attention
signs in the row are lighted, and the
instrument displays the reading. When the engine successfully started, the key
switch is set in the“ON”position.
6 Check if all control and warning lights have
Warning gone off.
7 Honk the horn.
Do absolutely not use the start adjuvant (e.g.
8 Depress brake pedal and release parking
ethyl ether), which may cause serious damage
brake.
on the engine.
9 Select the gears and increase the engine
Do not run the cold engine, because there is risk
speed.
of serious damage on the machine.
52
Engine external start/stop button start (N-position of gearbox);

2 Apply the parking brake;
1 Set the operating handle in the N-position
3 Turn the key to the“LOCK”position. Now,
(N-position of gearbox);
all circuits are powered off and the engine
2 Press the engine external start/stop button start
flames out. If equipped with a turbo delay-off
button to start the engine and idle. device, the turbo is slowed down and the
Jumper start of engine engine is delayed off.
1 When battery runs out, a jumper lead and a
temporary battery can be used to start the
engine;
Attention
1 Be sure that the battery is of the nominal
voltage, otherwise, it will cause the
irreparable damage on the battery;
2 Do not place any metal parts on the
battery, otherwise, there will be risk of
short-circuit;
3 The exhausted battery will be frozen at
External On/Off button on the engine
ca. -10℃, before the jumper start, let it
1 On/Off button
thaw at first;
4 When the engine is started on rood, the
maximum voltage on the vehicle shall not
Warning
exceed 28V (when exceeded 28V, it will Unless a special situation, the vehicle must
cause damage on the electronic parts of stop to ensure the parking safety, apply
control device). timely the parking brake to prevent the
2 First of all, connect the positive terminal of coasting.
battery and then the negative terminal; The External On/Off button on the engine
3 Start the engine and let it run in short time; is gone off
4 Remove the jumper lead in reverse order. 1 Let the machine fully stop, set the operating
Flame out of engine handle in the N position (N-position of
gearbox);
2 Apply parking brake;
Attention 3 Press the External On/Off button on the
engine to flame out the engine.
In general and non-emergency cases, the
engine flames out by use of the key switch, If the engine is turned off, the system may
the External On/Off on the engine. The continue to operate for a short period of
External On/Off-button on the engine must time. Depending on the installation location,
be used for the convenience of operation; In
operating condition and outside
emergency case, the machine can stop by
temperature, circulation of the diesel
use of the emergency stop button of engine.
exhaust fluid (DEF) is necessary to ensure
cooling. For this reason, the Diesel Exhaust
Flame out by the key switch
Fluid (DEF) transfer pump will run during
1 Step on the brake to fully stop the machine,
this time.
set the operation handle to the N position
53
Operating Limits
Emergency stop button of engine The electronic engine management system can
The emergency stop button of engine is set on the monitor.
vehicle operating console in cab. There is also an  Emission-related faults in the exhaust gas
reprocessing system
emergency stop button (red) on the rack near the
 Faults in the exhaust gas reprocessing system
armrest rail on the left side of the vehicle outside the electronic monitoring
cab, with the same function. Press this button,  Diesel exhaust fluid (DEF) reductant
engine will stop immediately. consumption, level and quality
 Efficiency of the catalytic converter as defined
by the permissible threshold of nitrogen oxide
(NOx) emissions
Attention Operating limits manifest themselves as reduced
torque, which in turn may result in output power
Only in case of an emergency, shut down the limitation and engine speed limitation.
machine. Turn off the machine normally. Please
use key switch.
Emergency switch for exceeding
operating limits
Diesel Exhaust Fluid (DEF)
Emission-related faults detected in the supply can
lead to operating restrictions (engine torque and
engine speed limitation).
In an emergency, the operating limits can be removed
Emergency stop button of engine (red)
by pressing a button. This means that the engine can
run at full power for up to 30 minutes. This
emergency function can be enabled up to three times
by operating the switch.
Engine operation monitoring The button is deactivated when the final operating
limit (20% of idle speed and torque) is reached.
Charging current
The charging current indicator must go out when the Display
engine is started.
If the indicator light does not go out or comes on
when the engine is running, turn off the engine. Tachometer
Find and troubleshoot the cause of the problem.
Warning
Electronic Engine Management System
The indicator and warning lights must go out when If the maximum permissible engine speed is
the engine is started. exceeded, a warning tone will sound.
If the indicator or warning light does not go out or You should drive and shift gears according to the
comes on when the engine is running, there is a fault engine speed displayed on the tachometer, not the
in the engine electronic management system. sound of the engine.
Find and troubleshoot the cause of the fault. Avoid driving at speeds in the red overspeed zone as
Each fault is stored in the system by its respective this may result in engine damage.
fault code. Temporary faults are also stored.
Fault codes can be read at a qualified professional
service center using a diagnostic tester. General notes about the tachometer.
● Pay attention to the tachometer display during
driving and keep the RPM in the economic RPM
Oil pressure zone
In some cases, it may be necessary to run the engine
If the indicator light does not go out or comes on at a speed outside the engine economy RPM zone,
when the engine is running, turn off the such as when climbing a hill or overtaking a car.
engine.Find and troubleshoot the cause of the fault. ●If you run the engine within the economic engine
speed range, it will help to reduce fuel consumption
54
and wear Fuel consumption

●In engine braking mode, drive the vehicle at
moderate engine speed. The best engine braking General notes
effect will be obtained when the red speed zone is
Fuel consumption depends on.
about to be reached.
● Vehicle type
●When driving downhill, make sure the engine speed
●Driving conditions
does not enter the overspeed zone (marked in red)
● Fuel grade
●Engine idle speed is automatically set according to
● Maintenance
the coolant temperature
● Driving resistance
●If the vehicle is at a standstill, the engine is running
●Driving style
and the transmission is in neutral, the engine only
Therefore, it is not possible to provide accurate data
slowly increases the throttle
on fuel consumption per engine.
Diesel exhaust fluid (DEF) level Diesel Particulate Filters

Diesel exhaust fluid (DEF) reducer is required to
reduce engine emissions.
Warning
Driving a vehicle without DEF will void the
environmental permit. Fabric or flammable material left in the engine
If the Diesel Exhaust Fluid (DEF) level has dropped compartment can ignite if it comes into contact with
to approximately 10%, the Diesel Exhaust Fluid the exhaust system or heated engine components.
(DEF) reserve level warning light on the instrument There is a risk of fire! After performing maintenance
panel will illuminate. Please refill the DEF tank work, ensure that no external flammable material
promptly. remains in the engine compartment or on the exhaust
If this display is ignored and the DEF level continues system.
to drop, engine torque and engine speed may be
reduced.
Engine torque may be limited to a maximum of 20% Warning
over the entire engine speed range. Engine speed
may be limited to idle speed.
If flammable materials generated by environmental
influences or carried by animals come into contact
Operating Instructions with the exhaust system or heated engine parts, these
substances may ignite. There is a risk of fire.
Conduct regular inspections to ensure that no
Break-in Vehicle flammable foreign material enters the engine
The break-in phase of the engine has an important compartment or exhaust system.
effect on the vehicle, especially for.
● Service life
● operational safety Warning
●Economy
During the break-in phase [up to 2000 km (30 Flammable materials such as leaves, grass, fine
working hours)], observe the following precautions： branches, etc. may ignite if they come in contact with
● Avoid running the engine at full load. hot exhaust system parts or exhaust streams. There is
●Build up the engine carefully at different speeds a risk of fire.
and engine speeds. Do not allow flammable materials to come in contact
●Avoid super running the engine at high RPM. with hot vehicle parts while parked. Take special care
●Do not exceed 3/4 of the maximum speed in each not to park the vehicle on hay or harvested grain.
gear.
●Select the appropriate time to change gears. Ensure that the exhaust gas re-treatment unit is
●Do not brake the vehicle by downshifting. cleaned and cared for.
● For automatic transmission vehicles, do not push
the accelerator pedal past the resistance point (forced
downshift). Attention
After 2,000 km (30 operating hours), you can
gradually use the vehicle at optimal performance and Extremely hot exhaust gases will escape from
increase the engine speed. the exhaust pipe during automatic and manual
regeneration. Keep a distance of at least 1
meter from other objects, such as parked
55
vehicles, to avoid property damage. Turn on/off: Press the button or switch. When
the indicator light comes on, regeneration is
Do not allow anyone to stay in the intake and
deactivated.
exhaust area.
Initiating manual regeneration
Attention
If you drive mainly short distances or light Warning
loads, the regeneration cycle may increase
significantly. As a result, fuel consumption Flammable materials such as leaves, grass, fine
increases and the functional range of the branches, etc. may ignite if they come in contact with
exhaust system may be affected. hot exhaust system parts or exhaust streams. There is
a risk of fire.
If you do not follow this instruction, there is a risk Do not allow flammable materials to come in contact
that. with hot vehicle parts while parked. Be especially
● Decrease in engine torque careful not to park the vehicle on hay or harvested
● Decrease in engine speed grain.
● Diesel particulate filter must be replaced
If excessive particulate builds up on the diesel
particulate filter, the indicator light on the instrument
Automatic regeneration panel will illuminate. The exhaust gas
reprocessing system prompts you to begin manual
When the indicator light on the instrument panel is regeneration.
on, it indicates that the automatic regeneration of the
diesel particulate filter is in progress. Attention
The automatic regeneration can be started while the
vehicle is in motion or while the vehicle is stationary. During the regeneration process, the engine
The automatic regeneration will only start when all speed may increase and the engine noise may
operating conditions are met (e.g. engine oil change. Please be aware of the increased engine
temperature and exhaust temperature are high speed and the drive train.
enough). If an operating condition is no longer met
while regeneration is in progress, the indicator light
will turn off and the regeneration process will be Attention
interrupted. As long as the indicator light is on,
If the electronic engine management system
avoid interruptions in operation. Regeneration prompts you to perform a manual regeneration
will automatically restart when all conditions are met
when the outside temperature is low, start the
again. If the regeneration is repeatedly interrupted,
regeneration before turning off the engine.
stop the regeneration temporarily. Then start a
If the engine is turned off without regeneration,
manual regeneration.
manual regeneration can only be started after the
engine warm-up phase.
Attention If the AdBlue® solution/diesel exhaust fluid (DEF)
During regeneration, engine noise and idle freezes, start a manual regeneration after a thawing
speed may vary. time of no more than 120 minutes.
Regeneration interruption Manual regeneration lasts from 15 to 90 minutes.

The regeneration process can be interrupted if it is The manual regeneration is initiated by means of a
necessary to prevent an increase in exhaust gas button.
temperature during regeneration (e.g. when the Requirements for initiating manual regeneration.
vehicle is driven into a hazardous area). Automatic ● Warning light and indicator light are on
regeneration and manual regeneration can then no ● Regeneration interruption is not turned on
longer be initiated and any regeneration currently in
progress will be interrupted.  Stop the vehicle while paying attention to
Regeneration interruptions can only be activated in road and traffic conditions and keep the
hazardous situations. If regeneration interruption has engine running.
been enabled, regeneration will remain deactivated Keep a distance of at least 1 meter from
even after restarting the engine. This may result in a other vehicles, objects and all flammable
rapid accumulation of large amounts of particles in materials when performing the operation.
the diesel particulate filter. Do not allow anyone to stay in the exhaust
area of the air intake.
56
 Press the button for about 3 seconds.

Manual regeneration is enabled only when. Do not start at this time and the warning buzzer will
● the engine oil temperature and exhaust sound.
gas temperature are high enough ● Exceed the maximum allowable engine speed.
●AdBlue® solution/diesel exhaust fluid ● Engine speed or speed is too high when shifting
(DEF) is not frozen gears.
● The system is running without fault ● Coolant level is too low or exceeds the maximum
The indicator light on the instrument panel is flashing permissible coolant temperature. The safety of the
and the engine speed is increasing. engine operation is compromised.
After regeneration is complete. ● An emission-related fault is detected or an
● The indicator light on the instrument panel goes emission-related fault causes an operating restriction
out to occur.
●Engine speed drops to idle speed
After regeneration is interrupted, the engine speed Refill fuel
drops to idle speed
Fuel
Replace the filter
Warning Warning
Fuel is toxic and hazardous to health. There is a risk
of injury.
Direct contact or inhalation of soot particles is Be sure to avoid accidental ingestion of fuel or
harmful to health. Risk of injury exists. contact with skin, eyes or clothing.
Please replace the air filter at a qualified professional Do not breathe fuel aerosols. Keep fuel out of the
service center. reach of children.
Keep doors and windows closed when filling with
Replacement of the diesel particulate filter is part of fuel.
the maintenance work and has a service interval of If you or others come into contact with fuel, observe
4500 hours. Maintenance and repair work requires the following points.
special skills and must be carried out at a qualified ● Rinse the fuel immediately and thoroughly with
professional service center. soap and water on your skin.
●If fuel comes in contact with your eyes, flush them
AdBlue® solution / Diesel Exhaust Fluid immediately with water and seek immediate medical
attention.
(DEF) consumption ●If fuel is swallowed by mistake, seek medical
attention immediately. Do not induce vomiting.
Depending on the use of the engine, AdBlue® ● Change the clothing that has been contaminated
solution / Diesel Exhaust Fluid (DEF) consumption with fuel immediately.
is up to 5% of the fuel consumption.
Warning
Engine oil consumption
Fuel is highly flammable. Improper disposal of fuel
poses a risk of fire and explosion.
After engine break-in, oil consumption may reach Avoid ignition, open flames, sparking and smoking
0.2% of the actual fuel consumption of the vehicle. under any circumstances. Turn off the ignition switch
Deterioration of driving conditions into increased and auxiliary heating system before working on the
mileage may cause engine oil consumption to exceed fuel system. Always wear protective gloves.
this value.
Warning
Warning buzzer
If fuel is mixed with gasoline, its ignition point will
If the warning buzzer sounds and the symbol on the
be lower than that of pure diesel fuel. When the
instrument panel indicates that the engine is
engine is running, the exhaust system components
abnormal, do not start or stop safely as soon as
may overheat without being noticed. There is a risk
possible while paying attention to road and traffic
of fire.
conditions. Otherwise, the engine may be
Do not fill with gasoline. Do not mix gasoline with
damaged.
diesel fuel.
57
contamination.
Attention
Observe the vehicle's fuel label to prevent Fuel filling
Illegal use of fuel can cause harm to people and the
incorrect refilling.
environment. Do not allow fuel to enter the sewage
system, surface water, groundwater or soil.
Attention  Turn off the engine.
Use only fuel with the specified quality grade.  Secure the vehicle to prevent skidding.
Use of unapproved fuel can cause irreparable  Observe fuel grade regulations.
damage to the engine and exhaust gas  Check for condensation in the rough fuel
re-treatment system and significantly shorten filter with heated oil-water separator.
the expected service life.
AdBlue® solution / Diesel Exhaust Fluid (DEF)
Attention Attention
High fuel sulfur levels can accelerate the engine Do not allow diesel fuel to mix into the
oil aging process and damage the engine and AdBlue® Solution/Diesel Exhaust Fluid (DEF)
exhaust system. reservoir. Otherwise, the exhaust gas
retreatment system may be damaged.
Attention
Never use gasoline to refill a diesel engine Attention
engine vehicle. Even small amounts of gasoline
can cause fuel system and engine damage. Use only AdBlue® solution/Diesel Exhaust
Fluid (DEF) with the specified quality grade.
Attention The use of unapproved AdBlue® solution/DEF
can cause irreparable damage to the engine and
If improper fuel is accidentally added, do not
the exhaust gas retreatment system and
turn on the ignition switch. Otherwise, fuel will
significantly shorten the expected service life.
enter the fuel line. Notify a qualified
professional service center and completely Attention
drain the fuel and fuel lines.
Use only AdBlue® solution/diesel exhaust fluid
Attention (DEF) with the specified quality class. The use
of non-permitted AdBlue® solution/diesel
Do not mix diesel fuel with any special fuel
exhaust fluid (DEF) can cause irreparable
additives.
damage to the engine and exhaust gas
Special fuel additives can cause.
retreatment system and significantly shorten
● Malfunction
● Damage to the catalytic converter the expected service life.
● Damage to the engine
Attention
Attention If AdBlue® Solution/Diesel Exhaust Fluid (DEF)
AdBlue® solution/Diesel Exhaust Fluid (DEF) comes into contact with painted surfaces or
is not a fuel additive and must not be added to aluminum surfaces while filling, immediately
the diesel tank. If AdBlue® Solution/Diesel flush the affected areas with plenty of water.
Exhaust Fluid (DEF) enters the diesel tank,
engine damage may result.
Attention
Do not mix additives into AdBlue®
Environmental Note solution/diesel exhaust fluid (DEF). Never use
Illegal use of fuel can cause harm to people and the non-distilled undiluted AdBlue®
environment. Do not allow fuel to flow into sewage Solution/Diesel Exhaust Fluid (DEF), as this
systems, surface water, groundwater or soil. may damage the exhaust gas treatment system.
Attention
Attention Be sure to properly close the AdBlue®
If you fill your vehicle with fuel from a drum or Solution/Diesel Exhaust Fluid (DEF) reservoir
filler can, filter the fuel before filling it. This to add excess solution. Otherwise, at very low
will prevent fuel system failure due to fuel temperatures, the AdBlue® solution/DEF
58
reservoir may be damaged. (Society of American Engineers Standard)

Environmental instructions classification when the outdoor temperature is
Please dispose of the AdBlue® solution/Diesel very low. Using an engine oil that is not suitable
Exhaust Fluid (DEF) reservoir in an environmentally for extremely low outdoor temperatures may
friendly manner. result in engine damage.
When opening the AdBlue® Solution/Diesel Exhaust

Fluid (DEF) reservoir, a small amount of ammonia Before the cold season begins, make sure that
vapor may escape.
Ammonia vapors have an irritating odor and can  The coolant contains sufficient antifreeze
particularly irritate the following areas.  The fuel used is suitable for winter use
● Skin
● Mucous membranes  Select the SAE (Society of American Engineers)
●Eyes classification of the engine oil based on the
Ammonia vapor may cause a burning sensation in the outside temperature
eyes, nose and throat, and may cause coughing and
tearing. Cross-connected starting
Do not breathe ammonia vapors. Only fill the
AdBlue® solution/diesel exhaust fluid (DEF)
reservoir in a well-ventilated area. Warning
If you come into contact with AdBlue®
Solution/Diesel Exhaust Fluid (DEF), do the
following. Liquid or gas based jumper start aids react
● Wash your skin immediately with water and soap if immediately to fuel aerosols and are highly
it comes into contact with AdBlue® solution/diesel flammable. Risk of explosion!
exhaust fluid (DEF) Do not use liquid or gas based jumper start aids to
●If your eyes come in contact with AdBlue® start the engine.
Solution/Diesel Exhaust Fluid (DEF), flush your eyes
with water immediately. Seek immediate medical
attention Coolant preheater
If you swallow AdBlue® Solution/Diesel Exhaust
Fluid (DEF), rinse your mouth with water and drink Warning
plenty of water immediately.Seek immediate medical
attention
High voltage in the 230 volt battery if
●Change clothing that has been exposed to AdBlue®
 230 volt power is set
solution/diesel exhaust fluid (DEF) immediately.
 Fault interruption is turned on
Adding AdBlue® solution/Diesel Exhaust Fluid
Putting your fingers in the socket may result in
(DEF) is not part of the maintenance work. The
solution should be added to the reservoir periodically electric shock. This is especially important for
while the vehicle is in motion or at the latest when children. There is a risk of fatal injury.
the first event message is displayed in the electronic Do not put your fingers in the outlet and keep
engine management system. children away from the outlet. Always check that
the fault disconnect is working properly after
Refilling the fuel connecting to the 230 V local grid.
 Turn off the engine. , , and The coolant preheater consists of an electric heating
 Secure the vehicle to prevent skidding. unit and is installed in the engine crankcase. The
 Turn off the auxiliary heating system. coolant preheater operates at 230 volts and is not
Always fill the AdBlue® solution/diesel exhaust affected by the on-board electrical system.
fluid (DEF) reservoir with more than 10% solution, Please observe the information in the vehicle
as filling below this value may cause a malfunction. operator's manual.
You can have the basic wiring of the coolant
Winter Driving preheater modified at a qualified professional
service center.
Winter driving instructions Battery
Observe the instructions in the vehicle operator's
manual for jumpering the vehicle from another
Attention vehicle.
Make sure that the battery is fully charged. This can
Never add engine oil to the appropriate SAE be achieved by careful maintenance and by
59
maintaining low power consumption. When the

battery is cold, the cold start volume may be
reduced. For example, when the temperature is
-10 °C, the cold start volume is only about 60% of
the normal volume.
Diesel fuel
Warning
Fuel system components can be damaged if they are
heated (e.g. by using a heat gun or open flame). This
may result in fuel spillage and ignition. Depending
on the type of damage, fuel may not spill until after
the engine has started running. There is a risk of fire
and explosion.
Do not apply heat to fuel system components.
Contact a qualified professional service center to
repair the problem.
60
machine can still use the complete loop to brake.

When the pressure in whatever loop is incorrect,
Steering system
the warning will show up in the message display
The steering system is a full hydraulic steering screen.
system. Auxiliary brake
Assisting steering system The auxiliary brake is a complement to the
The machine is outfitted with the assisting steering conventional brake.
system, which works through the ground pump on Engine brake
the transfer case, and ensures the steering at the The engine brake is a reduced pressure brake with
min. speed of ca. 5km/h, even though the engine a controlled exhaust valve that provides high
comes up with a fault. braking power. The engine brake can be controlled
or adjusted in steps.
When too low steering pressure alarm is displayed It is used to enhance the braking force of the
in the monitor, shut down immediately and get in engine by restricting the exhaust.
contact with the XCMG-authorized service shop. In whole range of engine speed, the engine brake
can provide good braking performance and the
brake performance is higher at greater engine
speed.
The engine brake can make the operation smooth
and comfortable, and decrease wears of machine
conventional brake system.
Steering system fault warning The engine brake force depends on its coupled
gear, lower the gear, greater the brake force is,
otherwise, the brake force decreases.
Brake system
In the following situations, the engine brake
works:
●The brake switch of engine is closed;
●The accelerator pedal is completely released.
In the following situations, the engine brake is
engaged:
● The brake switch of engine is disengaged
● depress accelerator pedal
Enable/disable continuous braking
Attention
1 Service brake If you apply continuous braking or shift to a
2 Loading and dumping brake lower gear to increase engine braking power on
3 Engine brake slippery surfaces, the drive wheels may lose
4 Parking brake traction, increasing the risk of skidding and
accidents.
5 Exhaust brake of engine and gearbox retarder Do not apply continuous braking or shift to a
Service brake lower gear to increase engine braking on
The vehicle should be braked smoothly, especially slippery roads.
on a frozen and slippery road surface.
If the continuous braking is deactivated and the
When operating downhill, first use your engine indicator light on the instrument panel does not
brake to reduce wheel brake wear. go out, have the continuous braking checked by
a qualified professional service center.
The service brake is divided into two individual Engine braking can be used as continuous braking.
loops. When one of the loops has a fault, the You can take advantage of the engine braking effect,
61
especially on longer downhill stretches, when

 Initiate continuous braking
 switch to a lower gear in good time Attention
 When driving downhill, if the engine braking is
ineffective, slowly depress the brake pedal. The loading and dumping brake is enabled only
when the machine is loading, dumping and in
Engine braking static state！
The engine braking effect depends on the engine This function is blocked at speeds above 0.5
speed. If the engine speed is higher, the braking km/h (0.31 mph).
effect will be better.
The maximum allowable engine speed may be This function is deactivated when shifting the
limited depending on the vehicle application. gear selector out of neutral.
In very low outside temperatures, engine braking
may be limited or completely ineffective when the
engine is started. Parking brake
When the vehicle stopped for a long time, use the
parking brake; Use the parking brake before the
Attention operating personnel leaves the driver seat.
To minimize the wears of service brake, the
brake shall be used in the order of:
1. Engine brake
2. Service brake
Attention Parking brake button

When service brake has a fault, you should stop
the machine at once and call the XCMG
authorized maintenance shop for help.
Warning
When the machine is moving, the application of
parking brake will result in abnormal wear of
Attention machine. When the parking brake has been
When none of two brake loops has the brake used as the emergency brake, you have to
effect, you should activate the engine brake, contact the XCMG authorized maintenance
and parking brake to stop the machine, where shop to check the parking brake after the event.
the parking brake has to be involved in the
brake.
Warning
The parking brake cannot be used as the
Loading and dumping brake loading and dumping brake！
The loading and dumping brake enables the Emergency brake
service brake and set the gearbox to the N-position. In case of emergency, the parking brake can be
This can avoid the wears of parking brake and used for brake, at the meantime, the engine brake
power train. and hydraulic retarder can be applied for brake.
Loading and dumping brake button
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Parking 9 If it has been more than 20,000 km (or

approximately 300 operating hours) since the
Anti-theft last oil change, change the engine oil and oil
Remember that the implementation of the filter.
following key points can minimize the stolen and The engine oil and oil filter should also be
changed if the oil is more than 12 months old.
break-in risks: 10 Check and adjust the coolant level or change
● Avoid parking the truck in the high the coolant.
prevalence areas of the events such as the 11 Check and correct the level of anti-corrosion
theft, illegal intrusion and malicious agent/antifreeze in the coolant.
12 Fill AdBlue® solution/diesel exhaust fluid
destruction. (DEF) until the reservoir is full to prevent
● When the machine is unattended, the ignition crystallization of AdBlue® solution/diesel
key should be pulled out. exhaust fluid (DEF).
● After the completion of work, lock up the 13 Drain the fuel system oil/water separator
door, rack and battery cap. Measures to be taken while parked
● Use the cut-off switch of battery to Start the engine at least once a month and run it at
disconnect the PS and remove the handle. approximately 900 rpm for 15 to 30 minutes.
Parking  Turn on the air conditioning system
1 Try to place the machine on a horizontal  Turn on the heating system
terrain. If impossible, the wheels shall be  Turn on the auxiliary heating system
wedged to prevent the sliding. If the engine is running on fatty acid methyl ester
2 Apply the parking brake. (FAME)-free fuel (biodiesel fuel/no biodiesel
component 1), it does not need to be started every
3 Be sure that the body is lowered. Avoid
month, even if it is subsequently stopped.
parking the machine in load. The engine oil and coolant levels must be checked
4 Confirm that all switches and control parts before each engine start. If the vehicle has a fuel
are in the Off or N-position. filter or rough fuel filter with an oil/water separator,
the oil/water separator must be drained additionally.
5 Close the windows and pull out the ignition Note the oil pressure and coolant temperature before
key and lock up the cab door. starting or when the engine is running.
6 Turn off the cut-off switch of battery on the Measures to be taken before re-use.
ladder at the left front of the head and the  Install and connect the battery
disconnector of engine start.  Check that the electrical system is operating
Parking for longtime correctly
1 Take above measures.  Check cables, hoses and lines for breaks and
2 Place in a sheltered, dry and well-ventilated leaks
area. The room temperature should not drop to  Check engine oil level
-10°C.  Check oil level in steering system and
3 Clean the machine and carry out the painting hydrostatic fan drive
make-up and rust protection.  Check coolant level and correct if necessary
4 The exposed parts should be subject of the
 Check AdBlue® solution/diesel exhaust fluid
rustproof treatment; the machine should be (DEF) level
thoroughly lubricated. Grease should be  Check fuel level
sprayed on the uncoated surface (lifting oil  Start the engine and run it at medium engine
cylinder, steering oil cylinder). speed until it reaches operating temperature
5 Check the tire pressure. (coolant temperature). Also, watch the oil
pressure, coolant temperature and oil
6 Refuel the fuel tank and hydraulic oil tank up
temperature indicator
to the maximum mark.
 Vehicles with auxiliary heating system: activate
7 Cover the exhaust pipe. the auxiliary heating system and check the
8 Drain out water from the compressed air tank. working condition
63
 Check the working condition of the steering dumping materials behind the body.
system and brakes 4 Lower the body.
 Check if maintenance is due and perform 5 While operating the conveyor according to
maintenance if necessary
the Step 1, let the auxiliary machine lift and
push the tail of body until the machine gets
Inspection after parking for longtime
no stuck any further.
● All levels of oil and working solution
Step 4
● Tension of all safety belts
Get rid of being stuck with help of the rescue aid.
● Tires pressure
When the conveyor didn’t sink and the wheels are
● Air filter
slipping, you can connect the towing bar, wire
● Battery status
rope or chain to the towing eye for hauling, or
push it away by another machine.
Measures to be taken when stuck
Step 1(Zigzag operation/“Duck walk”)
Warning
1 Use the foot button to couple with all
differential locks. After got rid of being stuck, you need clean the
2 Keep the stable engine speed and avoid the clods and debris the first time at the position of
wheel slip. articulated body position, otherwise, they may
3 Alternatively turn the steering wheel to the cause wears on the rear PTO shaft of gearbox
left and then the right sided positions. When a and piston rod of steering oil cylinder.
direction stop position is achieved, continue
to operate in this direction until the machine
is about to stop before turning to another
direction stop position.
After turning for 3–4 times, the machine keeps
static or sinks deeper, now stop it and execute the
Step 2.
Step 2(Loosen through swing)
1 Release the accelerator pedal to stop the
rotation of wheels.
2 Hitch the differential lock.
3 Select the gears D and speed up.
4 Lift the accelerator pedal and brake.
5 Select the R gear and speed up again.
6 Repeat this step until the machine becomes
loose by “Swing”.
When the machine gets stuck and remains
motionless, you have to stop and execute the Step
3.
Step 3
1 Towing with the help of crawler tractor,
loader or excavator.
2 When it is impossible to unload because of
the overturn risk, the support machine must
be used during the dumping operation.
3 Use the support machine to move the
64
Salvage and hauling ● The towing should be completed in the

distance as short as possible.
Warning ● The maximum towing speed is 10km/h
(6.2mph).
Before taking the salvage or hauling measures, ● Use a trailer if possible.
you must apply the parking brake to prevent the
machine from rolling over. In conducting the
Prompt
hauling, it must be very careful to avoid the
personnel injuries. The engine cannot be start by towing.
Prompt
Warning
During the salvage by towing, the machine
When the engine is unable to start, the braking and
should be unloaded. Otherwise, there will be
driving functions will be restricted. In that case,
fault risk at the frame hinge joints.
the hauling can be done only when necessary. Do
Case 1 (The engine runs)
absolutely not shorten the distance. The hauling
The gear selector should be set in the N-position
should be performed by the experienced personnel
and the parking brake released. In case, where no
(See the Part: Hauling). When possible, please use
special precautions were taken, the machine can be
the trailer for the transport of machine.
towed for 10km (6miles).
During the salvage by towing, the engine should
Case 2 (The engine doesn’t run)
run. The brake and steering functions should be
When the engine doesn’t run, the following
provided if possible.
measures must be taken before towing.
Salvage by tow
● Use the towing bar, cable or chain to connect
with the towing eye in front/rear of machine, Prompt
so as to tow the machine to the appropriate When the engine doesn’t run and the brake
position or passable road. performance cannot be guaranteed, a towing
● The connected towing bar, wire rope or chain bar should be applied for towing.
size should be selected according to the ● Connect the towing bar. No use of chains or
machine weight. cables is allowed.
● All of two towing eyes should be used to ● Mechanical tripping of parking brake.
avoid shearing load on the frame. ● Remove the transmission shaft between the
● Be sure no persons stay in the hazardous area. gearbox and transfer case.
Towing Connection with the towing vehicle
● After the salvage by tow, the machine must 1 Be sure that the machine cannot roll.
be towed in a service shop. Use the towing 2 Connect with the towing bar.
bar or cable to connect with the towing eye in 3 Release the parking brake as shown below.
front. 4 In the related cases, remove the transmission
● When the towed machine has no brakes shaft between the gearbox and transfer case.
available, the towing bar must be used. 5 Removal the stop dogs of wheels.
● The weight of towing vehicle or machine
must be equivalent to that of towed vehicle
and the sufficient engine output power and Warning
brake performance should be provided, so as Risk of fatal accident.
to tow or stop two machines during the The parking brake cannot work after manual
up/downhill operation. unscrewing. The travel speed of towed machine
65
may be faster than that of towing vehicle. This relevant to the failure of parking brake
will result in fatal accident and cause serious performance label on the steering wheel.
casualties. Do not use the machine until the parking brake is
Always use the towing bar. restored, which must be done by a XCMG special
Be sure that the towing vehicle has sufficient maintenance plant.
brake force to stop the machine and towing 1 Block the wheels or prevent the machine
vehicle. from rolling in other ways.
2 Remove the hand pump, which is used to
relieve the parking brake.
Warning 3 Start and run the engine, until the brake
Do not leave the machine before the parking energy accumulator achieved the correct
brake performance is restored. working pressure.
It must be clearly indicated through the label 4 Use the switch on the control panel to release
containing the massage relevant to the failure of the parking brake.
parking brake performance label. 5 Afterward, check the performance of parking
Do not use the machine until the parking brake brake.
is restored, which must be done by a XCMG
special maintenance plant.
Mechanical tripping of parking brake Tipping

When the switch cannot be used to release parking
brake due to the PS or abnormal brake pressure,
the manual release brake can be applied instead. Position 1
During the towing for a long distance, the parking
brake must be drawn by the mechanical tripping.
Operations are defined as follows:
1 Block the wheels or prevent the machine Position 2
from rolling in other ways.
2 Remove the brake pipe.
3 Connect with the hand pump pipe.
4 Manually pressurize to release the parking Position 3
brake.
After salvage by tow/towing
After salvage by towing, the following safety
Dumping
measures should be performed before the
During the dumping, attentions should be paid to
disconnection with the towing bars, cable or chain:
the following points:
1 Place the machine on a level ground.
● Hold the machine stand, and place the load
2 Apply the parking brake.
unit on a level ground.
3 Block the wheels to prevent sliding.
● Be sure no persons nearby machine.
Apply parking brake after the mechanical ● When conditions allow, the dumping
tripping operation can be made while moving.
Do not leave the machine before the parking brake Drop of cargo compartment
performance is restored. It must be clearly When the handle is pushed forward from the initial
indicated through the label containing the massage position 2, to position 1, the cargo compartment falls
66
by gravity. When the cargo compartment returns from

position 3 to the original position 2, the cargo
Floating cargo compartment compartment enters the hold state, which keeps the
When the cargo compartment handle returns to the cargo compartment position in a certain position.
initial position from position 1, the cargo If the operator leaves the seat or turns off the
compartment is floating at this time. machine with the ignition key, the vehicle enters
When the vehicle is walking, then the vehicle the hold position.
automatically into the floating position.
The floating position should be used for all
operations with an empty or loaded cargo
compartment. Maximum dumping height
Dumping It can adjust the maximum dumping height. It can
When the handle is pushed backwards from the be used when the machine is located at the
initial position 2 to position 3, the cargo restricted height.
compartment is lifted upwards and the cargo is The speed limit when the container is lifted
dumped.
When lifting from the top of container for
When the cargo compartment reaches the
maximum dumping height, it enters the holding unloading of cargos, the speed is restricted at 8
state. km/h (5 mph).
Cargo hold
67
Drop of the cargo compartment,

alternative method
The main valve contains a set of solenoid valves with
manual override function. By manual override, the
Float valve 1 cargo box is forced to be in floating position. When
the vehicle breaks down and the cargo box cannot be
dropped, the cargo box can be lowered manually by
this function.
Float valve 2 Warning

Never stay under a cargo compartment that is not
secured by a safety.
Warning
Floating valve position on main valve
Make sure that no one is near the machine when
the cargo compartment is being lowered to avoid
Manual knob Manual knob
the risk of injury to people!
Lowering the cargo compartment can be

done manually by the following methods.
The main valve and the internal pilot valve are
located under the cab and need to be operated after
raising the cab.
1. Remove the main valve cover and find the float
valve 1 and float valve 2 according to the location
Normal position Manual position shown.
2. There is an operating knob on the top of the float
Normal and manual position of the float valve
valve. By operating the knob, make the float valve 1
and float valve 2 switch from the normal position to
the manual position.
Tips
The manual position of the float valve will force the
cargo box to be in floating state, and the loading and
unloading handle will not be able to control the
movement of the cargo box.
3. Then, the cargo box will slowly drop on the frame.

Unless the cargo box is in the top position or the
vehicle is tilted back. In this case, the loading body
needs to lower the cargo box by lifting the rear of the
Lowering of the cargo box by means of a loade cargo box with the help of excavator or wheel loader.
4. After the cargo box is lowered onto the frame, the
float valve 1 and float valve 2 need to be restored to
their normal positions.
68
Transport of machine articulated body 4 by pin 2 and safety pin 3.
5. Stop the engine and apply the parking brake.

Warning 6. Place a "NO OPERATION" label so that it is
visible to all who enter the operator's console.
During the engine running, be careful to the Staff can now enter the area around the articulated
frame hinge points. There is risk of squeezin g body.
injury. Before operating the machine, the articulating
When the machine is driven from the loading safety lock lever must be released and
and rotate it back to its original fixed position.
platform onto the vehicle or truck platform, To remove the articulating safety locking lever,
attention should be paid that this vehicle should proceed as follows.
be safely braked, e.g. the wheels are blocked. 1. Remove the safety pin 3 and pin 2.
Also note that the vehicle has no risk of tipping 2. Screw the articulated safety locking lever 1 into
the original fixed position.
or rollover when driven. 3. Install pin 2 and safety pin 3.
When other vehicles are used during the lifting, Tie down the machine for transport
machine transport and the maintenance, the
articulated body should be locked up. 1 Tie down the machine through the front
Transport by other vehicle towing eye.
● The transport vehicle must be safely braked and 2 Tie down the machine through the rear
the wheels blocked. towing eye.
● During the lifting of machine, the articulated 3 Use the tie-down hole on the hoist cylinder
body must be locked up. attachments to tie down the middle of
Lock up of articulated body machine. Tie down the machine to the trailer
1. Park the machine straight on a level surface. body of transport vehicle, to prevent the
vehicle from sliding, overturn or rolling.
Besides, the national regulations must be
observed. Before the reoperation of machine,
Remember to unlock the articulated body and
fix the articulated body lock on the special
bracket.
2. Remove the safety pin 3 and pin 2.

3. Screw out the articulating safety lock lever 1 to
align it with the hole in the articulating body 4.
Alignment of the holes may require turning the
steering wheel to slightly adjust the hinge
angle
4.Secure the articulated safety lock lever 1 to the
69
Ensure the transportation road as flat as possible.

● Plan the machine operation
Operating technique Plan the machine operation and lift the accelerator
Fuel-efficient driving pedal before stop.
Let the truck stop on the last road, instead of
energy consumption by brake. Do not use the
Attention
brake performance of engine In case of
Turn on the air conditioning system only when unnecessary condition.
necessary. Fuel consumption increases when the
air conditioning system is turned on. ● Cooperation
In cooperation and planning with other operators,
try to enable the machine to work more efficiently.
● Hold it within the economic speed
During the driving, try to keep the low engine Higher engine speed cannot improve the
speed, to optimize the use of machine and ensure productivity, but increase often the fuel
the lowest consumption of fuel. consumption.
The fuel consumption has the closest relation with ● Adapt the machine operation to the
the engine speed. The low engine speed provides corresponding occasions.
lower fuel consumption, lower noise and higher Follow the suggestion of different applications.
comfort. ● Service and maintenance
The operating mode of fuel saving also means less The maintenance of machine according to the
wears of machine and less effect on the maintenance plan is of great importance.
environment. ● Use the tires of correct type and same rolling
● Do not depress the accelerator pedal when circumference, to avoid the stress presence in the
starting the engine power train.
●Avoid frequent cold starts Use tires of sufficient tread, to avoid unnecessary
wheel slip.
●Do not idle in place to warm up the car
● Maintain the tires with the correct inflation
●Shut off the engine when waiting for a long time
pressure
due to traffic conditions Follow the recommendation relevant to the
●Avoid frequent acceleration and rapid inflation pressure of tires. Correct tire pressure can
acceleration reduce the fuel consumption and machine wears.
●Drive the vehicle carefully and smoothly

Avoid reaching the maximum speed
●Switch gears as required
●Avoid frequent gear changes
● Deployment of the working scene

According to the machine analysis, plan your
working area and its layout, so to make the work
more organizational and efficient. Comply with the recommendation on the machine
● Transportation road halt and ensure the lubrication of turbocharger.
Try to plan the shortest transport route. This allows For more relevant information and the possibility
not only increasing the productivity, but also for taking part in the XCMG Mine Truck Training
lowering the fuel consumption. Courses, please contact your local dealers.
70
Transport operation
Body vibration
Warning
The whole body vibration produced by the
construction machinery is affected by many factors, Risk of machine tipping
e.g. the operating methods, ground condition and High-speed operation will result in serious
travel speed etc. casualties.
The operator has great influence on the actual Always drive slowly
vibration level, because the machine speed, ● Downhill
operating method and transport route are ● Turning
controlled by the operator. Therefore, the vibration ● On uneven road surface
level for different machines of same model may be ● On slippery road
quite different. ● For all operations on moderate off-chruby
Guideline of earth-moving machinery for roads, you should engage the gear D. Then,
vibration decrease the machine will automatically shift
● Use the machine of correct model and according to the demands of rim pull.
specifications, outfitted with properly ● Use the maximum speed of machine by good
selected equipment and attachments. judgment. Always adjust the speed according
● Maintenance of ground and haul road in good to the road and traffic conditions for safety,
condition. comfortable operation.
Clear large stone or obstacles. ● Attention should be paid to the movement of
Fill and level up the pits and trenches. trailer unit during the operation.
Provide the terrain renovation equipment and ● The loads should have no risk of falling
timetable. during the transport.
● Adjust the speed and transport route to ● Do not forget to disengage the differential lock
minimize the vibration level. when using it on a good road (firm surface).
Driving around the obstacles and on rough road. ● Please remember that the total weight of
When you have to pass uneven road surface, slow machine is up to 75t and the brake distance
down the speed. will be very long, especially when driving on
● Maintain he machine in accordance with the slippery road or at high speed.
manufacturer’s recommendation.
Tire pressure
Brake and steering systems
Operation controller, hydraulic system and
connecting device.
● Ensure the maintenance and correct
adjustment of operator seat.
Adjust the seat and seat suspension according to
the operator weight and height.
Check and maintain the seat suspension and adjust
the mechanism.
Use the diagonal safety belt and correctly adjust it.
● Minimize the long operation cycle and the
vibration in long distance driving.
The machine should be transported when the
distance between the contraction sites is longer.
71
Up or downhill operation In driving downhill, holding the gearbox at N

gear may cause the damage on the dynamic
The operation of machine is allowed on 20–30%
gearbox, or you may lose your control of
up/downhill road only on special occasions.
machine. On the downhill, one forward gear
Do not exceed the operation speed as
should be always engaged.
recommended on the deceleration label of
windshield.
The following rules must be complied with:

Operation across the gradient road
1. Slow down before downhill.
Only on special occasions
2. During the driving downhill, the same gear
The machine can be operated to cross the road
necessary for climbing should be engaged.
with the gradient more than 15%. Even if on
3. Use the engine/exhaust brake the first time
smaller gradient, the factors such as the limited
towing force and bad condition on the transport
route etc., will force the machine to slid or
overturn.
In general, the auto-gearbox can guaranty the
uphill driving with correct wheel swing force.
Under certain conditions, the gearbox may start
"Shift swing”. In other terms, the gearbox will
shift often between two gears (Up/downshift).
The shift swings because the engine power is
sufficient to up gear from a lower gear, but not
enough to operate at higher gears.
There are two methods to prevent the shift swing:
1 Select a next lower gear.
2 Enable the shifting lock function by use of the
switch on the control panel.
Downhill operation
Warning
During the downhill operation in full load, it is
possible that the composite effect of engine
brake cannot provide sufficient brake effect.
This will cause increase of service speed. Use
the service brake to lower the speed. Brake pedal
A. Engine brake/gearbox ambling
B. Service brake and engine brake/gearbox
ambling
Warning
72
Off-road operation
Different ground conditions need various
operating techniques. When you don’t expect that
the machine is trapped, you should check the
terrain before the operation.
● During the off-road operation, longitudinal

differential lock must be used when the
wheels have risk of slippage.
● During the operation in particularly difficult

situations, it should be used in combination
with the inter-axle differential lock with
stranded steering, to “restore” the towing force
of wheels, i.e. “Duck walk”.
● During the operation off the transport route,

the permission of the administrative
department should be gained.
● When the ground is very spongy and the
space allows a new route to be selected for
each operation. This can avoid the deeper
traveling track.
Prompt
During the running, try to avoid passing over
the abrupt slope, sharp gravels and tree
stumps.
Duck walk
73
250000 - 500000 8 26
Operation in hazardous areas
500000 - 550000 11 35
● Do not operate too close the border of wharf, 550000 - 750000 13 43
stones and ramps etc. 750000 - 14 46
● Conduct slow operation in narrow space. Remember that the voltage of power line decides
Check and make sure that sufficient space is the safety distance. When the high voltage arcing
available for the movement of machine and occurs, it will result in damage on the machine and
load. operator injury even if there is a long distance
● During the operation in the weaker light away from the power line.
condition, use the machine lighting, e.g. When the operator is already exposed to the high
indoor and in the channel. voltage arcing, necessary emergency measures
● When the visibility (Field of view) is very should be taken.
poor, e.g. in heavy fog, blizzard or rainstorm,
do not work or operate the machine.
● During the operation in contaminated or
health harmful environment, the machine
must have special outfits. Please contact the
dealer. Before the machine enters into the
working area, please refer to the local rules. Before working nearby the high voltage facilities,
Overhead high-voltage line be sure to contact the Owner.
Warning Attention
Be sure that the machine won’t touch the cable. During the machine transport, the overhead
When the body gets in touch with the charged cable should be also considered.
machine, it will result in the personnel injury. Railway overhead contact system
The high voltage is fatal and causes the damage on
the machine and attachments. Before the operation
nearby the high voltage power line, be sure to Warning
contact the electric power company in charge. Please always remember that adjacent tracked
Check and read the special instructions for the cable is charged.
operation nearby the power line published by the The loading and unloading can be done
electric power company. between the specific limit signs. The label may
It should be considered that all power lines are be fixed on the contact line or special post.
charged, even if some of the power lines were not. ● Before loading or unloading, please contact
When the machine or its load reaches too close to the responsible railway official for approval.
the power line any time (more than the minimum ● After a short rest during the work, always
safe distance), the conduct of operation is very contact again the responsible railway official.
dangerous. Please refer to the following table. Electromagnetic field (EMF)
Work exposed to the electromagnetic field:
Distance ● The site management personnel has the
Voltage(V)
Meter inch
responsibility for knowing if the strong
- 50000 3 10
magnetic field exists and notifying this
50000 - 69000 4.6 15
message to the machine operator.
69000 - 138000 5 16.4
● The operator should be active in search of
138000 - 250000 6 20
information to verify if the work site is
74
exposed to the strong magnetic field.

Subterranean cable and pipeline Warning
Be sure that the mechanism or company At very low temperature, the hydraulic system
responsible for the underground cable and pipeline of machine will become very slow. Therefore,
has been contacted and its operation instruction you should operate with cares to avoid accident
followed. It is also necessary to check which rules before the work temperature is reached.
are applicable to the underground personnel Please read the recommendation about starting:
exposed to the cable and pipeline during the ● Before use of the machine, no ice or snow
operation. In general, only employees of the should remain on the cab door and windows.
service company can deal with and lay out the ● Be careful to the sliding part on the machine.
cable. Only step on the ant sliding part.
● Use the ice scraper to clear up ice and snow
Operation on slope on the doors and windows. To this end, ice
● Be careful by opening the door, because it scraper with long handle or ladder can be
can swing off due to its gravity. When closing used when necessary.
the cab door, be sure it is fully closed.
● Do not retreat and drop on slope.
● When approaching the ramps or traveling on Warning
ramps, you should slowly operate.
Avoid your skin exposed to very cold metal
● During the operation on ramp or traveling
objects, because your skin will freeze together
sideways on slope, do not change the
with the metal.
direction.
Operation in water and swampy areas
Take special cares when operating in water or Warning
passing through the stream, especially in dark,
In maintenance of machine, disconnect the
turbid water or turbulent flow. Under water, there
electronic engine heater. Otherwise, there will
are hidden obstacles or the depth changes suddenly,
be risk of burn and electric shock.
which endanger the operator and machine. When
no risks can be ensured, you should restrain
Operating in polluted environment
yourself not to operate in such places.
The machine working in the contamination
● After the operation in water, the lubricating
environment /detrimental health place should have
points of chassis, which were immersed in
the special equipment applicable to the operation
water, must be lubricated to remove water.
in such environments.
● When operating in marshland, use very heavy
After the operation in the environment
wood pad to support machine. The padding
contaminated by asbestos or other toxic dust, the
should be kept as flat and clean possible.
used cab and engine air filter must be contained in
sealed plastic bags(bag to pack the new filtered)
Work in cold weather
and handed over to the destroy department for
special treatment
75
ARTICULATED DUMP TRUCK XDA45U Operation technique
of machine. This will cause serious casualties.

Loading
Before unloading, check the ground condition.
1 Park the conveyor at the assigned position. When passing over the edge for unloading, do not
By taking advantage of hinged steering, set reverse further. Be sure that the rear axle stays on
the machine at optimal loading angle. In solid ground. Check the edge strength.
reversing, always observe the instruction of The dumping method depends on the status of
loader operator through the rearview mirror. unloading terrain.
2 Apply loading and dumping brake. Method A: This is the fastest unloading method.
3 In loading, be sure to lower the body. The unloading terrain is very large and loads are
Otherwise, the full load will press on the pushed to the edge.
lifting cylinder instead of the frame. Method B: Try to back up the machine to the edge
as far as possible, so that the most part of loads
Prompt can unload over the edge. This exempts use of
bulldozer on the unloading terrain for the leveling
Please remember you are conveyor operator, it is
operation.
up to you, who decides the size of load and
weight.
Before leaving, it must be ensured that no loads
such as the tree stumps or stones will drop and
cause injury or damage. Protruding objects must
be moved away.
Operation
The Conveyor XDA45U possesses the excellent
off-road performance, which can often shorten the
transport distance and decreases the transport time.
You have to comply with the designated transport
route. In consideration to use the off-road shortcut,
or leave the road so to cope with the coming traffic
condition, you have to gain the permission of
administrative department.
The transport route condition has great influence
to the work capability of conveyor. When the
transport road is long and the maintenance not
good, try to persuade the administrative
department to
Maintain the road up to the higher standard. This
allows you to keep higher speed and means the
higher transport capability.
Unloading
Warning
Turnover risk
The gradient ground will result in the turnover
76
Prompt
Do not back up to exceed the extent, where you
are certain that the rear axle is still located on
solid ground. The edge strength should be
checked.
In back-up, you should always look at the rearview
mirror. Before the wheels of rear axle reach the
dumping edge, do not stop. Avoid driving on the
same wheel track to decrease the stuck risk of
wheels. Reserve a part of loads and unload it to the
edge.
Method C: During the stockpile unloading, back

up to the stockpile and unload. At the final stage of
unloading, tip slight forward.
Method D: When establishing the road

embankment or slightly prominent surface, you
can make best of your machine mobility at the
dumping ground.
The followings are applicable to all dumping

operations:
● Before lifting the body, be sure no persons
nearby the conveyor.
● When the ground is uneven, do not lift the
body when back up.
● When the machine is located at a steep ramp,
the machine should be move before the
unloading of loads.
● Place the machine flat. Apply the loading and
dumping brake. Move backward the dumping
bar to the unloading position and increase the
engine speed.
● Before the body just achieves its top position,
lower the engine speed.
● Before lowering the body, you should move
forward the conveyor several meters. Move
the dumping bar to the floating position.
Do not operate the body more heavily than
necessary. When the while load is stuck and the
body begins to lift, it is prohibited for the
conveyor to make the steering motion.
77
Safety for the maintenance methods, lubrication oil and parts other than
those described in this Operation Manual are
Please read before maintenance used, XCMG will assume no responsibility
Prevention of personal injury therefor.
● Before conducting any machine operations ● Be sure that no tools or other objects were
please read the operating instructions in this forgotten in or on the surface of machine;
Operation Manual. Read and comply with the otherwise, it will result in the damage.
information and instructions on the nameplate ● Before starting the maintenance work, the
and label. pressure in hydraulic system should be
● Do not wear loose cloths or jeweler, because released. The pressure set by the valve should
they can be stuck and cause injury. be no higher than that recommended by the
● In case of the demand by the work, be sure to valve manufacturer.
wear the helmet, protective eyewear ● The machines used in the polluted
(goggles), gloves and protective shoes. environment or health hazardous areas belong
● When the engine is started indoors, assure the to the equipment added for this kind of
smooth ventilation. operations. In the same way, there are also
● during the engine running, do not stand in special safety rules for the maintenance
front or rear of the machine. conducted on these machines.
● Before removing any shields or opening the ● When the two-way wireless communication
engine hood, turn off the engine at first. equipment, mobile phone or similar devices
● Even if the engine shut down, there is still are installed, the interference on the
accumulative pressure in the system. Direct functional units of electronic system and
opening of system in failure of pressure machine must be eliminated according to the
decrease at first will cause the injection of instructions of manufacturer.
high pressure liquid. ● Before the engine start and machine operation,
● Use a piece of paper or paperboard to check be sure that all guard plates, shields and
the leakage. Do not check directly with hand. protecting cover on the machine remain in the
● Be sure that no oil, diesel oil, dirt and frost appropriate position.
remain on the tread surface, handle and ● When cleaning or wiping the windshield,
skid-resistant surface. three-point support gesture should be adopted
● Only step on the machine parts with the (two feet and one hand).
anti-sliding protection construction. Prevention from the environment impact
● Use of correct tools and equipment is very In doing the service and maintenance, the
important. Faulty tools or equipment must be environment factors must be considered. Old and
maintained or replaced. other working solutions are harmful to the
● When the maintenance has to be done under environment. If there are released to the
the lifted attachments, they must be fixed at environment, it will cause damage. Oil degrades
first. very slowly in water and deposits. One liter of oil
● engage the control lock device (If equipped will pollute millions of liters of potable water.
with the machine) and apply the parking
brake. Prompt
Prevention from machine damage
The common grounds of following measures
● When necessary to lift or support the machine
require that all wastes must be handed over to
or its parts, the equipment having sufficient
the treatment plant and waste disposal
lifting or support capability should be used.
company recognized by the management body.
● Provided the lifting devices, tools, operating
78
● The battery contains the health and

● In drainage, oil and working solution must be environment harmful substances. Therefore,
collected into an appropriate vessel and the the used batteries must be regarded as the
anti-overflow measures taken. environment harmful waste.
● before the disposal of used filter as waste, all ● The consumables, e.g. the used rags, gloves
liquids must be discharged from the filter. For and bottles may contain the environment
the machines working in the environment full harmful oil and working solution, so they
of asbestos or other harmful dust, the used must be regarded as the environment harmful
filter on the machine must be placed into a waste.
bag provided with the new filter.
79
1 Use the appropriate key to open the lifting

Preparing work before maintenance
valve.
Guard plate 2 As shown in Fig., rotate clockwise the valve
For special maintenance, it is necessary to turn control bar of lifting pump to the end.
down or remove the guard plate of underframe.
Place the machine at the maintenance position.
Guard plate of front underframe
Warning
The work includes the handling of heavy parts.
In case concentration, it will cause serious
injury.
1 If possible, place a jack under the trailing
edge of guard plate. The clean guard plate at
the trailing edge weights ca. 60 kg(132lbs).
Warning
Soil and dust etc. will accumulate in the guard
plate. It means that its weight will increase
significantly.
2 Remove the bolts (4pcs) behind the guard 1. Front bottom guard plate
plate. The guard plate weights very heavy, 2. Bolt
therefore, lower the guard plate with care. 3. Gasket
Guard plate of heel slab 4. Rear bottom guard plate
The clean rear bottom guard plate weights ca. 5. Bolt
37kg (81 lbs). 6. Gasket
1 Remove the bolts (4pcs) at Rear bottom guard
plate.
2 Lower the guard plate with cares because it is
very heavy.
Engine hood
Open & Fall Back
1 Enter the cab and power on the vehicle.
2 Press the hood lift switch on the dashboard,

press the hood up to raise, press the hood back
down.
3 Be careful not to lift the hood while the vehicle

is in motion, so as not to block the line of sight
and cause serious danger to driving.
80
1. Engine hood
2.Cab
Steering lock
When servicing the vehicle, especially at the hitch body, lock the steering lock in place.
Warning
Squeezing can cause personal injury. The machine may turn. Lock the steering lock
1. Park the machine straight on the horizontal ground.
2. Remove the safety pin 3 and pin 2.

3. Turn the articulating safety lock lever 1 out so that it is aligned with the articulating body 4 hole.
Alignment of the holes may require turning the steering wheel to slightly adjust the hinge angle
4. Secure the articulated safety lock lever 1 to the articulated body 4 by pin 2 and safety pin 3.
5. Stop the engine and apply the parking brake.
81
6. Place a "NO OPERATION" label so that it is visible to all who enter the operator's console.
Staff can now enter the area around the articulator.
Warning
The hitch must not be locked while operating the machine.
Cargo Box Support Bar

Cargo Box Support
Warning
An accidental landing of a raised cargo box can result in personal injury or death. Install a cargo
box safety locking bar when it is necessary to work under a vehicle with a raised cargo box.
When parking or performing maintenance, lower the cargo box to the frame whenever conditions
permit. Install the cargo box safety lock bar when machines must be parked or serviced with the
cargo box raised.
To install the cargo box safety locking bar, proceed as follows.
1.Park the machine on a level and solid surface, making sure the cargo box is empty and free of any
material.
2.Remove the pin 2 and safety pin 3 from the upper end of the cargo box safety lock lever 1.
3. Raise the cargo box 4 completely and then move the cargo box lifting handle to the holding position.
4. Stop the engine.
5. Screw out the free end of cargo box safety lock lever 1 to align with the cargo box 4 trunnion hole and
connect it with pin 2.
6. Install safety pin 3 on pin 2 to prevent pin 2 from falling off accidentally.
Before landing the cargo box, the cargo box safety lock lever must be released and screwed back to the
original fixed position.
82
ARTICULATED DUMP TRUCK XDA45U Safety for maintenance
are not damaged by wears and have possible

Fire protection
damage risk due to incorrect installation or
clamping. This is especially applicable to the
Warning non-fusible cable. These cables are in red
When the machine is used in the environment color and marked with the sign R (B+) and
easy to catch fire, e.g. explosive environment, arranged:
the special equipment is necessary. ● Between the batteries;
Fire protection ● Between the battery and starter motor;
1 In refueling of machine or when the fuel ● Between the A/C generator and starter motor.
system is exposed to the air, no smoking or 9 The electric cable cannot be attached directly
use of open flame. to the oil or fuel pipeline. Do not weld or
2 The diesel fuel is inflammable and cannot be grind the parts containing the inflammable
used as the detergent. Instead you should use liquid e.g. the oil tank and hydraulic oil pipe.
the automobile maintenance products special When performing the “high temperature
for cleaning and degreasing. Remember that service” nearby the inflammable fluid, special
some of the solvent will cause the skin rash cares must be given. The extinguisher should
and inflammable. be placed at nearby.
3 The workplace for maintenance should be
kept clean. Oil and water will make the floor Firefighting measures
and tread slippery. This will endanger the When conditions allow and no risk of the
electrical equipment or electric tools. The oil inherently safety exists, the following measures
stained clothing is likely to lead to a fire. can be taken when the fire is weak:
4 Check and confirm every day if there is dust 1 Stop the machine when it moves
and oil on the machine and equipment. This 2 Turn the start key to the Stop position.
will reduce the fire risk and easier to detect 3 Leave the cab.
the loose or damaged parts. 4 When the cut-off switch of battery can be
accessed safely, turn it off.
5 Call the fire brigade.
Prompt
6 Try to extinguish fire if possible, otherwise,
Be careful by use of high pressure washer for leave the machine and hazardous area.
cleaning, because the electrical component and
layer of cable may be damaged under relative Post-fire measures
lower pressure and temperature. Use the In handling the machine damaged by fire or
appropriate method to protect the electrical exposure to high temperature, the following
component and cable. protective measures must be taken:
● Wear the goggles and thicker rubber
6 When the machine is used in inflammable protective gloves.
environment, e.g. sawmill and landfill, ● Do not touch with bare hand, the burning
special cares must be given while cleaning. parts, to prevent the contact with the molten
To install the thermal-protective coating on polymer materials. Use large amount of lime
the muffler guard plate may further decrease water and rinse thoroughly (Calcium
the risk of spontaneous combustion. hydroxide solution formed after the slaked
7 The extinguisher must be provided for the lime dissolved in water).
standby application.
8 Check and confirm that the fuel pipe,
hydraulic hose, brake hose and electric cable
83
rubber. At very high temperature, the

Disposal with hazardous materials
fluorocarbon rubber will produce the
Heated paint substances, which have the strong corrosivity
for the skin and lung. Wear the protective
Warning facilities.
Heated paint surface, rubber or plastic parts When handling the machine damaged by fire or
will produce the health hazardous or exposure to high temperature, the following
environment substances. During the welding, protective measures must be taken:
polishing or gas cutting, cares must be taken. ● Wear the goggles and thicker rubber
Wear the protective facilities. protective gloves.
When heated, the paint will release the toxic gas. ● The gloves and rags etc., which are used to
Therefore, before the welding, polishing or gas contact the heated fluorite rubber, should be
cutting, the paint in area with the radius of at cleaned with lime water before discarded
least10cm (4in.) must be removed. Except health (Calcium hydroxide solution, i.e. slaked lime
hazardous, it will result in the fault from the resolved in water).
welding part because the welding area is in poor ● The fluorite rubber parts baked under high
quality and strength. temperature should be thoroughly rinsed and
Methods and preventive actions for paint removal: purified with the great amount of lime water.
● Abrasive blasting ● For the sake of precaution, all sealing
Use the respiratory protective device and goggles elements (O-ring and other oil-rings) should
● Paint remover or other chemicals be disposed as the accessories made of
Use the portable extraction equipment, respiratory fluorite rubber.
protective device and protective gloves ● The hydrofluoric acid solution formed by fire
● Grinder can persist on the machine parts for several
Use the portable extraction equipment, respiratory years.
protective device, protective gloves and goggles ● When the swelling symptom appears, or there
Do not burn the discarded paint parts, which is the stinging sensation and it is susceptible
should be processed by the authorized waste that this is caused by the contact with the
treatment plant. heated fluorite rubber, you should see the
Heated rubber and plastic doctor. It is possible that the symptom shows
During the heating of polymer materials, there will up in several hours without any symptoms.
be health and environment harmful chemical ● The acid on the skin cannot be rinsed or
compounds. Therefore do not destroy this material washed clean. Therefore, they should be
by burning. processed by use of hydrofluoric acid burn
When the gas cutting or welding has to be done cream or similar Items before seen the doctor.
nearby these materials, the following safety Refrigeration agent
instructions must be followed: Prompt
- Protect the materials from the high
All maintenances of air conditioning system
temperature.
must be done in a certified service shop.
- Use the protective gloves, goggles and
recognized respiratory protective device. Warning
Heated fluorite rubber
R134a is harmful to health. In disposal with the
Warning refrigeration agent, wear close goggles and
protective gloves. Liquid refrigeration agent
The sealing, which can withstand the high
will cause frost bites. Gaseous refrigeration
temperature, can be made of the fluorocarbon
84
agent in high concentration has a kind of sprayed into eyes, you have to rinse them with
anesthetic effect. When it is at low water. When the electrolyte gets contact with
concentration, it mainly affects the nervous your skin, you should use soap water to wash it
system. clean and call a doctor for the medical
Before the factory delivery, the air conditioning treatment.
system of machine has been filled up with the ● It is prohibited to smoke nearby the battery,
refrigeration agent R134a. R134a will not damage because the battery will release explosive gas.
the ozone layer of the atmosphere, but it helps ● Be sure that no metal objects, e.g. tools, key
form the Greenhouse Gas (GHG) Effect. Therefore ring, watch strap etc., will contact the battery
it should not be arbitrarily exhausted to the terminal.
outside. ● Be sure to always fix the battery terminal
Do absolutely not mix R134a with other types of cover.
refrigeration agents, e.g. R12, because this will ● do not incline the battery in any direction.
result in the unit fault. The electrolyte in the battery may leak.
When contacted with the leaked refrigeration ● do not connect in series the discharged
agent, the following measures should be taken: battery with the fully charged battery. Risk of
● The heated refrigeration agent will become explosion!
the gas. Even if the concentration is very low and ● In removal of battery, you should firstly
the smell not obvious, it will be harmful to the disconnect the grounding cable. In
respiratory and nervous system. installation, you should connect the ground
cable at last to reduce the risk of sparks.
Gas in high concentration has the anesthetic effect. ● Discard of battery must be disposed in line
Persons exposed to this gas should leave the with the relevant state management
hazardous area and breathe the fresh air outside. regulations.
When the symptom doesn’t disappear, you should
see the doctor immediately. Silicon dioxide crystal dust (quartz powder)
● Liquid refrigeration agent will result in frost
bite. Use warm water or a piece of warm Warning
cotton fabric to carefully apply hot When working in the environment containing
compresses on the injury part. When the the harmful dust like asbestos, it may cause
symptom doesn’t disappear, you should see serious health problems. Special measures must
the doctor immediately. be taken to prevent the dust spread. For further
● When the liquid refrigeration agent enters information, please contact a XCMG special
your eyes, you should see your doctor maintenance plant.
immediately.
● When the existence of leakage is suspected, The silicon dioxide crystal is the basic elementary
you should leave the hazardous area and component made of sand and granite. Multiple
contact the authorized service shop to know activities in the construction site and mine will
which appropriate measures should be taken. produce dust containing the crystal silicon dioxide,
e.g. trenching, sawing and punching, which may
Battery cause the silicosis (miner’s consumption).
Warning The employer or site management personnel

Disposal of battery may cause your eyes, skin or should provide the operator with the information
clothing contacted with the electrolyte. Wear on the existence of crystal silicon dioxide in the
the protective facilities. When the electrolyte is construction site, specific operation guide, safety
85
measures, as well as necessary personnel ● Park the machine in a place designated to the
protective equipment. cleaning.
● Follow the instructions provided by the
The local and national regulations relevant to the vehicle care products.
silica and silicosis should be also checked. ● Water temperature should be no higher than
60℃ (140℃).
● When the high pressure washer is used, a
Repair and maintenance distance of at least 20-30cm (8-12in.) must be
This chapter introduces the service and kept between the nozzle and machine. Too
maintenance conducted by the machine operator. high pressure or too close distance will cause
the damage. Appropriate methods should be
Inspection of arrival and delivery applied to protect the electric lead.
Before the delivery from the factory, the machine ● Use the soft sponge.
will be subject of the testing and adjustment. If the ● finally, only use water to rinse the whole
guarantee clause applies, the dealer must machine.
implement the “Ex-factory and Delivery ● After washing, be sure to lubricate the
Inspections” according to the corresponding form machine.
and sign it. ● When necessary, recondition the paint
coating.
Delivery instructions
Upon the delivery of machine, if the guarantee Maintenance of paint coating
clause is applicable, the dealer must In corrosivity condition, the used machine is more
Provide the buyer with the “Delivery Statement” vulnerable to rust. As a preventive measure, it is
according to the corresponding form and sign it. recommended that the paint coating should be
maintained once every 6 months. When it is
Maintenance procedure impossible to determine if the service condition is
In order to validate the guarantee clause of factory, corrosive, please contact the dealer.
the machine should be maintained according to the ● First of all, clean the machine.
maintenance procedures established by XCMG. ● Smear one coating of Dinol 77B in thickness
The maintenance procedure should continue of 70-80μ (or equivalent transparent wax rust
according to the fixed cycle. The operation time inhibitor).
between the cycles is just applicable to the ● a protective layer of the underseal Dinol
machines used in normal environment and 447(or equivalent) should be coated beneath
working conditions. For the correct procedures of the fender, where mechanical wears come up
your specific machine, please consult your XCMG easily.
dealer.
Coat finishing
Machine cleaning ● Firstly, clean the machine.
The traditional automobile maintenance products ● Check if the paint coating has any damages.
should be used to clean the machine at the regular ● Recondition any damaged paint coatings in a
basis, to eliminate the damaged paint coating and professional way.
other risks of machine surface. Avoid using the
powerful detergent or chemical agent, to minimize
the damage risk of paint coating.
Recommendation of machine cleaning:
86
Cleaning of engine compartment

When the machine works in a dusty and fire
Attention
exposed environment, e.g. operations in the wood Only clean after the exhaust aftertreatment
system has cooled down. Otherwise, the sensors
industry, wood refuse handling and processing of
may be damaged.
other inflammable materials etc., it is necessary to Do not point the water gun at the exhaust pipe
check and clean the engine compartment and during cleaning. Otherwise, the system may be
adjacent areas every day. damaged.
When using a high-pressure cleaner, keep the
distance between the high-pressure nozzle and the
engine parts as short as possible. Otherwise,
engine parts may be damaged.
In operation under other conditions, it is necessary Keep the following minimum distances.
to make the check and cleaning at least once every  Approx. 70 cm (when using round nozzles)
week.  Approx. 30 cm (when using 25° flat nozzles)
 approx. 30 cm (with cluster nozzles)
Warning
Fabric or flammable materials left in the engine Attention
compartment can ignite if they come in contact
with the exhaust system or heated engine Move the water gun continuously while cleaning.
components. There is a risk of fire! After This will prevent damage.
performing maintenance work, make sure that no Do not aim the water gun at the following areas.
external flammable material remains in the  Electrical components
engine compartment or on the exhaust system.  plug connectors
 Seals
Warning
If flammable materials generated by
environmental influences or carried by animals Cleaning the engine
come into contact with the exhaust system or
heated engine parts, these substances may ignite. Attention
There is a risk of fire.
Conduct regular inspections to ensure that no Observe the following precautions when cleaning
flammable foreign material enters the engine the engine to avoid engine failure and damage.
compartment or exhaust system.  When using a pressure washer or steam cleaner,
do not point the nozzle directly at electrical
components and cables.
Ensure that exhaust gas reprocessing units are
 Make sure that water does not enter the air
cleaned and cared for. There is a risk of fire. Adjust intake and vents.
cleaning intervals if operating in dusty conditions on  After cleaning the engine, treat the engine with
a regular basis. Check for flammable material an anti-corrosion agent. Do not get the belt
buildup and clean before using the exhaust gas drive system wet with the corrosion inhibitor
re-treatment unit under dusty operating conditions or while cleaning.
when operating in dusty conditions on a regular  Use only a wax-based protectant that meets the
basis. requirements of Mercedes-Benz Working Fluid
Routine maintenance contributes to engine system Specification Data Sheet No. 385.4 on the
preservation. engine.
High Pressure Cleaning

Environmental instructions
Clean vehicles only in a dedicated washroom. Please Warning
dispose of empty containers and used cleaning
When the compressed air, water column or
supplies in an environmentally friendly manner.
steam cleaning method are applied, be sure to
wear the appropriate protection clothing, to
87
protect eyes and exposed part of body. Always systems work properly.
shut down the engine and let it cool down, and The regular inspection is of great importance for
then clean the machine. reduction of accident and downtime risk.
● It is best to make the cleaning before the The cycle between these checks depends on many
parking of machine and shifting of duty. factors, e.g. the machine service life period,
● Use the personnel protective equipment, e.g. application type, structural modification, load,
the goggles, protective gloves and respiratory transportation road state and regular maintenance
protective device. types already done on the machine etc.,. When
● It begins from the maximum zone of machine used in extremely demanding working conditions,
and ends to the lowest point on the top of fuel the conveyor needs more frequent inspections, but
tank and the area nearby the fuel tank. we recommend that these inspections should be
● Use the compressed air etc., to eliminate the done for the first time in 6000hrs, then once every
loose materials/dirt. 2000hrs-12000 (included)hrs, thereafter, once
● After the cleaning, check and eliminate any every 1000hrs.
leakages. Shut down all lids and engine hood. When the machine suffers a collision or an
accident of any kind, the operation must stop
Areas necessary to check and clean: immediately and the check carefully made,
1 Hydraulic tank and fuel tank top as well as whatever when the last one was done.
around the fuel filling point. To make the proper check, it is very important to
2 Inlet port of engine. clean conveyor thoroughly.
3 Hot surfaces, e.g.: postprocessor, exhaust Try to detect faults as early as possible and
pipe (from the turbine to the postprocessor), eliminate them, this will ensure the continuity of
exhaust manifold, turbine, preheating coil, machine function, improve its usability and
A/C generator and starter motor. decrease the accident risk. The knowledge in
4 Oil and fuel filters. relevant materials, design of frame parts and
5 Inside of the radiator case. maintenance technology recommended by the
6 Underframe under the machine, in the manufacturer etc., are necessary for correct
antiskid plate, especially around the hydraulic maintenance of frame and other supporting parts.
pump. When necessary to repair, it is advised to contact
your XCMG dealers, because they have the
Use the high pressure to clean the equipment; In qualification necessary for the repair.
cleaning, special cares must be given: The front and rear frames, connecting device and
1 Starter motor. body have to be carefully checked to know if there
2 Turbocharger. are cracks and defects. This is especially
3 A/C generator. applicable to the weld structure.
4 Radiator. Test run and inspection
5 Venting device, hydraulic /fuel tank as well as
transmitter. Warning sticker
6 Conventional interface. Check if all warning labels are in place,
7 Acoustic material. identifiable and without any damages.
Routine inspection of machine

External inspection
All earth-moving machinery will bear great stress 1 Check and confirm that the machine has no
and wears. Therefore, it is necessary to make the external damages, especially tires, hose and
regular inspection and research of machine in pipeline.
terms of the structural damage and ensure that all 2 Check and confirm there are no visible
88
leakages. 4 Start the truck carefully, and then test the

3 Clean/scrap the window and rearview mirror. brake. The brake application should be
4 Check and confirm that the back-up camera uniform, smooth and without noise.
(when installed) is clean, intact and works
properly. Brake system (parking brake)
5 Confirm that the cut-off switch of battery is 1 Confirm that the pressure level is achieved on
powered on. the instrument panel.
6 Confirm that the connecting lock of steering 2 Depress and hold the brake pedal, so that the
frame has been disconnected. machine cannot move.
7 Confirm that the stop dogs of wheel have 3 Release the parking brake.
been removed. 4 Move the gear selector to the position“D” and
8 Confirm that the engine hood and guard plate feel the engagement of machine. Gear up
have been closed. 5 Apply the parking brake.
6 Lift the brake pedal.
Lighting, instrument and control devices 7 Check and confirm that the parking brake can
1 Adjust the operator seat. keep the machine motionless, and the throttle
2 Turn the ignition switch to the “ON” position valve is opened, increase the speed up to
(operation position). 1100 rpm (18.3 r/s).
3 Confirm that all control lamps went on, and 8 Move the gear selector to the N-position.
the reading displays on the instrument. 9 Confirm there are no warnings or error
4 Confirm that there is sufficient fuel in the oil messages.
tank. Steering system
5 Check the functions of work light and head 1 Turn the vehicle to both sides.
light, confirm that they are clean and intact. 2 Check and confirm that the steering has no
6 Check all reflectors. gaps and noise.
7 Check and confirm that no persons stay Dumping function
nearby the machine. 1 Lift the body. Confirm that it can lift
8 Check and confirm that the diagonal safety normally.
belt can fasten and there is no damage. 2 Confirm that the damping at the end of travel
9 Fasten the diagonal safety belt. works.
10 Turn the ignition switch to the “START” 3 Lower the body. Confirm that it can lower
position (start position). normally.
11 Check and confirm that all control lamps and 4 When started, confirm that the function of
warning light went off, and that the parking maximum dumping height works.
brake warning light goes on when the parking Reversing alarm
brake is applied. 1 Move the gear selector to the reverse gear.
12 Confirm the horn works. 2 Confirm that the reversing alarm works.
3 Turn off the engine.
Brake system (service brake)
1 Run the engine at idle speed, until the Works to be done after the operation
pressure is established. Refuel the oil tank. This can prevent the water
2 Confirm that the brake pressure established in condensation.
two loops is normal.
3 Depress the brake pedal and release the When any of the above-said problems occurred,
parking brake. Confirm that the machine please contact the XCMG authorized maintenance
didn’t trigger the alarm. shop.
89
ARTICULATED DUMP TRUCK XDA45U Repair and maintenance
Engine skills that cannot be acquired by consulting a few

operating manuals. Always perform this work at a
The OM471 engine is an original imported diesel qualified professional service center.
engine from Mercedes-Benz, Germany, 6-cylinder,
inline with engine electronic management system, For instructions and important information on
4-stroke direct injection, one fixed geometry carrying out maintenance work, please visit the
cross-section supercharger, supercharged intercooling, workshop information system on the Internet.
EGR and EGR cooler, multi-point electronic Make sure you have access to this information
injection, diesel engine with DOC+DPF+SCR when performing maintenance work.
exhaust aftertreatment technology. Non-road EU
Stage 5 (EU Stage V) emission standard.
Warning
If the engine is accidentally started during
service or maintenance work, the limbs of
personnel may be crushed or pinched. There is a
risk of injury.
Always take safety precautions before
performing maintenance or repair work to
prevent the engine from starting unexpectedly.
Warning
Fabrics or flammable materials left in the engine
compartment can ignite if they come in contact
with the exhaust system or heated engine
components. There is a risk of fire! After
Warning performing maintenance work, make sure that no
Failure to perform the required external flammable material remains in the
service/maintenance or necessary repairs may engine compartment or on the exhaust system.
result in failure or system malfunction. There is a
risk of accident.
Be sure to have all required service/maintenance Warning
work and necessary repairs performed at a If toxic vapors and/or vapors hazardous to health
qualified professional service center. may be generated during initial operation after
maintenance or repair work.
Before performing maintenance and repair work, This may be caused by
please observe the regulatory requirements of the
country in which you are currently driving.  Leaking working fluids
Before performing maintenance and repair work,
observe the regulatory requirements of the  Totaling of auxiliary materials used
country in which you are currently driving. Please
ensure that all safety regulations, such as  Care products and cleaners used
operation manuals
Please ensure that all safety regulations, such as  Freshly applied paint
operating manuals, hazardous material Risk of injury exists.
regulations, environmental protection measures, Please observe the following before initial
operating operation.
regulations, environmental protection measures,
operational safety and accident prevention  Please use a professional engine cleaning device
regulations, etc. to thoroughly clean the
Please ensure that you comply with all safety
regulations, such as operating manuals,  Engine. Rinse the care products thoroughly with
hazardous material regulations, environmental water.
protection measures, operational safety and
accident prevention regulations.  Ensure good ventilation.
Please observe the safety data sheets.
 Wear protective gear.
Inspection and maintenance work requires special
90
 Do not inhale steam. Exhaust gas reprocessing is performed by means of
 Diesel oxidation catalytic converters (DOC)

Environmental instructions
If you perform certain maintenance work  Diesel Particulate Filter (DPF)
yourself, be sure to observe environmental
 Selective catalytic reduction (SCR) with
protection regulations. When disposing of
ammonia escape catalytic converters
working fluids (e.g. engine oil), always observe
the legal requirements. This also applies to all
To ensure that the exhaust gas retreatment system
parts that come into contact with working fluids
works properly, operate the engine with AdBlue®
(e.g. filters).
solution reducer. The addition of AdBlue®
Please dispose of empty containers, cleaning solution/diesel exhaust fluid (DEF) is not part of the
cloths and care products in an environmentally maintenance work. Therefore, the AdBlue®
friendly manner. Solution/Diesel Exhaust Fluid (DEF) reservoir
Please follow the instructions for the use of the should be refilled regularly.
care products.
Do not run the engine unnecessarily when the Failure to use AdBlue® Solution/Diesel Exhaust
vehicle is stationary. Fluid (DEF) or operating the engine with other media
Do not step on the engine or the exhaust gas not approved by Mercedes-Benz can result in
reprocessing system. Otherwise, damage may result. invalidation of the engine's operating approval or
As with all technical equipment, the engine system certification.
requires care and maintenance.
The scope and frequency of maintenance work Mercedes-Benz Genuine Parts
depends primarily on
 The various operating conditions The operational safety of the engine system may be
 The working fluid used compromised if parts not approved by
Mercedes-Benz are used. This may result in the
failure of safety-related systems. Use only genuine
Attention Mercedes-Benz parts or parts of equivalent quality.
Only use parts that are approved for your engine
The increase in engine output results in: All model.
maintenance intervals and work are performed on
original Mercedes-Benz components, as well as on Changing engine output
accessories and working fluids that have been
expressly approved by Mercedes-Benz for use
with the engine. Attention
If operating in dusty conditions on a regular basis, An increase in engine output results in
the driver must clean the exhaust gas re-treatment
system outside of the service interval. Refer to the  Change in emission values
vehicle operator's manual for information on  Failures
cleaning by the driver.  Indirect damage
Under no circumstances can the engine be
Please record any work performed in the guaranteed safe to operate.
maintenance manual for confirmation. Be sure to Unauthorized changes to the engine management
present this proof of scheduled maintenance when system to increase engine output will result in loss of
making a warranty claim. warranty rights.
Safe/emergency operation mode

The engine is equipped with an electronic engine
BlueTec® Exhaust Gas Retreatment management system to monitor the engine and
System exhaust gas reprocessing unit.
The exhaust gas retreatment system is activated upon When a fault is detected by the electronic control
engine start-up and remains activated for the duration system, one of the following measures is
of engine operation. This ensures that the pollutant automatically implemented after the fault has been
emissions in the exhaust gas are reduced to the limit evaluated.
values specified in the emission standards.  Indication of malfunctions during operation by
91
means of corresponding warning lights.  Information on the status of the vehicle and its
 In conjunction with the electronic engine various components. This includes vehicle
management system, the fault code can be speed, deceleration, gas pedal position, etc.
displayed on the display together with
additional information.  Failure of important system components
 The system switches to the appropriate standby  Repair work
function to continue (with restrictions) running  Vehicle reactions and operating conditions
the engine. This includes torque and speed
under special driving conditions
limits as well as constant emergency running
speed, etc.  Modifications, installations and alterations
 Environmental conditions, which include:
Proper Use outside temperature of the vehicle.
The engine and exhaust gas reprocessing system This type of technical data is used exclusively to
must not be modified. Mercedes-Benz is not  Assist in the detection and correction of faults
responsible for any damage caused by modifications
to the engine and exhaust gas re-treatment system.  Analyzing vehicle functions, e.g. after an
The regulations require that the engine system should accident
not be modified or altered, as this will have a Such data cannot be used to track the movement of
negative impact on safety and may invalidate the EU the vehicle.
type approval. When the vehicle receives one of these services, the
technical information can be read from the event data
The correct use of the engine system also requires memory and the fault data memory.
compliance with the instructions in this operating
manual, as well as compliance with maintenance Services include
intervals and professional performance of  Repair services
maintenance work.
 Service items
 Implied warranties and warranty status
Implied warranty
 Warranties
Please observe the instructions in this operating The vehicle can be read by employees of the service
manual regarding the proper operation of the engine outlet (including the manufacturer). If necessary,
system and possible damage to the engine system. detailed information can also be obtained here.
Any damage to the engine system caused by
violation of these precautions is not covered by the The information in the fault memory will be deleted
implied warranty. or continuously overwritten after the fault has been
removed.
Stored Data
Some electronic components in the engine system Qualified professional service centers
contain data
memory. Attention
These data memories can temporarily or permanently
store the following technical information. Repair work on the engine electronics and its
Technical information. associated components (e.g. control unit, sensors,
actuating parts or connecting leads) should only
 Motor system condition be carried out at a qualified specialist service
 events center. Failure to do so may result in accelerated
 Failures wear of the vehicle components and may
invalidate the vehicle's operating license.
This type of technical information typically records
the condition of the component, module A qualified service center has the necessary expertise,
block, system, or environmental conditions. tools and qualifications to carry out the necessary
These include operations on the engine according to professional
standards. This is especially true for safety-related
 Operating conditions of system components, operations.
such as working fluid levels
Please visit a qualified professional service center for
92
the following maintenance work. Disposal

 Safety-related work
Environmental Instructions
 Maintenance and repair work Please dispose of the working fluid in an
 Repair work environmentally friendly manner.
If used improperly, working fluids can be harmful to
 Alterations, installations and modifications the environment.
Do not dispose of working fluids into the sewer
 Work performed on electronic components
system, surface water, groundwater or soil.
Please observe the safety data sheet.

Working fluids Observe the laws and regulations of each country
when handling.
Warning
Working fluids can be toxic and pose a health Engine Oil
hazard and risk of injury. Engine oil grade quality
Observe the instructions for using, storing and
disposing of working fluids on the label of the
corresponding original container. Always store Attention
working fluids in their original, closed containers. Use only engine oil of the specified quality grade.
Always store working fluids out of the reach of The quality of the engine oil is essential for the
children. function and service life of the engine.
Mercedes-Benz has approved engine oils that meet
Observe the working fluid safety data sheet. current technical standards based on extensive
When working on vehicles, be sure to observe all testing.
safety regulations, such as operation manuals, Use only engine oils that meet the requirements of
regulations regarding hazardous materials, the Mercedes-Benz working fluid specifications
environmental protection measures, country-specific (Data Sheet No. 228.51 or 228.31).
operational safety and accident prevention Engine oils meeting the requirements of Data Sheet
regulations, etc. No. 228.51 are of higher quality and have the
following effects.
 Extend oil change intervals
Notes on working fluids  Reduces engine wear
Working fluids include  Reduces fuel consumption
 Fuel (e.g. diesel fuel)  Reduces exhaust emissions
 Lubricants (e.g. engine oil, transmission oil, Multi-grade engine oils that meet the requirements of
grease) Data Sheet No. 228.51 or 228.31 are available
 Coolant, antifreeze year-round.
 AdBlue solution/diesel exhaust fluid
Engine oil blendability
 (DEF), exhaust gas re-treatment system reducer
Approved working fluids meet the highest quality When filling your engine oil, Mercedes-Benz
standards and are documented in the Mercedes-Benz recommends that you use only engine oil of the same
working fluid specifications. Therefore, only use quality grade and SAE (American Society of
working fluids that are approved for the Engineers) classification as the last oil you filled.
vehicle/equipment. High quality engine oils are less effective if mixed
with other engine oils.
Engine oils are differentiated according to the
Additives following factors.
Additives (other than approved fuel additives) are  Engine oil brand
neither required nor allowed to be used with  Quality grade (data sheet number)
approved working fluids. Additives may damage the  SAE (American Society of Engineers Standard)
engine system. Therefore, working fluids should not viscosity classification
be mixed with any additives. You are responsible for In exceptional cases, if the type of engine oil
the consequences of using fuel additives. currently used in the engine is not available, other
mineral or synthetic engine oils approved for
Mercedes-Benz vehicles may be used.
93
Please observe the following: If you fill with an  Engine oil grade used
engine oil of a lower quality grade, the service The maximum oil change interval can only be
interval must be adjusted to the lower quality grade achieved when using a very high quality engine oil
(data sheet number). grade that meets the requirements of Mercedes-Benz
The maintenance interval will be shortened. If you Working Fluid Specification Data Sheet No. 228.51.
fill with a higher quality engine oil, the service The classification of oil change intervals is specified
interval will remain the same. in the maintenance booklet.
Engines shipped with initial operating oil
Engines are shipped with SAE (American Society of Coolant
Engineers) rated 5W-30 initial operating oil.
Coolant quality
These high quality engine oils are good for
mechanical break-in. Attention
With these engine oils, you can also change the oil
for the first time at the appropriate oil change interval. Use only coolant of the specified quality class.
This eliminates the need for special break-in oils and This will prevent damage to the engine cooling
eliminates the need for additional oil changes. system and engine.
Oil changes The vehicle is factory-filled with coolant with

anti-freeze/anti-corrosion protection and other
important protective effects.
Attention Coolant is a mixture of water and an
Engine damage may occur if an SAE (American anti-corrosive/anti-freeze agent.
Society of Engineers) rated (viscosity) engine oil is The anti-corrosion agent/anti-freeze in the coolant
used that is unsuitable for use in sustained cold has the following properties.
temperatures below -20†. Transferring heat
The temperature specified by the SAE classification  Provide protection against corrosion
is always for freshly filled engine oils. Over the  Provide protection against cavitation
course of vehicle use, engine oil will deteriorate due (anti-cavitation)
to carbon and fuel residue build-up. This can affect  Provide anti-freeze protection
the characteristics of the engine oil, especially in cold  Increases boiling point
outdoor temperatures. It is important to ensure that coolant is used in the
Mercedes-Benz strongly recommends the use of SAE engine cooling system all year round, even in
(American Society of Engineers) rated 5W-30 or countries/regions with hot climates.
0W-30 engine oils when the outdoor temperature is Check the concentration of anti-freeze/anti-corrosion
below -20 °C. agent in the coolant every 6 months.
Only all-season engine oils may be used Change the coolant at the intervals specified in the
maintenance manual.
When the coolant must be filled, only use an
anti-corrosion agent/antifreeze approved to the
requirements of Data Sheet No. 325.5 or premixed
coolant to the requirements of Data Sheet No. 326.5.
Mix water and anti-corrosion agent/antifreeze outside
the coolant circuit, then fill the cooling system with
the mixture.
When replacing the coolant, make sure that the
coolant contains 50% by volume of anti-corrosion
agent/antifreeze. This corresponds to antifreeze
protection down to -37°C.
The volume of anti-freeze/anti-corrosion agent must
Engine oil SAE (American Society of Engineers) not exceed 55% (freeze protection down to approx.
classification (viscosity) -45°C). Otherwise, cooling performance and
 The SAE (American Society of Engineers) anti-freeze protection may be affected.
classification (viscosity) of the engine oil is The water used in the coolant must meet certain
selected based on the average outdoor requirements, and potable water is usually sufficient
temperature of the season of the year. for such requirements. If the water quality does not
The oil change interval depends on the following meet the required standards, treatment is required.
factors. Please observe the instructions in Mercedes-Benz
 Engine operating conditions
94
Working Fluid Specification Data Sheet No. 310.1.  Fatty acid methyl ester (FAME) (biodiesel fuel)
No mixing of other anti-corrosion agents/antifreeze is
allowed.
Attention
Fuel
Higher fuel sulfur content accelerates the engine
Fuel grade oil aging process
process and damage engines and exhaust systems.
For information on current fuel sulfur content by
Attention country, please consult a Mercedes-Benz Truck
Center/Truck Service Center/Contract Repair Station
Use only fuel with the specified quality grade. Use or refer to the information in Mercedes-Benz
of non-permitted fuel can cause irreparable Working Fluid Specification Data Sheet No. 136.2.
damage to the engine and exhaust gas
reprocessing system and significantly shorten the Water content
expected service life. The maximum allowable water content at the
Diesel fuel must meet the following standards in connection point between the vehicle and the engine
order for the engine to perform as specified and meet must not exceed 200 mg/kg. If the water content is
exhaust emission standards. high, an additional oil/water separator must be
European Union Stage V (EU Stage V) installed in the chassis.
 Engine OM471. If the dirt and water content increases when the
EN 590 (maximum sulfur content 0.001% by weight) engine is running, an additional fuel coarse filter with
from 2010 (10 ppm) (compatibility label B7) oil-water separator must be installed on the chassis.
or
 Engine OM 471.
EN 15940 (compatibility label XTL) Storage
The following types of fuel are prohibited. Diesel fuel may decompose. If the maximum storage
 Sulphur-containing fuels with a sulphur content period of 90 days is exceeded, the fuel grade must be
weight ratio greater than 0.0010% (10 ppm) checked.
 Marine diesel fuel If the maximum storage period of 90 days is
 Aviation turbine fuels exceeded, the fuel grade must be checked.
 Fuel oil
 Fatty acid methyl ester (FAME) (biodiesel fuel)
U.S. Tier 4 (US Tier 4)
Diesel fuel in low temperature conditions
 RASTM D975 Ultra low sulfur road diesel fuel Diesel fuel may not flow well when the temperature
(maximum sulfur content 0.0015% by weight) outside the vehicle is low.
(15 ppm) To prevent operational problems, use diesel fuel with
The following types of fuels are prohibited. better flow in winter.
 Sulfur-containing fuels with a sulfur content In Germany and other Central European countries,
weight ratio greater than 0.0015% (15 ppm) commercially available winter diesel fuels can keep
vehicles running at temperatures as low as -22°C
 Marine diesel fuel outside the vehicle. Winter diesel fuels generally
 Aviation turbine fuels work well at the expected outdoor temperatures in
the countries where they are sold.
 Fuel oil
 Fatty acid methyl ester (FAME) (biodiesel fuel)
U.S. Tier 4 (US Tier 4) Fuel Additives
 ASTM D975 ultra low sulfur highway diesel
fuel (max.
Sulfur content 0.0015% by weight) (15 ppm) Attention
The following types of fuels are prohibited.
Use only approved fuel additives when necessary.
 with a sulfur content weight ratio greater than Failure to do so may affect engine performance or
0.0015% (15 ppm) damage the engine and catalytic converter. It is
Sulfur-containing fuel your responsibility to select the proper fuel
 Marine diesel fuel additive.
 Aviation turbine fuels
 Fuel oil Do not improve the flow of diesel fuel by adding
95
any gasoline or kerosene. Gasoline or kerosene

can affect the lubricity of diesel fuel. This can Attention
damage components such as the diesel injection
system. Containers made of the following materials are
not suitable for storing AdBlue® solutions.
At lower temperatures, the engine may be equipped  Aluminum
with a fuel preheat system. This improves the flow
 Copper
characteristics of the diesel fuel depending on the
output of the installed heater.  Copper alloys
Flow enhancers are fuel additives used to improve  Unalloyed steel
flow characteristics.
 Galvanized steel
Do not add flow enhancers to winter diesel fuel that
can be used normally at temperatures as low as -22°C. If placed in the above-mentioned types of containers,
The flow of the fuel in the cold state may be the metal content may decompose and damage the
deteriorated by flow enhancers. exhaust gas reprocessing system beyond repair.
Only containers made of the following materials may
AdBlue® Solution / Diesel Exhaust Fluid be used to store AdBlue® solutions.
(DEF)
 Chromium-nickel (Cr-Ni) steel according to
AdBlue® Solution / Diesel Exhaust Fluid DIN EN 10 088-1/2/3
(DEF) Quality  Molybdenum-chromium-nickel (Mo-Cr-Ni)
according to DIN EN 10 088-1/2/3
 Polypropylene
Attention
 Polyethylene
Use only AdBlue® solution/Diesel Exhaust Fluid
(DEF) with the specified quality grade. The use of
non-permitted AdBlue® solution/diesel exhaust Purity
fluid (DEF) can cause irreparable damage to the
engine and exhaust gas retreatment system and Attention
Impurities (e.g. due to other working fluids,
AdBlue® solution/diesel exhaust fluid (DEF) must
cleaning products or dust) in AdBlue®
meet the following criteria in order for an engine to
solution/diesel exhaust fluid (DEF) of the
meet the EU VI legal emission standards: AdBlue®
following materials may lead to
solution/diesel exhaust fluid (DEF) meeting the
requirements of DIN 70070/ISO22241.  Increased emission values
The terms "Urea" and "Diesel Exhaust Fluid (DEF)"  Damage to the catalytic converter
can be used in place of "AdBlue® solution".  Engine damage
 Failure of the exhaust gas re-treatment system
Always ensure the purity of the AdBlue®
Outdoor high temperature solution/diesel exhaust fluid (DEF) to avoid
If the temperature of the AdBlue® solution/Diesel exhaust gas re-treatment system failures.
Exhaust Fluid (DEF) rises to 50°C for an extended If the AdBlue® solution/diesel exhaust fluid (DEF)
period of time (e.g. due to direct sunlight on its is withdrawn from the reservoir (e.g. during repair),
reservoir), its chemical composition may decompose. do not refill the reservoir with this working fluid.
This generates ammonia vapors. Otherwise, the purity of the solution will no longer
be guaranteed.
Outdoor low temperature
AdBlue® solution/diesel exhaust fluid (DEF) can Engine oil level, check
freeze at temperatures of approximately -11°C.
Depending on the equipment and country, the Warning
vehicle's dBlue® solution/Diesel Exhaust Fluid (DEF)
supply system may be heated, see vehicle operation Working fluid may be toxic and can be
manual. This allows for normal winter driving in hazardous to health and present a risk of injury.
temperatures below -11°C. Follow the instructions on the label of the
appropriate original container for use, storage
Additives, non-distilled water and disposal of the working fluid. Always store
the working fluid in the original, closed container.
96
Always store the working fluid out of the reach  Turn off the engine.
of children.
 Wait approximately 5 minutes.
 Turn on the ignition.
Attention
Do not overfill with oil. If you overfill the engine
with oil, the engine or the exhaust gas retreatment
unit may be damaged, and excessive oil may be Attention
discharged. Check the engine oil level before each
The current oil level information can only be
trip or before each engine start.
called up when the vehicle is stationary and the
engine has been off for at least 5 minutes. Then
If the engine oil level is too high, the engine oil may
turn the ignition on and wait for the light failure
enter the combustion chamber when the engine is
indicator.
running. At this point it may no longer be possible
to adjust the engine speed and may not be possible
to shut down the engine again. The oil level must be
corrected immediately; there is a risk of engine Warning
failure.
Use only engine oil with the specified quality
The engine is equipped with an electronic oil level grade. Using unapproved engine oil can cause
detection system.
The engine is also equipped with an oil dipstick
which can be used to assist the electronic oil level
detection system.
Electronic Oil Level Detection - System

Description
The engine oil level sensor is installed in the oil pan
and is used to detect the oil level.
When the engine is off and the ignition switch is on, irreparable damage to the engine and significantly
the oil level is shown on the indicator or display. shorten the expected service life.
The engine oil level is not displayed when the engine
is running. Use only approved engine oil.
 If necessary, use filler port ℃ to fill the engine
Electronic check of oil level oil.
Does not display when the engine oil level is too Oil level indicated by indicator light
high. If the oil level is low, the indicator light comes on.
The oil level is low. Add oil. Use the oil
Check the engine oil level before each trip or before dipstick to determine the amount to be added.
each engine start.
Attention
Refill the missing amount immediately. If the
Attention engine oil level is low, the indicator light flashes
and the warning buzzer sounds. Low oil level: Do
To measure the oil level, the vehicle must be on not start the engine and refill the oil immediately.
level ground. If the oil level is measured with the Use the oil dipstick to determine the amount to be
vehicle on a slope, an incorrect reading will be added.
displayed. Oil level shown on the display
The oil level display information is
 Park the vehicle on a level surface. determined by the vehicle manufacturer.
Follow the information in the vehicle
 Apply the parking brake. operator's manual.
If the engine oil level is low, fill the
97
engine oil according to the amount of oil

missing shown in the display. Warning
Working fluids can be toxic and pose a health
If the engine oil level is low, do not start hazard and risk of injury.
the engine and fill it with the missing Follow the instructions on the label of the
amount of oil shown on the display. appropriate original container regarding the use,
storage and disposal of the working fluid. Always
Checking the oil level with the dipstick store the working fluid in the original, closed
container. Always store the working fluid out of
Attention the reach of children.
To measure the oil level, the vehicle must be on
level ground. Attention
If the oil level is measured with the vehicle on a
Never operate the vehicle when the coolant level is
slope, an incorrect reading will be displayed.
too low. Otherwise, the engine may be damaged.
Attention  Check the coolant level according to the vehicle

operator's manual.
Do not add too much oil. If you add too much oil,
you may damage the engine or the exhaust gas  Refill the cooling system as needed. Use only
retreatment unit. Drain or suck out excess oil. coolant that is approved for that engine.
Check the engine oil level before each trip or before

If there is a loss of coolant, do not just fill with water,
each engine start.
but also with an approved anti-corrosion
 Park the vehicle on level ground.
agent/antifreeze.
 Apply the parking brake.
 Turn off the engine.
 Wait about 5 minutes.
 Use the dipstick ℃ to check the engine oil level.
The oil level should be between the upper and Checking Fuel Levels
lower limit marks of the dipstick ℃. To check the fuel level on the fuel gauge, refer to the
vehicle operator's manual. Fill with fuel if necessary.
Checking the coolant level

Check the water level in the rough fuel filter
Warning on the chassis frame
The cooling system is under pressure, especially Environmental Instructions

when the engine is hot. If you open the cap, you Please dispose of the water-fuel mixture in an
may be scalded by hot coolant spraying out. There environmentally friendly manner.
is a risk of injury.
Allow the engine to cool before opening the cap.
Wear protective gloves and goggles when opening.
Open the cap slowly to relieve pressure.
Warning
If antifreeze enters the engine compartment and
comes in contact with the hot parts inside, it may
ignite, posing a risk of fire and injury.
Allow the engine to cool before refilling with

antifreeze. Make sure that the antifreeze does not
spill onto the side filler ports. Before starting the
engine, thoroughly clean any parts that have been Example: Fuel filter on chassis frame
exposed to antifreeze. ℃Fuel filter
98
℃Drain plug increase.

℃Inspection window No matter how many hours it run, the engine
℃Manual fuel pump oil should be replaced at least every two year.
℃Exhaust screw
If water accumulates in the inspection window ℃,
empty the fuel filter ℃ on the chassis frame.
Warning
If there is a danger of frost, drain the fuel filter on the
chassis frame ℃ periodically. Only when the engine is at normal working
Drain the fuel filter on the chassis frame. temperature, the oil can be replaced.
 Please place a collection tray under the drain
The hot oil will cause burns. Wear the appropriate
plug ℃.
 Open the drain plug ℃. protective gloves, protective suit and eyes
 Press the manual fuel pump ℃ and collect the protection device. Process the oil with special
oil-water mixture. cares. Collect oil and dispose it in an
 Close the drain plug ℃. environmentally friendly way.
Checking the AdBlue® solution/AdBlue®

solution/diesel exhaust fluid (DEF) level Attention
To check the AdBlue® solution/diesel exhaust fluid Dispose the filter and oil according to the
(DEF) level current environmental regulations in the region,
(DEF) table in the AdBlue® Solution/Diesel Exhaust
where the engine is applied.
Fluid (DEF) table
(DEF) level in the AdBlue® Solution/Diesel
Exhaust Fluid (DEF) table, please refer to the vehicle
operator's manual. Fuel, refill
Fill with fuel if necessary.
Warning
Replacement of engine oil and filter Fuel is toxic and harmful to health. There is a
Replace the engine oil once every 300hrs. risk of injury.
Oil replacement capacity: ca. 40l Make sure to avoid accidental ingestion of fuel or
Conditions applicable to the replacement cycle of allowing it to come into contact with skin, eyes or
clothing.
300hrs: Do not breathe fuel aerosols. Keep fuel out of the
● The oil filter should be replaced for each oil reach of children.
replacement. Keep doors and windows closed when filling with
● The oil filter element is the original Benz fuel.
If you or others come into contact with fuel,
filter element
observe the following points.
● Select the oil of correct grade (quality)
 Immediately and thoroughly rinse the fuel
● The sulfur content of engine fuel meets the from your skin with soap and water
specifications. Rinse the fuel immediately and thoroughly with
soap and water.
● According to the diagram, select the oil
 If fuel comes in contact with your eyes, flush
viscosity in conformity with the existing them immediately with water and seek
conditions of temperature. Follow the used oil immediate medical attention.
If fuel comes in contact with your eyes, flush
brand and sulfur content of fuel and comply them immediately with water and seek
with the recommended replacement cycle. immediate medical attention.
 If fuel is swallowed, seek medical attention
immediately. Do not induce
Vomit.
Attention  Immediately change clothing that has been
contaminated with fuel
Please use the recommended oil brand,
otherwise, the clogging of oil filter element will Warning
99
Fuel is highly flammable. Improper disposal of contamination.

fuel will result in the risk of fire and explosion.
Ignition, open flames, sparking and smoking Fueling
should be avoided under all circumstances.
Before working on the fuel system, turn off the
 Secure the vehicle to prevent skidding.
ignition switch and auxiliary heating system.
 Observe fuel grade regulations.
Always wear protective gloves.
 Check for condensation in the rough fuel filter
with heated oil-water separator.
Warning  Observe the information in the vehicle
If diesel fuel is mixed with gasoline, its ignition operator's manual.
point will be lower than that of pure diesel fuel.
When the engine is running, the exhaust system
Venting and draining the fuel system
components may overheat without being noticed.
There is a risk of fire. After filling a fuel system that has been completely
Do not fill with gasoline. Do not mix gasoline with depleted of fuel, vent the fuel system manually using
diesel fuel. a manual fuel pump.
Before venting the fuel circuit on the engine, vent the
rough fuel filter with the oil/water separator on the
Attention vehicle. Use the manual fuel pump integrated in the
fuel filter to do this.
Observe the vehicle's fuel label to prevent incorrect
refilling. Venting the fuel system using the fuel filter
Use only fuel with the specified quality grade. The on the chassis frame
use of unapproved fuel can cause irreparable damage
to the engine and exhaust gas retreatment system and Environmental instructions
High fuel sulfur levels can accelerate the engine oil Please dispose of the water-fuel mixture in an
aging process and damage the engine and exhaust environmentally friendly manner.
system.
Never use gasoline to refill a diesel engine vehicle.
Even small amounts of gasoline can cause fuel
system and engine damage.
If improper fuel is accidentally added, do not turn on
the ignition switch. Otherwise, fuel will enter the fuel
line. Notify a qualified professional service center
and completely drain the fuel tank and fuel lines.
Do not mix diesel fuel with any special fuel
additives.
Special fuel additives can cause.
 Failure
 Damage to the catalytic converter
 Damage to the engine
Example: Fuel filter on chassis frame
AdBlue®/Diesel Exhaust Fluid (DEF) is not a fuel If water accumulates in the inspection window ℃,
additive and must not be added to the diesel tank. If empty the fuel filter ℃ on the chassis.Drain the fuel
AdBlue®/Diesel Exhaust Fluid (DEF) enters the
filter on the chassis ℃ periodically.
diesel tank, engine damage may result.
Drain the fuel filter on the chassis frame.
Environmental Note
 Place a catcher under the drain plug ℃.
Illegal use of fuel can cause harm to humans as well
 Open the drain plug ℃.
as the environment. Do not allow fuel to flow into
sewage systems, surface water, groundwater or soil.  Press the manual fuel pump ℃ and collect the
oil-water mixture.
Attention  Close the drain plug ℃.
If you fill your vehicle with fuel from a drum or Use the manual fuel pump with the fuel filter on
the chassis frame
filler can, filter the fuel before filling it.
Venting
This will prevent fuel system failure due to fuel
 Loosen the fuel tank filler cap.
100
 Place the collector under the fuel filter ℃. button until the engine is running at a higher
 Loosen the air vent screw ℃. engine speed.
 If the engine starts, gradually increase the
 Press the manual fuel pump ℃ repeatedly until
engine speed. If motor does not start or does not
the fuel spilled from the vent screw ℃ does not
run at higher engine speed, repeat step 5 (using
foam.
manual fuel pump to pump). Turn off the
 Tighten the vent screw ℃. engine.
After approximately 40 seconds, the start step is

Attention automatically canceled.
If there is no fuel in the fuel tank, press the manual
fuel pump ℃ again until there is significant
 Wait about 1 minute and repeat the start
resistance.
procedure. After 3 attempts to start, wait about 3
 Tighten the fuel tank filler cap. minutes and try again.
 Tighten the fuel tank filler cap.
Attention  Operate the engine at a higher engine speed for

a short time.
Then vent the fuel circuit on the engine using the
Fully vent the fuel system.
manual pump on the main filter as described in the
"Venting the fuel system on the engine" section. Drain the fuel filter with oil/water separator
on the engine
Venting the fuel system on the engine
Use the manual fuel pump on the engine to vent the
Warning
fuel system.
Fuel is highly flammable. Improper fuel handling
can lead to risk of fire or explosion.
Ignition, use of open flames, smoking and
Attention sparking should be avoided under all
Do not bleed the fuel system through multiple starts. circumstances. Turn off the ignition switch and
Otherwise, the starter may be damaged. auxiliary heating system before performing work
on the fuel system. Always wear protective gloves.
 Secure the vehicle to prevent skidding.
 Turn on the ignition switch. Environmental instructions
 Shift into neutral. Please dispose of the water-fuel mixture in an
 Loosen the fuel tank filler cap. environmentally friendly manner.
 Press the manual fuel pump ℃ handle on the Please visit a qualified professional service center for
this maintenance work.
main filter about 250 times in about 3 minutes
or until resistance is clearly felt.  Park safely and secure the vehicle to prevent
 Use the engine start/stop button to start the skidding.
engine within 5 seconds. Press and hold the  Turn off the auxiliary heating system.
101

 Place a suitable collection tray under the drain
hose ℃.
 Open the drain plug ℃ until the oil-water
mixture flows out of the drain hose ℃.
 Close the drain plug ℃.
 Dispose of the collected oil and water mixture
in an environmentally friendly manner (e.g. at a
qualified professional service center).
 Make sure the drain plug ℃ is closed. When the
engine is running and the drain plug ℃ is open,
fuel is lost through the drain port.
102
should be removed and sealed temporarily. After

Precipitation and drainage of fuel tank the completion of cleaning, the temporary plug can
The fuel tank should be subject of the be detached.
decontamination once every 1000hrs (frequency
increased as required). Fuel tank, replacement of Respirator
Replace once every 1000 hrs the Respirator
Attention
Dispose the filter element, oil and liquid in an
Attention
environmentally friendly way. Dispose the filter element, oil and liquid in an
environmentally friendly way.
1 Ventilation filter of fuel tank

1
1 Take off the lid.
2 Replace the filter element.
1 Drain plug screw 3 Refit the lid.
Drain the deposits through the drain plug screw at
the bottom of fuel tank. Use the steam or solution Engine Air Filters
Featuring Donaldson's new PowerCore® air
to clean the deposits.
filter, a side-maintenance model that integrates a
Before the cleaning, take off the drain plug screw. two-stage filtration structure, including a main
Select the appropriate vessel to contain the deposit element and a safety element, in the same
from the oil tank. After the cleaning, refit the drain compact unit to prevent dust or other
plug screw. contaminants from entering the engine.
In cleaning the deposits, it is unnecessary to
remove the oil tank from the dumping truck. But
when the oil tank wall and rusts on the partition
and scale are cleaned, it is necessary to remove the
oil tank. Let the detergent contact all internal
surfaces by removing the oil tank to different
positions.
Before doing this kind of cleaning procedure, the
connections of all respirator, sensors and hoses
103
End cap
End cap clips
handle
Main Cartridge
PowerCore Safety
Technology cartridge.
This position allows

connection of the air
inlet line attachment
High efficiency
pre-filter
Differential The filter element needs to be replaced only when the

pressure indicator intake air resistance reaches the maximum intake air
Can be connected to connection port
a dust extraction Integrated mounting brackets on
resistance recommended by the engine or host
valve or exhaust air three sides of the housing manufacturer, or when scheduled maintenance is
diversion unit
Injection molded housing scheduled.
Vacuator Available in standard and extended
exhaust valve versions (except PSD14) 2 Check the dust exhaust valve and pre-filter cyclone
The connection of the air inlet and outlet
ports to the housing is permanent.
The degree of engine wear depends to a large extent

on the cleanliness of the air drawn in. Therefore, it is
important to regularly check and properly maintain
the air filter element. Pay special attention to the
cleanliness of the air filter when handling it.
Attention
Do not under any circumstances run the engine
without a filter element or with a damaged one,
and regularly check the hoses and tube
connections from the air filter to the engine intake
manifold to make sure there are no leaks.
Engine air filter main element, cleaning and
replacement
The length of time between cleaning/replacement
depends entirely on the operating environment of the
machine. The main air filter element should be
cleaned when the air filter alarm light comes on.
The filter element should be replaced every 6
cleanings or every 500 hours (whichever comes
first).
The main filter element and the safety filter
element shall be replaced at the same time.
Attention
Dispose of the cartridge in an environmentally
friendly manner.
This machine adopts the side maintenance type air

filter, and the end maintenance type photo is used as
an example to illustrate the maintenance steps.
1 Check the air inlet resistance
104
toward the center of the housing and remove it.
Attention
The safety cartridge only needs to be replaced on
the third main cartridge change.
5 Checking the new cartridge before installation
Turn off the engine and inspect the dust exhaust

valve for damage, and replace it if damaged. Check
the pre-filter cyclone tube for blockage, and clean it
if there is any blockage. Open the clips and remove
the housing maintenance end cover.
3 Remove the main filter element
Visually inspect the sealing surfaces for damage,

tears or indentations prior to installation. If there is
any visible damage, do not install.
6 Replace the safety cartridge
Pull the cartridge out of the housing. On the side

maintenance type product you must first loosen the
cartridge fixing seal, tilt the cartridge about 5° with
the help of the handle and press down on the
cartridge to loosen the seal.
4 Checking the safety cartridge

If the safety cartridge needs to be replaced, use the
handle on the safety cartridge to slide the cartridge at
an angle into the outlet side and push into position
until the cartridge is firmly and flatly seated in the
housing.
Attention
For side maintenance type products, insert the
safety cartridge wings into the positioning slots
before pushing the cartridge into position.
7 Insert the main cartridge
Visually inspect the safety cartridge and do not

remove it unless the safety cartridge is damaged or
needs to be replaced. Using the plastic handle on the
For end-maintenance products, slide the cartridge
surface of the safety cartridge, pull the cartridge
into the housing until the sealing surface rests against
105
the housing. For side maintenance type products,

slide the cartridge at an angle of about 5° until it Attention
touches the end of the housing, and then rotate the
Indicator fitting installation direction
cartridge toward the outlet section to complete the
seal. Indicator connector
8 Put back the maintenance end cap
Product number: P100080

Male thread on both ends
1/8*-27NPT
11mm hexagonal nut
Sintered copper core inside
Cleaning of cooling system

Clean the radiator every other 500hrs or as
required. Clean the cooling system as required.
Warning
Collect used coolant, cleaning fluid and
detergent and dispose them according to the
current local regulations with responsibility for
For end maintenance type products, insert the wing environmental protection.
for fixing the position into the housing, tilt the Use the compressed air to blow out the foreign
maintenance end cap to the correct position and lock
debris (dust, insects etc.,) in the fin plates of
the clasp. For side maintenance products, place the
maintenance cover in the correct position and tighten radiator or use water jet to eliminate foreign
the clips. matters on the back of radiator (facing the cooling
air flow).
Attention
If the maintenance end cap does not fit, remove
and recheck the cartridge position. If the
cartridge is not installed correctly, the Attention
maintenance end cap will be difficult to install. Only use the appropriate pressure for cleaning,
9 Check the entire air filter system
otherwise, the fin plates of radiator will be
damaged.
Warning
Because the overpressure is in the cooling
system, there is the risk of burns when the
expansion tank cap is opened.
Make sure the air inlet and outlet connections are in 1 Only when the coolant temperature is lower
good condition and the alarm is reset. than 90℃, the cooling system can be opened;
106
2 Slowly open the pressure cap and unscrew

sealing pressure cap and release the
overpressure in the cooling system;
3 In disposal of coolant, wear the appropriate
protective gloves, protective suit and goggles.
Warning
If the coolant gets into mouth, there will be a
risk of poisoning.
1 It is prohibited to swallow the coolant;
2 Do absolutely not place the coolant into the
beverage can;
3 Put the coolant in a place, where children
cannot get access to.
Decontamination
1 Add into the cooling system with the
dissolved solution of 5% concentration
formed with water and mildly alkaline
detergent, e.g. “P3 Croni”(detergent in water
50g/l);
2 Preheat the engine up to ca.80℃ at moderate
speed (the coolant thermostat start opening)
and allow it to run for ca. 5min.;
3 shut down the engine and let it cool down to
ca. 50℃;
4 Drain the cleaning solution completely;
5 After the drainage, add the clean water into
the cooling system, turn on the engine to
preheat it. In 5min., drain it out. Then repeat
once the operation;
6 Fit a new seal ring, retighten the choke plug
of discharge outlet and the tightening torque
is 47N.m.
107
Electrical system during the engine running. Otherwise, the

electrical system can be damaged. The cut-off
Battery, charge
switch of battery isolates the positive cable from
Warning the battery.
During the quick charge of battery, the cap of

battery cavity must be taken off. While it is
charging, the alleged oxyhydrogen gas will
accumulate in the battery. The short circuit
nearby the battery, open flame or sparks will
cause powerful explosion. Please always
disconnect the charge current before the charge
clamps are removed. Keep good ventilation,
especially a battery is charging in a closed space.
The battery electrolyte contains the corrosive
vitriol. The electrolyte sprayed on the skin
should be removed immediately. Wash by use of Battery charge
soap and plenty of water. When the electrolyte
gets into eyes or other vulnerable body parts,
Prompt
wash them with plenty of water immediately
and call the doctor for help. Even if the PS is turned off by uses of the
Connection with the charger cut-off switch of battery, various parts of engine
1 Use the cut-off switch of battery to turn off electrical system have the voltage.
the PS.
2 Cut off the cable from the battery terminal. Battery
3 Clean around the battery cap. The battery is made of two tandem 12V batteries,
4 Remove the cell cap. which provides the system with the 24 V voltages.
5 Add distilled water when necessary. Do not
let dirt ingress into the battery.
6 Fit the charger clamps with the positive to the
Warning
terminal (+), the negative to the terminal (-). Explosive gas, open flame and sparks will cause
7 Be sure to set the battery charger to the explosion. Do not smoke nearby the battery.
correct voltage.
8 Activate the charger. Check the charging state of battery
Use the acid tester to check the battery charging
Disconnection from the charger state. When there is risk of frost, it is very
1 Turn off the charger. important to avoid the discharge of battery,
2 Remove the charger clamps. because the discharged battery electrolyte may be
3 Fit the battery cable. frozen, and damage the battery.
4 Use the cut-off switch of battery to turn on
the PS. Use the assistant battery to start
5 Start the machine.
Warning
Disconnection switch of battery When a fully charged battery is connected to a
Prompt run out battery, the battery will explode due to
the excessive current. Therefore it will cause the
Do not turn off the cut-off switch of battery
108
personnel injury. electronic system.

The booster battery or any other PSs must have Before doing the work relevant to the equipment
the same voltage as the machine battery. of A/C generator, the battery cable should be
disconnected and isolated.
Prompt Battery connection
Do not confuse the battery terminals. Each
Under any circumstances, do not connect the
terminal is clearly marked with the sign (+) or (–).
battery charger to the battery of machine when
When the cable connection is wrong, the rectifier
trying to start the engine, because this will
of A/C generator will be immediately destroyed.
damage the electronic system in the machine.
In disconnecting the battery, use the cut-off switch
of battery to turn off the PS.
1 Use the cut-off switch of battery to turn off
the PS.
Welding
2 Connect in series two 12V batteries. The
Before performing the electric welding on the
terminal (+) on the one battery is connected
machine or connecting to the attachments of
to another terminal (–) on the battery.
machine, the following operations must be done:
3 A jumper start cable is connected between the
positive terminal of machine battery and
positive terminal of booster battery. Attention
4 Another start cable is connected between the
Before the welding, the connection leading to
terminals (–) of booster battery and the earth
the battery (pack) must be disconnected.
point of machine.
All connections leading to the control units
5 Use the cut-off switch of battery to connect
(engine controller, gearbox controller, main
the PS and the machine battery.
controller, hydraulic controller etc.) must be cut
6 Wait for a couple of minutes, and then use the
off.
ignition key in cab to start the engine.
The earth cable connecting the weld unit should be
7 After the engine start, wait for a couple of
nearby the welding point as close as possible.
minutes, and then remove the start cable on
1 Use the cut-off switch of battery to turn off
the earth point of machine and remove the
the PS.
start cable clamps from the terminal (–) of
2 Disconnect the battery, including the
booster battery.
positive/negative connection terminals.
8 Finally disconnect the jumper start cable
3 Disconnect the electronic unit.
between the terminals (+).
For more information, please contact XCMG
9 Remount the terminal cap on the battery
authorized maintenance shop.
terminal.
4 connect the ground joint of welding
10 Remount the rubber guards cover on the
equipment, making it nearby the weld points
battery and close the guard cover.
as close as possible, and ensure that the
current won’t pass the bearing.
A/C generator
5 Provide good ventilation.
If the A/C generator is sensible to the normal
6 Remove the paint around weld points in at
electric connection, therefore, the following
least 10cm (4 in.) area.
instructions should be observed:
Disconnection
The battery cannot be disconnected with the cable Warning
of A/C generator during the engine running;
Heating paint surface, rubber or plastic parts
otherwise, it will damage the A/C generator and
may cause the production of health or
109
environment hazardous substances. Be careful

during the welding, polishing or gas cutting.
Wear the protective facilities.
Attention
In doing all welding jobs, the extinguisher
should be readily accessible.
Relay
It is located on the terminal board in the electric
box at the right side of driver in cab. When one of
the relays has fault, another one of less important
function can be used to replace it, thereby to
eliminate the fault temporarily. In replacement of
relay, it should be checked if the relay is identical.
110
Gearbox 7Repeat the check procedure to verify the oil level.

Note: When checking the oil level, keep the
Check the gearbox for oil leaks dipstick upright with the needle pointing down.
Under the machine, check the machine for oil
leaks.
Pay special attention to check the transmission
transmission range for oil leaks.
Transmission gear oil change interval is 2000

hours and filter element change interval is 1000
hours.
Transmission lubricant oil level
Oil Scale Scale
When the transmission level is checked using the
electronic display method, the oil level is
displayed on the electronic display.
Oil drainage
1 The machine shall be parked at the
maintenance position.
2 The gear selector should be set in the
N-position. Apply the parking brake.
3 Remove the plug of oil drain hole and
exhaust the gearbox oil. If equipped with the
quick-filler device, Remove the pipe joint
connecting the quick filler and gearbox to
When the electronic display method is used to
check the oil level, the transmission lube oil drain the gearbox oil.
temperature must be between 40°C and 104°C 4 Screw the plug of oil drain hole or the pipe
(104°F and 220°F), and the display condition is joint of quick-filler.
invalid if the temperature is below 40°C (104°F)
or above 104°C (220°F).
When measured with an oil scale, the scale is
divided into "cold" and "hot" levels.
The "cold" level is used to check that the
transmission fluid is sufficient to start and run, and
is only used to confirm that sufficient fluid is
required for a cold start and that the machine is
only allowed to run for a short period of time.
When the transmission level is between the cold
minimum and maximum, the machine is idled
until the transmission fluid temperature is normal
(71°C to 93°C/160°F to 200°F), then the hot fluid
check is performed and the transmission level
should be between the "hot" level minimum and 1
maximum.
The transmission fluid level check procedure is as
follows.
1 Park the machine in the service position.
2 Idle the engine.
3 The gear selector should be in neutral and the
parking brake applied.
4 Unscrew and remove the dipstick from the pipe 1 Drain hole of gearbox oil
and scrub it clean.
5Clean the pipe ports before inserting the dipstick.
6Insert the dipstick into the pipe and remove it to
check the level.
111
1 Keep the vehicle on level ground throughout,

Attention apply the parking brake, wedge and prohibit
the vehicle from moving.
When the gearbox oil is too little, the gearbox 2 Prolonged operation of the vehicle is
will come up with abnormal lubrication, and prohibited until HOT MAX is reached.
cause the gearbox damage. 3 The amount of oil between the hot lower and
When the gearbox oil is excessive, the gearbox upper positions is approximately 2L
efficiency is low and produces the foams, and Transmission pre-diagnosis
cause the overheating of gearbox.
TUPIAN
Transmission respirator replacement
Attention The respirator on the gearbox is inspected and
Before checking the oil level, always clean cleaned every 500 hours and if required, the area
around the dipstick. Dirt in the oil will damage around the area is cleaned. If clogged, replace the
unit. Or when use reaches 2000 hours, replace
the gearbox. Use a downless rag to wipe the again.
dipstick. TUPIAN
Warning Distributor Box

The hot oil will cause burns. Use the protective Check the distributor box oil level (viewing
equipment and carefully dispose the hot oil. In hole)
Clean the observation hole cover and the area
disposal of the replaced gearbox oil and filter around it.
should meet the provisions of national Check the distributor oil level through the
environmental protection standards. observation hole 1, which should be in the middle
Filling of the observation hole.
1 Fill 42L quantitatively first.
2 Idle in neutral for at least 15 seconds to fill the
torque converter with lubricant.
3 Apply the parking brake, put on forward gear
and keep the engine speed 1000-1500rpm for at
least one minute to evacuate the air inside the
cooling system.
4 Return to idle speed, with the transmission in Refill
neutral, and check the transmission oil level.
5 When checking the oil level, the oil dipstick 1 Park the vehicle on a level road.
should always be unscrewed. 2 Clean the sludge and debris near the oil filler, open
6 Check cold, add transmission fluid so that the the oil filler plug and fill the gear oil until it
level is at the upper cold level of the transmission overflows, about 11L.
fluid scale (COLD MAX). 3 Check the oil level observation hole at the same
7 Apply the parking brake, apply light throttle, half time, the oil level should be in the middle of the
power, forward gear, and hold for 15 seconds. observation hole.
Then idle, shift to neutral, rest for 15 seconds, and 4 Put back the filler plug
repeat in reverse until the oil pan temperature
reaches between 71°C and 93°C or the engine
water temperature stabilizes.
8 Check the oil level again by using the dipstick or
gear selector with the engine idling and in neutral.
9 Add transmission fluid in the proper amount to
bring the fluid level near the upper level of the hot
state (HOT MAX)
Attention
112
I Refueling hole
II Observation hole
Drain oil
1 Stop the vehicle on a level surface.
2 Clean the oil drain and the area around it.
3 Open the oil drain screw plug and place a container
under it to drain the oil.
4 Screw in the oil drain screw plug.
III Oil Drain Hole
Warning
Hot oil can cause burns. Use protective equipment
and handle hot oil carefully. Dispose of the
replacement gearbox oil and filter in accordance
with the provisions of the relevant national
environmental standards.
Distributor oil replacement interval

The oil filled in the transfer case conforms to GL-5
standard, the filling volume is about 11L, the first
oil change interval is 100 hours (or 1000km), and
the oil change interval after the first warranty is
1000 hours (or 10000km). Every time the oil is
changed, the filter element needs to be changed at
the same time.
Transfer case respirator replacement
The respirator on the transfer case is inspected and
cleaned every 500 hours, and if there is damage
and blockage, the respirator is replaced.
113
Axle container.
3 Put the drain plug back in.
Check of leakage
Every day when the shift is changed, check the
axle leakage:
maintenance position.
2 Visually check if the axle has any leakage.
Check of axle oil level
III Oil Drain Hole
maintenance position. Axle pack oil drain
2 The gear selector should be set in the 1 Clean the oil drain port and the area around it.
N-position. Apply parking brake. 2 Open the drain plug and put the oil into the oil
container.
3 Before the check, wait for ca. 2mins, so that 3 Put back the drain plug.
the oil level becomes stable.
4 Disassemble the filling plug, The oil level
should be flush with the lower edge of the filler
hole.
Replacement of axle gear oil
Gear oil is changed for the first time at 100 hours (or
1000km) and then every 1000 hours (or 10000km).
The filling volume for front axle, middle axle and
rear axle is about 55L. III Drain hole
Warning Fill the gear oil at the wheelside

1. Clean the oil drain port and the area around it.
The hot oil will cause burns. Use the protective
2. Adjust the wheel so that the oil filler is in the
equipment and carefully dispose the hot oil. center line, and the oil drain is at its lowest point.
The disposal of replaced axle gear oil should 3 .Open the filler plug and fill with gear oil until the
oil level is at the lower edge of the filler port.
meet the provisions of national environmental
4 .Wait a few minutes and check the oil level again to
protection standards. see if it is still at the lower edge of the filler neck. If
the oil level drops, continue to refill to the lower
Drain oil from the wheelside reducer edge until the oil level stabilizes.
1 Clean the oil drain port and the area around it. 5. Put back the filler plug.
2 Adjust the wheel so that the oil drain port is located
at the lowest point of the gearbox.
3 Open the oil release plug and put the oil into the oil
container.
4 Put back the drain plug.
I Refueling hole
II Observation hole (the same hole as the
refueling hole)
Bridge pack filling gear oil

1 Clean the oil drain and the area around it.
2 Open the filler plug and fill with gear oil until the
III Oil Drain Hole oil level is at the lower edge of the filler port.
Wheel-side brake oil drain 3 Wait a few minutes and check the oil level again to
see if it is still at the lower edge of the oil fill port. If
1 Clean the oil drain port and the area around it. the oil level drops, continue to refill to the lower
2 Open the drain plug and put the oil into the oil
114
edge until the oil level stabilizes.

4 Put back the filler plug.
I Refueling hole
II Observation hole (the same hole as the
refueling hole)
Axle respirator replacement

The respirator on the axle is inspected and cleaned
every 500 hours. Replace the respirator if it is
damaged, clogged, or spraying oil.
115
Brake system
The brake system uses the hydraulic brake. It is
the multi-plate wet disc self-cooled brake.
Check of brake performance

Every day before starting the engine, check the
brake performance. When the brake performance
is abnormal, please contact the XCMG authorized
maintenance shop.
Brake bleeding
After the brake system works for the first time or
after changing the brake fluid, it must be bled.
1 The vehicle is parked on a level surface.
2.
Brake system fluid replacement
The brake system system brake fluid replacement
interval is 4000 hours, and the filter element is
replaced together with the brake fluid replacement.
116
Wheels The overhauled of tires or rims must be done

by special personnel operation.
In failure to conduct the maintenance or replace
the wheels or tires according to correct steps, the
Inflation of tires
wheels or tires can burst and cause the damage,
The instructions listed below are applicable to the
serious injuries or death.
inflated tires to be pressurized. When tires have no
When doing these maintenances, consult your
pressure, they should be disposed by the trained
XCMG or tires manufacturer.
maintenance personnel.
Tires, check air pressure

Tire pressures are calculated specifically for
Warning
XCMG vehicles to provide maximum tire life and To inflate one tire can cause its explosion. This
should be used under all normal operating may result in an accident.
conditions. It is important to note that the tire
pressure calculated from the design axle load is the Use of a pneumatic chuck and a hose in
cold tire inflation pressure (the load/pressure table sufficient length allows you to stand nearby the
in the tire company data book is usually based on a tire pattern at the time of inflation, but as far as
reference ambient temperature of 18°C). Tire possible.
manufacturers have taken into account extreme
conditions and recommend increasing pressures to
avoid excessive tire deformation. Due to these
factors, optimal performance and safe operation
can only be guaranteed if the inflation pressure is
determined based on operational and site-specific
data (e.g., actual axle load, traction conditions and
operating ambient temperature). Overinflated or
underinflated tires can shorten the life of the tread.
Tire inflation pressure should be checked every 50 Constantly inflated hose
hours. ● Let all other personnel leave far away from
● When checking the air pressure, the tires should the hazardous area (in front of the rim).
be at room temperature and the machine should be
empty. ● It is prohibited to strike the tire surface. The
● The recommended air pressure should normally installation of tires on the assembled rim can
be used, 4.25Bar (Double Money)/5.25Bar result in explosive (causing personnel injury,
(Techking)/3.75Bar (Michelin) for the front and even deaths).
4.75Bar (Double Money)/5.75Bar
(Techking)/4.75Bar (Michelin) for the rear, and ● When the machine was operated with the tire
other brands of tires should be inflated pressure lower than 80% of the minimal
according to the manufacturer's recommended recommended as required in the technical
pressure. specifications operation, or when the tires or
Please observe the tire manufacturer's instructions
and do not exceed the maximum allowable air rim were visibly damaged or mighty be
pressure. The pressure must not be modified for damaged, do not inflate the tires.
overloading, as this will not only cause excessive
vibration of the machine at no load, but also Check of tire wear
overload the load-bearing parts, which can lead to
premature failure. Check:
● Tires have the sufficient tread.
● Tread: Confirm that the cord ply is invisible.
Warning ● Lateral tire: Confirm that no deep cut on the
Repair or welding on the rims with inflated cord ply.
tires can lead to the rim crack or tires
explosion. Check and tighten the wheel nut,
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After the replacement of wheels or when one Rims

wheel has been removed due to other reasons,
check the tightness of wheel nut after running for Rims are designed with an inherent safety factor
3hrs. and, when used properly, are effective in
preventing safety critical failures. However,
Other tires, overloading and improper operation of the vehicle
can significantly shorten the service life of this rim.
Warning XCMG recommends that the rim should be
When use of tires was not according to the carefully inspected and tested by the wheel
conditions as specified, they can be overheated manufacturer at least every two years and
and exploded or stuck by sharp stones on rough re-certified for fitness for use. Inspection items
road, then exploded. This will result in serious include, but are not limited to, cleaning,
injury or damage. sandblasting, ultrasonic or magnetic particle
For the safe maintenance of tires, the following inspection, necessary repairs and recertification
principle must be adhered: stamping. By implementing the above measures,
● Inflate the tires to the pressure as specified. the vehicle owner will benefit by extending the life
Especially, when the inflation pressure is too of the rim and improving safety within the
low, it will produce the abnormal heat. operating site and for the operator. It is
● Use the specified tires. recommended that a visual inspection of the rim
The inflation pressure of tires and allowed speed should be performed at least once with each tire
provided in this Manuel are the universal value. change.
The actual value can be different, which depend on • The condition of the wheels should be
the type of tires and special operation conditions. inspected regularly. Thoroughly cleaning all
For further information, please consult your tires surfaces prior to inspection will help to more
manufacturer. easily detect any possible defects. Carefully
inspect all parts after disassembly to ensure
Storage of tires they are in good condition and check for any
As the basic principles, the tires should be stored non-conformities.
in the warehouse. Personnel without permission
• Wheels are a safety-related part, so rims must
are not allowed to get in. When tires are stored
not be broken, deformed, twisted, severely
outdoors, they should be fenced up, and attached
corroded, excessively worn, bent or twisted
with the label “No entry” or other warning label,
(if present), or other similar defects. These
which even children can understand.
parts cannot be reused and must be destroyed
Place the tires on a flat ground and block them
and scrapped. In addition, if damage is
with wedges so that they cannot roll and fall down.
suspected or the suitability of a wheel/rim
component is in question, the part in question
When the tires fall down, try to escape from the
must be replaced.
scene. The tires of mining equipment are very
heavy. When the tires fall down, do not try to keep Typical defects requiring replacement parts
them upright. The weight of those tires will cause include, but are not limited to
serious injuries or deaths. • Cracks present within the spoke surface,
especially in the bolt hole area.
• Distortion or abnormal indentation of the
bolt/stud mounts.
• Air leakage from tubeless tires caused by
micro cracks within the rim, or wear marks on the
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rim-tire mating surface.

• Bending of the rim flange (usually caused by
hitting an obstacle).
• Circular cracks on the rear flange or in the
groove in the base of the combination rim.
• Damage, twisting or bending of the rim rim of
a combination rim, or excessive wear.
• No technical modifications may be made to
any part of the wheel.
Warning
It is absolutely forbidden to repair a damaged
rim or wheel by heating, welding, adding or
removing material.
Since these modifications may introduce

additional stress in critical high stress areas,
there is no warranty on the repaired part.
119
Frame
Check of engine and gearbox bearers
Check the engine and gearbox bearer once every 1000hrs, be sure that the shock absorber is intact and the
bolt connecting points not loosened.
1.Engine shock absorber

2. Transmission damping
1. Bolt connecting points(18)

2. Shock absorber(6)
Attention
Failure to check the shock absorber can cause brake fade and shorten the service life of machine.
1. Articulated joint inspection and adjustment of axial clearance

2. Check and adjust the axial clearance at the articulated joints every 4000 hours.
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Air Conditioning
When the system installation is completed, or after the system maintenance is completed, system
commissioning is to be carried out (commissioning must be operated by professionals).
1. Precautions when refilling refrigerant.
1) Refrigerant has a low freezing point and is highly volatile, so gloves and glasses must be used to prevent
frostbite and blindness caused by contact with the skin.
Attention
If the refrigerant hits your eyes or comes into contact with your skin, flush the contact area with water and get
medical attention from an ophthalmologist or dermatologist. Do not rub your eyes with your hands or
handkerchiefs.
2) When handling refrigerant, the place must be easily ventilated. Although the refrigerant is harmless, it may
cause oxygen deprivation if it is discharged in large quantities in a closed area.
● Allowable discharge amount: 1,000ppm (4184mg/㎡)
● Excessive discharge may cause heart and blood relations, immune system abnormalities or allergies,
respiratory system abnormalities or skin diseases.
3) When operating the refrigerant, the surrounding environment must be free of moisture, dust, and other
foreign substances, which will damage the air conditioning system if they flow into the system.
4) It is necessary to prepare a gas leak detector. R-134a refrigerant will produce harmful gas when it comes
into contact with the spark of the sensor, so be careful.
5) Refrigerant must be R-134a. The use of other refrigerants may have adverse effects on system
components.
6) R-134a refrigerant is not compatible with R-12 refrigerant, so a very small amount should not be mixed.
If mixed together, it may cause pressure loss.
7) When operating the refrigerant, there must be no ignition or ignitable objects around the vehicle, and the
exposure of the refrigerant tank to a heat source may cause an explosion, so be careful. The R134a container is
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under high pressure and should never be placed in a high temperature environment. Also, check that the storage
environment temperature is below 52°C.
8) A/CON components are generally covered with dust caps to prevent the inflow of sewage, dust, and
moisture. The dust cover must be removed before operation and sealed after operation. R-134a applicable
refrigeration oil is easier to absorb moisture than R-12, and the absorption rate is 10 times higher than mineral
refrigeration oil. Excessive moisture affects the compressor lubrication function and durability. Moisture has an
extremely bad effect on air conditioners, so it is best to avoid rainy day operation.
9) When the A/CON system is uninstalled and then installed, the O-ring must be coated with refrigerant oil,
especially the screw type connection parts are installed manually first and then assembled with two wrenches,
and the flange type connection parts are assembled by gently pushing the pipeline while connecting the nuts and
bolts. The joint is used to fix and seal the refrigerant line.
Sealing: Initially, the flare type was used, and the end of the pipeline was processed into a flare, but O-rings
were produced to reduce leakage.
Fixing: The nut and live joint type is fastened with a live wrench, the fixed joint type suitable for
installation in production lines is fastened with a socket wrench, and the current single-touch type does not need
to be fastened with a tool.
10) When A/CON system is installed, assembling with a torque above the specified one or when the O-ring
is clamped, it will lead to refrigerant leakage, so it should be operated according to the specified torque.
Item kg-m
Compressor mounting bolts 1.5 ~ 2.0
Expansion valve mounting bolts 0.8 ~ 1.2
Expansion Valve Mounting Nut 1.0 ~ 1.5
Compressor and refrigerant tube
0.5 ~ 0.7
connection flange type nut
Flanged nut for suction and liquid pipe
0.5 ~ 0.7
connection
11) The hose should not be twisted.
12) Never separate the air conditioning system before complete recovery of the refrigerant. If the system is
separated before recovery, the refrigerant and refrigerant oil will be discharged under the influence of system
pressure and will pollute the surrounding environment.
13) When replacing air conditioning parts or confirming refrigerant, make sure to replenish refrigerant oil.
Amount of
Item
refrigerant oil
Refrigerant
30cc
re-injection
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Evaporator
50cc
replacement
Condenser
30cc
replacement
Piping
30cc
Replacement
Reservoir dry
cylinder 30cc
replacement
14） When replacing a new compressor, confirm the amount of refrigerant oil of the compressor to be
exchanged and then replace it after draining the excess refrigerant oil. (About 1/2 paper cup is drawn out).
2. Refrigerant refilling method

2.1 Air conditioning refrigerant operation essentials
In order to ensure the performance of the air conditioner and the durability of the compressor, the
appropriate amount of refrigerant must be maintained in the air conditioning system, the vacuum state in the
system before the refrigerant injection, the injection method has a great impact on the compressor, so it is
necessary to correctly understand the main points of refrigerant injection after the operation.
Air conditioning refrigerant operation should be carried out in the following order, and try to use automatic
recovery/charging equipment (such as fully automatic refrigerant recovery and filling machine) in order to avoid
operational errors.
Check for refrigerant leakage
Refrigerant recovery (discharge) Repair of leaks
Vacuum implementation (min. 15 min.)
Confirm vacuum leak (10 minutes) Repair of leaks
Re-vacuum (10 minutes)
Refrigerant injection
Leakage
Operation test and leak check
2.2 Order of refrigerant refilling

1) Installation of the meter
℃ When using the meter, first turn the high and low pressure valves "off".
℃ Then connect the high and low pressure piping connector to the refrigerant service injection port of the
air conditioning system. Connect the low pressure pipe to the low pressure service port and the high pressure
pipe to the high pressure service port, and then tighten the nuts of the pipeline by hand.
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Low pressure
High pressure
Closing direction
Closing direction
Vacuum pump or cold

coal tank
2）Vacuum operation
Be sure to vacuum the air conditioning system after the refrigerant is discharged. The purpose of this vacuuming
operation is to remove all air and moisture from the system, maintaining the system for about 15 minutes after
installing each part, and maintaining the vacuum for about 30 minutes for parts that have been opened during
repair.
℃ Confirm that the engine is in "OFF".
℃ Connect the pressure gauge to the access port of the compressor gauge, and then turn off both sides.
℃ Check that the refrigerant is discharged from the system.
℃ Connect the middle line of the pressure gauge to the suction part of the vacuum pump.
℃ Drive the vacuum pump and open the high-pressure and low-pressure valves of the pressure gauge.
3）Refrigerant injection method (using refrigerant tap valve)
℃ Before connecting the valve to the refrigerant container, turn the handle fully in the counterclockwise
direction (HANDLE).
℃ Turn the DISM counterclockwise to the highest position.
℃ After connecting the intermediate line to the Tap Valve, turn the DISK fully counterclockwise.
℃ Turn the handle clockwise and dig a hole in the upper part of the seal.
℃ Loosen the pipe nut attached to the middle of the instrument.
℃ Tighten the nut after releasing the air for a few seconds.
Low High
pressure pressure
Handle
Close Close
Connection
Air
Vacuum pump Disc
4）Charging of refrigerant - gas state

This is the method of filling the system through the low pressure side when the refrigerant is in the gas state, and
the refrigerant flows into the system in the gas state.
① TAP VALVE is installed in the refrigerant container. (Refer to "Use of Refrigerant TAP VALVE")
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℃ Open the low pressure valve and adjust the valve so that the scale does not exceed 4.2kg/㎠.
② Immerse the refrigerant container in warm water (about 40°C) and maintain the pressure of the gas in
the container slightly higher than the system gas pressure.
℃ Run the engine and start the air conditioner. [Ref] To prevent liquid refrigerant from being charged
through the low pressure side and damaging the compressor, the container should be placed squarely.
℃ Fill the system to the specified value and close the low pressure valve.
℃ If the refrigerant fills too slowly, place the refrigerant container in a container filled with water at about
40°C.
Attention
Under no circumstances should it be heated above 52°C.
Low High Low

pressure pressure High
pressure pressure
Open
Open Close Open Close
Immerse in
Refrigerant warm water at
Refrigerant 40 "C
This operation is performed when the refrigerant in liquid state is filled into the air conditioning system through
the high pressure side. If the refrigerant container is emptied, the refrigerant flows into the system in a liquid
state.
℃ After vacuuming the system, completely close the high and low pressure valves.
℃ Install the refrigerant container TAP VALVE. (Refer to "Use of Refrigerant TAP VALVE")
℃ Open the high pressure valve completely and place the container upside down.
℃ If overfilling, the discharge pressure increases, the refrigerant should be weighed, the correct amount should
be filled, and the high-pressure valve should be closed.
℃ Close the valve of the pressure gauge after filling the refrigerant to the specified amount.
℃ Check for leakage with a refrigerant leak detector.
Attention
When filling through the high pressure side, do not start the engine; when filling the system with liquid
refrigerant, do not open the low pressure valve.
2.3 Maintenance of the air conditioning system
The service life of the construction machinery air conditioner depends largely on the correct maintenance
of the user.
2.3.1 General matters
Inspection and repair of air conditioners need to be doubly careful, and should be kept clean, for the normal
operation of the system, the repair must be used standard parts, and to fill the specified amount of standard
refrigerant.
2.3.2 Inspection and maintenance of each component parts
℃ Inspection of engine cooling system
℃ Confirmation of air exchange device
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℃Checking of air conditioning function parts

2.3.3 Performance inspection
℃ Park the vehicle in a place that is not exposed to direct light.
℃ Close all doors and windows.
℃ Open the inspection cap.
℃ Connect the pressure gauge to the low and high pressure side.
℃ Keep the engine speed at 1,500-2,000 rpm.
℃ Turn on the switch and turn on the fan to the maximum gear, and measure the temperature and pressure
of each part after 10 minutes.
Low
High
Atmospheric pressure Ventilation outlet air
pressure side Engine (rpm)
temperature(℃) side temperature(℃)
(kg/cm2 .G)
(㎏/cm2.G)
19 ~ 21 11.3 to 12.7 1.4 to 1.5 6 to 8
24 to 26 12.0 to 13.4 1.5 to 1.7 7 to 9

1,500 to 2,000
29 to 31 13.4 to 15.5 1.8 to 2.0 9 to 10
34 to 36 16.9 to 17.6 2.3 to 2.5 13 to 14
2.3.4 Daily inspection

a. Check and clean the air conditioning condenser, requiring cleanliness inside the heat sink, no blockage
inside the sink, cleaning application of cold water or compressed air, not hot water, hot air.
b. Check the amount of refrigerant in the refrigeration system, (if there is a sight glass) that is, observe the
sight glass, no bubbles in the observation window under normal circumstances, a small amount of bubbles when
the engine speed changes.
c. Check the degree of tightening of the compressor drive belt.
d. Check the appearance of the hose is normal, the joint flange is secure.
e. Check whether the refrigeration system power connection is secure, there is no short circuit, short circuit
phenomenon.
Attention
Whether the air conditioner is used or not, the pipeline and other devices should be regularly checked and
maintained.
If the air conditioner is not used for a long time, it should be turned on once a month for about 10 minutes
each time to facilitate the normal operation of the system.
Air conditioners with heating function, the circulating water used for heating must be added with antifreeze
to prevent the core or pipeline from freezing and cracking.
2.3.5 Regular maintenance of air conditioners
Air conditioning system regular maintenance items and cycles
Maintenance cycle
System components Maintenance work
Month 3 months Half Annua
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ly year lly
Refrigeration Check the wear and finish of the pipes o
pipes
Joints Check for leaks (leaks generally have oil stains) ○

Condenser Check the condition of the heat sink, clean the ○
accumulated dust and dirt

Refriger
Drying cylinder Check the condition of use or replace ○
ation
System Refrigerant Check the condition of refrigerant through the ○
sight glass
Air conditioner Check the fixed installation condition of the main ○
main unit unit (there should be no looseness)

System sealing Check the body and air conditioning seal ○
Electromagnetic Check clutch suction condition ○
clutch
Belt Check belt integrity and tightness ○
Compres
sor Fixing bracket Check the installation condition of fixed bracket ○
Compressor Check the operation sound for any abnormalities ○
operation
Electric wire Check the wear and tear of the wiring and its ○
Circuit condition
Connectors Check contact and integrity ○
system
Control switch Check contact and integrity o
Internal Check and clean the filter element for dust

○
circulation filter accumulation, dirt, etc.
Filter
Fresh air filter Check and clean filter elements for dust ○
accumulation, dirt, etc.
127
3. Air conditioning common troubleshooting

Fault Phenomenon Cause Measures
1. There is moisture in the
Replace the drying cylinder,
Refrigeration system, causing the expansion
re-vacuum, add refrigerant
Refrigeration system valve ice blockage
Repair or replace
interruption Abnormal 2. Temperature sensor failure
Check and repair
Work opening or 3. Poor grounding wire
Check and repair
stopping 4. Control switch poor contact
Inspection and maintenance
5. Relay contact is not good
1.Belt is loose
Adjustment or replacement
System 2.Compressor bracket is loose
Adjustment
Increased makes 3.Evaporator fan wheel is loose
Adjustment
noise Abnormal 4.Clutch slipping
Repair or replace
sound 5. Compressor internal wear and
Repair or replace
tear
1. The air door is stuck and not
Check the damper, remove the
moving
Insufficient foreign body
Hot air is not 2.The pipeline is blocked
heat Repair
hot 3. Engine cooling water
production Open after the temperature rises
temperature is not high
Repair or replace
4. Pipeline leakage
1. Compressor clutch
a) coil short circuit or broken Replace
circuit Repair or replace
b) Clutch slipping Check connected
Blower
2.wire head disconnected Replace
normal,
3.Belt breakage
compressor
4.Pressure switch operation Leak check, replenish
does not
a) Too much refrigerant leakage refrigerant
work
b) Too much refrigerant filling Release in proper quantity
c) Damaged switch Replace damaged parts
5.Temperature sensor damaged Replace damaged parts
No cooling 6.Compressor damage Repair or replace
Blower is
Check the leakage, replenish
normal, 1. Too much refrigerant leakage
the refrigerant
compressor 2. Refrigerant is overfilled
Release the right amount
is working
The blower
does not 1. Intake line power failure
turn, the a) poor ground contact Check and repair
compressor b) fuse broken Inspection and replacement
does not c) bad power switch Check and replace
work
The blower 1. Fan damaged Replace
128
does not 2.Fuse is broken Replace

turn, the 3. Wind gear switch is bad Replace
compressor 4. Bad speed control resistor Replace
works
1. Belt loose
2. Refrigerant leakage,
insufficient refrigerant in the
system
3.High pressure pressure is high, Adjustment
low pressure pressure is high Leak check, replenish
a) Condenser heat sink is dirty refrigerant
and blocked
b) Condenser fan stalled Cleaning
c) Too much refrigerant filling Repair or replace
d) There is air in the system, the Adequate release
pressure gauge jittering Leak check, release refrigerant;
e) Expansion valve open too re-evacuate and refill
large refrigerant
4. High pressure pressure is high, Adjust or replace
Blower low pressure pressure is low
Cooling normal a) expansion valve dirty plugging Clean or replace
effect b) Drying cylinder dirty plugging Replace
Bad c) High pressure line blockage Repair or replace
5. High pressure pressure is low,
low pressure pressure is low Check for leaks, refill
a) Refrigerant leakage, refrigerant
insufficient refrigerant in the Adjust or replace
system Repair or replace
b) Expansion valve opening is Repair or replace
too small Repair or replace
c) low pressure pipeline blockage Check the dampers, remove
d) Evaporator blockage foreign objects
6. High pressure pressure is low,
low pressure pressure is high
a) Compressor failure
7.Temperature damper jammed
Evaporator 1.Filter appearance is too dirty Replace the new filter
airflow is not 2. The air outlet is blocked Remove the blockage
enough 3. Evaporator core frost Stop the machine to defrost
129
Condenser cleaning
The condenser should be cleaned every 500 hours or as needed.
1 Park the machine in the maintenance position.
2 Remove the front grille.
3 Use compressed air to blow the condenser clean.
Attention
Pay attention to the hoses between the compressor, condenser and evaporator. There is always some
excess pressure in the system.
If you do not open the system, there may be some excess pressure, let an authorized XCMG service shop
perform this work.
130
Hydraulic system
Keep the hydraulic system free of contamination, which can cause excessive wear and costly breakdowns. Keep
all hydraulic components and hydraulic fluid extremely clean during operation.
Hydraulic oil
Attention
The hydraulic system has two tanks, a brake tank, located at the front, and a working tank,
located at the rear. The brake tank is used for the braking system and the working tank is used
for the steering and lifting system. Located on the left rear side of the cockpit, the two tanks are
integral on the outside and separate on the inside, each using a different specification of
hydraulic fluid.
The oil level of the brake tank and the working tank are read separately from the observation
mirror. If the oil level is too low, an alarm display will appear.
For the oil quality level, see the specifications section.

2 The cargo tank must be lowered onto the frame.
3 The oil level should be located above the 1/2 to 3/4 position of the measurement range on the viewing mirror.
In order to be able to read the correct value, the oil level should be read horizontally in the oil level viewing
mirror.
If the ambient temperature and brake fluid temperature are lower, the oil level may be below the MIN
(minimum) mark line of the measuring range. This phenomenon is completely normal.
If the machine has been operated with the brake fluid temperature reaching 90°C, the oil level may reach the
MAX (highest) mark of the measuring range. This phenomenon is also completely normal.
Levels at 25°C in the brake and hydraulic oil tanks
0°C 25°C 90°C
131
Brake fluid tank level and temperature
Attention
If the machine is using biodegradable hydraulic fluid, the same type of hydraulic fluid must be used when
adding or replacing it. Different types of biodegradable hydraulic fluids must not be mixed.
Hydraulic fluid tank, sediment discharge

Drain the oil tank every 1000 hours.
The hydraulic system has two tanks, both of which are separate internally, each with a drain. The drain port is
located below the tank level sight glass.
1 Remove the protective cover from the drain fitting.
2 Drain the sediment. Use the same drain hose (located inside the grill) used for the engine oil change.
3 Reinstall the protective cap.
Liquid level sight window Liquid level sight window

Brake Worki
oil ng oil
tank tank
Drain Drain
port port
Brake oil tank (front) Working oil tank (rear)
Hydraulic oil, replacement

The hydraulic system has two tanks, both of which are separate internally and use different sizes of hydraulic
fluid.
When replacing the fluid, different types of hydraulic fluid should not be mixed.
Replacement capacity:
Working fluid tank: approx. 250 liters (66 US gallons)
Brake fluid tank: approx. 140 liters (37 US gallons)
132
Attention
Be careful when changing the oil, hot oil can cause burns to unprotected skin.
Maintain maximum cleanliness during all work on the hydraulic system.
Prepare the container needed for the oil change.

2 Use the drain hose to complete the drain of the fluid from the tank.
3 When draining, you must drain the brake fluid tank and the working fluid tank separately. The brake tank
drain volume is approximately 140 liters (37 US gallons). The working tank drain volume is approximately 250
liters (66 US gallons).
4 Remove the drain hose and install the protective cap on the drain fitting.
5 Replace the return filters in the brake and working oil tanks respectively.
6 Replace the suction filters in the brake and working tanks respectively.
Attention
Always add oil through the return filter so that the oil can be filtered.
7 Refill through the top end cap of the oil return filter of the working oil tank so that the oil is filtered through
the oil return filter. Refill to 1/3 of the oil level on the sight glass.
8 Reinstall the top cover of the return filter of the working oil tank.
9 Refill through the top end cap of the return filter of the brake oil tank so that the oil is filtered through the
return filter. Fill to 1/3 of the oil level on the sight glass.
10 Reinstall the top cover of the oil return filter of the working oil tank.
11 Install the oil tank top shield.
12 Start the engine and check the oil level.
Filter top
cover
Oil filling
position
Oil return filter top cover and oil filling
133
Oil tank top diagram

1. Working tank return filter guard
2. Brake tank return filter guard
3. Brake tank breather
4. Working tank breather
5. Working oil tank suction filter guard
Attention
The hydraulic oil tank has pressure inside, when the hydraulic system needs to be serviced, the pressure
should be released first.
Biological oil
To replace mineral hydraulic oil with biodegradable hydraulic oil, please contact XCMG authorized service
workshop.
Hydraulic System, Breather Replacement
Replace the breather in the oil tank every 1000 hours. The brake and working fluid tanks are arranged side by
side at the top of the tank near the cab.
1. Remove the breather by directly rotating and unscrewing it.
2. Rotate and tighten the new breather directly.
Hydraulic system, oil suction filter replacement
The suction filter is replaced at the first 1000 hours. Every 2000 hours thereafter.
Working oil tank, suction filter replacement
Attention
Maintain maximum cleanliness in all work concerning the hydraulic system.
134
Dispose of filters, oil and fluids in an environmentally friendly manner.
1 Open the suction filter guard at the top of the working tank.
2 Thoroughly clean the top cover around the hydraulic oil return filter.
3 Remove the top cover.
3 Disassemble the filter as shown in the illustration and remove the filter element.
4 Clean the connecting rod of the filter thoroughly.
5 Check if the O-ring is broken and reset.
6 Install the new filter element and tighten the filter element with the lock nut.
7 Insert the filter element into the round seat at the bottom of the oil tank in the center.
8 Install the oil suction filter cover.
9 Fasten the round shield at the top of the tank.
Schematic diagram of suction filter of working oil tank

1. Suction filter cover plate
2. Seal ring
3. Suction filter lever
4. Lock nut
5. Oil suction filter element
Brake oil tank, oil suction filter replacement

The brake oil tank has two oil suction filters, one of slightly smaller size and one of slightly larger size.
Attention
Dispose of the filters, oil and fluid in an environmentally friendly manner.
Prepare the containers needed to hold the brake fluid oil. The brake fluid tank discharge volume is
approximately 140 liters (37 US gallons).
2 Use the drain hose to complete the drain of the fluid from the tank. Store the fluid properly.
135
3 Raise the cockpit.

4 Remove the line on the brake suction filter and remove both suction filters.
5 Check the O-ring for breakage and reset it.
6 Install a new oil suction filter.
7 Restore the suction line.
8 Drop the cockpit.
9 Add brake fluid through the return filter of the top brake tank.
Brake fluid tank suction filter diagram

1 Suction filter (small)
2 Oil suction filter (large)
Hydraulic system, oil return filter replacement

Replace the oil return filter and clean the rod when it reaches 1000 hours for the first time or when the
instrument panel indicates that the oil return filter is clogged and needs to be replaced, and every 2000 hours
thereafter.
Attention
Maintain maximum cleanliness in all work related to the hydraulic system.
Working tank, return oil filter replacement

1 Rotate open the round guard at the top of the working tank.
2 Thoroughly clean the top cover around the hydraulic oil return filter.
5 Thoroughly clean the bypass valve of the filter, the top cover and the inner wall of the housing.
7 Install the new filter element and top cover.
8Rotate and tighten the round shield at the top of the tank.
136
Diagram of the top of oil tank

1. Working oil tank return filter guard
Schematic diagram of oil return filter structure

1. top cover 2. bypass valve 3. filter element
4. o-ring 5. o-ring 6. stud
7. Housing
Brake oil tank, oil return filter replacement

1 Rotate open the round shield on the top of the brake oil tank.
2 Thoroughly clean the top cover around the brake return filter.
4 Thoroughly clean the bypass valve of the filter, the top cover and the inner wall of the housing.
6 Install the new filter element and top cover.
7 Rotate and tighten the round guard on the top of the tank.
137
Diagram of the top of oil tank

1. Working oil tank return filter guard
Schematic diagram of oil return filter structure

1. top cover 2. bypass valve 3. filter element
4. o-ring 5. o-ring 6. stud
7. Housing
138
Accumulator, pressure relief
Attention
Before starting any work, relieve the pressure of the hydraulic system and turn off the current, disconnect
the accumulator switch.
Discarded accumulators contain gas under high pressure and may explode.
Always park the machine in a maintenance position.
Hydraulic system
1 With the engine running, move the dump lever to the lower/floating position.
3 Turn the steering wheel to the left and right.
Braking System
2 Depress the brake pedal 30-40 times.
Attention
Before working on the system, connect a pressure gauge to verify that the system is pressure-free.
Brake System, Line Filter Replacement

Change the line filter at the first 1000 hours or when the instrument panel indicates that the line filter is clogged
and needs to be changed, and every 2000 hours thereafter. The line filter is located behind the engine sub-tank.
Attention
Maintain maximum cleanliness during all work on the hydraulic system.
1 Pressure relieve the brake system first.

2 Use a socket and ratchet handle or other suitable tool to remove the cylinder under the filter.
3 Remove the filter cartridge and install a new one.
4 Tighten the cylinder.
139
Cooling oil pot, oil return cartridge replacement

The oil return element in the cooling oil pot, located under the engine sub-tank, is replaced every 1000 hours.
Attention
1 Manually unscrew the hand tightening nut and remove the top cover.
2 Remove the circlip and remove the spring using the circlip tool.
3 Remove the filter element and install a new oil return filter element.
4 Put back the spring and install the snap spring.
5 Install the top cover and tighten the hand tightening nut.
1. Brake line filter

2. Cooling oil pot
Brake line filter, remove the cylinder
1 Hand tighten the nut 2 Top cover 3 Snap spring

4 Spring 5 Oil return element
140
Body
Check the contact with the rubber pad between the frame and body once every 1000hrs.
Check the rubber pad between the frame and body

1 Confirm that the body is empty.
2 Start the engine, so that the automatic floating position activates.
3 Measure between the front rubber pad and frame. The correct measuring value is 10±2mm. All rubber
pads should have the same clearance.
4 The rear rubber pad should be equally compressed at both sides.
1.Body 2.Frame 3. Fixed fastener

4.Adjusting gasket 5.Shock pad
It is very important to keep clean around and at the lower area of the rubber pad. Accumulative dirt here
will greatly increase the risk machine damage, especially the possible damage on the frame.
For the adjustment for the contact surface of rubber pad, please contact the XCMG authorized maintenance
shop.
Adjust the frame of corresponding body

Between the frame and spacing board of body, the maximum lateral clearance allowed by one side is 1mm.
Adjustment of block
For the lateral adjustment for the body, please contact the XCMG authorized maintenance shop.
141
Warning
Risk of crushing
The unlocked lifted body will possibly drop. Do not stand under the slipping dumping body, because
this will result in serious casualties. Before entering under the dumping body, be sure that it is safely
locked.
142
Centralized Lubrication System

The XDA45U articulated dump truck is equipped with a manual centralized lubrication system as standard,
where the vehicle is lubricated every 50 hours of operation.
There are three centralized refilling points.
Articulated body front refill point

This refilling point includes
Lubrication of the front and rear hinge points of the left and right steering cylinders.
Lubrication of the front support bearing of the drive shaft in the articulated body.
Lubrication of the upper and lower fork heads of the articulated body.
Rear frame front filling point

This filling point includes
Lubrication of the swing ring of the articulated body.
Lubrication of the lower hinge point of the cargo box lift cylinder.
Lubrication of the rear support bearing of the drive shaft in the articulated body.
143
Rear end of the rear frame filling point

This filling point includes.
Lubrication of the left and right hinge points of the cargo box lift
Lubrication of the upper hinge point of the left and right lift cylinders.
Lubricate the left and right hinge points of the cargo box baffle.
Attention
Each time the centralized filling each filling point should be observed to correspond to the
lubrication point grease overflow is appropriate
Lubrication point distribution
Articulated body front fill Rear frame front fill point Rear of rear frame filling
point point.
XDA45U manual centralized lubrication point distribution diagram
144
The front hinge

Left hinge point of
1 point of right 10
cargo box
steering cylinder
Articulated body
Left hinge point of
2 upper fork head 11
cargo box baffle
hinge point
Articulated body Upper hinge point
3 lower fork hinge 12 of left lift
point cylinder
Rear hinge point of After the swing
4 right steering 13 ring of the
cylinder articulated body
Lower hinge point Before the swing
5 of right lift 14 ring of the
Rear support point Lower hinge point
6 of articulated 15 of left lift
body drive shaft cylinder
Upper hinge point Rear front support
7 of right lift 16 point of hinge
cylinder body drive shaft
Right hinge point Left steering
8 of cargo box 17 cylinder rear
stopper hinge point
Left steering
Right hinge point
9 18 cylinder front
of cargo box
hinge point
145
Concentrated lubricating system (optinal) the lubricating system have no leakages, the
exhaust is free.
Regular inspection should be made on the grease
lubricating system. This job should be done in
coordination with other regular maintenances and
inspections.
Regular inspection should be made on the
following items:
1 Check the lubricating grease height and
lubricating grease in the oil tank.
Attention
Before no warning of low lubricating grease
level is displayed on the viewing screen in cab,
do not fill the lubricating grease tank. But after
Centralized lubrication pump (installed on the left
rear walking platform) the warning of low lubricating grease level is
displayed thereon, you have to fill up as soon as
possible, to prevent the air ingress into the
XDA45U articulated dump truck can be equipped system.
with automatic centralized lubrication system 2 Check the function of viewing screen in cab.
according to customer requirements, , where many 3 According to the working condition of
machine, check the selected lubrication
lubricating points will be automatically lubricated
interval. To change the cycle of lubrication,
according to the pre-selected lubrication cycle.
please refer to the “Change of lubrication
Refer to the diagram of lubricating point interval”.
distribution. In line with the working condition 4 Check if the pump unit has any damage and
and load of machine, the interval between leakage.
5 Check if the lubricating grease pipeline has
lubrication cycles can be adjusted by itself, see the
damage and leakage.
introduction of IS electric grease lubrication pump
6 Check if the refueling point has sufficient
after the specific adjustment method. lubricating grease (the lubricating grease
squeezes out from the refueling point).
Use the maintenance tool for the concentrated 7 Check the system function by running the
lubricating system, and preset the interval of single cycle of test lubrication. Refer to the
lubrication cycle. System Testing.
For the adjustment of lubrication cycle interval, 8 Clean the pump unit and its surrounding area.
please contact the XCMG after-sale service. 9 Clean or replace the filter behind the
When the parking brake is manually meshed, the lubricating grease nipple above the pump unit,
central lubrication will be automatically turned off; below the oil tank every other 4000 hrs.
When the parking brake is deactivated, the central For the failure overhaul, adjustment or repair of
lubrication will be enabled again. pump unit, please contact the XCMG authorized
maintenance shop.
Attention
Be sure that all pipelines and parts connecting
146
Distribution of lubrication points
Distribution diagram of XDA45U Automatic centralization lubrication points
Front hinge point of right steering

1 10 Left hinge point of cargo box
cylinder
Articulated body upper fork head Left hinge point of cargo box
2 11
hinge point baffle
Articulated body lower fork hinge Upper hinge point of left lift
3 12
point cylinder
Rear hinge point of right steering After the swing ring of the
4 13
Lower hinge point of right lift Before the swing ring of the
5 14
Rear support point of articulated Lower hinge point of left lift
6 15
body drive shaft cylinder
Upper hinge point of right lift Rear front support point of hinge
7 16
cylinder body drive shaft
Right hinge point of cargo box Left steering cylinder rear hinge
8 17
stopper point
Left steering cylinder front hinge
9 Right hinge point of cargo box 18
point
147
IS electric grease lubrication pump viscosity must be used.
Oil tank
Oil tank cover
Grease filler. Plunger pay Safety valve

Power plug 1+ 2-
Oil outlet 24VDC power input wiring diagram
Motor upper
cover
Controller Attention
4 Always keep oil in the tank. Oil cannot be
refueled to the full tank. During the oil
Motor lower
cover refueling, the speed should slow down and
even.
Attention 5 Do not excessively tilt the pump block or
headstand.
1 The lubrication pump with the controller
6 Please make regular inspection and
possesses the manual forced lubrication
verification on the safety valve.
button, which is applicable to the installation
and commissioning and manual lubrication,
and not controlled by the controller. By long Safety valve opening pressure of 16MPa or 25Mpa
press on the manual forced lubrication button, (has been adjusted at the factory, users are not
allowed to adjust).
it provides the lubrication; when released, the
button will reset and disconnect.
2 The PLC wiring should be made according to 7 The maintenance and cleaning of the plunger
wiring diagram and attention paid to the pair ass. (plunger pump ass.code:66309-6).
positive and negative polarity. After powered When no oil comes from the pump or the pressure
on, the green indicator light goes on when the is zero, remove the outlet assembly, use a solid
polarity is correct, otherwise it doesn’t, but wrench to unscrew the Part 7, use a tweezers to get
the pump motor runs. Now, you should cut out in turn the Parts 6 and 5; then remove in turn
off the power at once, adjust the PS polarity the Parts 1 and 2;Use kerosene to clean the Parts 3
correctly. and plunger 5. After the recleaning, refit them
3 The lubricating grease, which must be clean, orderly. If the fault cannot be troubleshot, please
pollution-free and within the specified r e p l a c e i t w i t h n e w p l u n g e r p u mp a s s .
148
Manual forced
run button
Power input port Signal input port
1. Spacing pad 2. Pump spring 3. Plunger 4. Pump block

5.Check of valve plunger 6.Spring 7. Compression straight pipe joint 8.Copper gasket
149
Filling of lubricant Grease filler
Handle
Lubricating grease filler The operation shall be done as below:
Regularly check the grease level of the lubrication 1 Clean carefully the greasing pipe joint and the
pump located in the do away table, when the grease connector on the greasing hose.
in the tank is lower than the MIN scale or the pump 2 Before refueling, fill up the hose with the
control panel low level alarm indicator (yellow), then plenty of lubricating grease. This can prevent
fill the grease storage tank with grease. the air ingress into the system.
3 Take off the protective cap on the refueling
Attention
pipe joint and connect the connector to the
In the event that the grease level is below the greasing pipe joint.
minimum scale, fill it up as soon as possible to 4 Fill the tank with the lubricating grease up to
prevent the air ingress into the system. the maximum height. When the lubricating
There is a grease filler port on the pump unit. grease is difficult for pumping, it is possible
When adding the oil, you can connect the hand that the filter behind the filling pipe joint is
pump or industrial pump to this adapter. clogging, or filling pipe joint itself is dirty.
Clean the filter as required, replace the
adapter and try again.
Attention
When using an industrial pump, it is very
important to regularly (at least once every 4000 Attention
hrs) clean the filter between the adapter and the When the lubricating grease is in cold state, it is
pump. The clogged filter crackles easily. There also possible to pump it into the pump unit. It is
is high risk of dirt and particles ingress into the recommended to store the lubricating grease in
lubricating system, which can result in machine a warm room for convenience of filling.
fault. 5 Refit the protective cover.
6 Store the lubrication pump in a dust-free
position and do not let it exposed to dust.
150
3. Operation instructions.
Lubrication Interval Change 3.1 Power on
After power on, the controller continues to work and
If the pre-selected lubrication interval is not display the data before power off, if you need to reset,
suitable for machine operation or load conditions, the please follow the next step.
lubrication interval time and lubrication operating 3.2 Parameter setting.
time can be adjusted independently by adjusting the (1) Press the "S" key and "R" key simultaneously to
lubrication pump programmer panel. enter the setting mode, the next cursor flashes in this
To change the lubrication interval, proceed as mode.
follows. (2) Follow the function prompts in the left 1 of each
setting item in the flowchart, and modify the
Power indicator
parameters by key and key.
(3) After a setting is completed, press the "S" key to
Operation indicator enter the next setting. (The same method of
Alarm indicator parameter modification)
3.3 Run and Stop
When all data settings are completed, press the "R"
key to store the set parameters and start the operation.
Control panel When the controller is in any working state, press
"R" key to restart the operation according to the
1. Panel display description. stored parameters, for example, when the system
Display window has four digital tubes, used to pipeline is pre-filled with oil, when you need to stop
display the system working status and programming. the pump motor that has been started, you can press
The remaining three LEDs are power indication "S" key and "R" key at the same time. "R" key.
(green), pump operation indication (red), and low 3.4 Program browse.
level alarm indication (yellow). When the controller is in any state, press the "S" key
to browse the stored parameters, without affecting
Key Description
the state at that time. Stop the key for a moment to
return automatically.
For switching programming steps and 3.5 Alarm.
viewing programs When the controller is in any kind of alarm state, the
For storing and starting the operation of internal fault relay operates and the output stops.
the programmed data Control mode description.
The user prefers the corresponding control mode
For moving the blinking position of the according to the configuration of the lubrication
digital tube (cursor) in the setting state
system, only very familiar with the working process
For changing the effect of the blinking of the lubrication system or under the guidance of
position of the shading tube in the setting professionals, can choose another control mode.
state.
3.6 Time mode (d=1):
This mode is used only for SLR system and PRG
2. Operation flow chart system
Setting mode Browse mode
"S" + "R" "S"
Lubrication system according to the controller pre-set
oil supply time (0-999 seconds) and intermittent time
Control mode (0-9999 minutes) for the cycle cycle.
1~4 kinds
3.7 Pressure mode (d=2):
Operation time Alarm time Cycle count Pulse
This mode is mainly used for PDI system
1~999 seconds 1~999
seconds
1~999 times period1~99 The lubrication system oil supply process is
Pulse on controlled by a pressure switch installed on the
time1~99 seconds
lubrication pump or system. Lubrication pump from
Interval time Pulse off the start of operation to the system pressure up to the
1~9999 (minutes) time1~99seconds rated value and make the pressure switch action of
Return the process time must be controlled in the controller
set alarm time to complete, so that when the pressure
Operation switch closed, the controller at that time data flashing
4, that is, a delay of 4 seconds (the default value of 4
Operation flow chart (Note: X:0-9) seconds, to ensure that the end of the pipeline to
establish pressure) after the pump running stop that
complete oil supply, into the interval time. Otherwise,
when oil supply failure occurs in the system (leakage,
blockage, pump damage, etc.) to extend the time to
151
establish pressure and reach the alarm time set by the controller output stop, into the gap time timing.
controller, both the oil supply failure alarm signal Lubrication system failure (blockage, leakage, pump
will be issued and the digital display will be "EEPP" damage, etc.), so that the cycle switch any time the
(the parameters should be modified in this state by action time extended to the controller internal set
pressing the "R ("R" key should be pressed to lift the alarm time (5 minutes, non-adjustable), the controller
alarm and then enter the setting state). The alarm both oil supply failure alarm signal, the digital tube
time should be set according to the actual situation of display in the current value flashes.
the system (length of pipeline, size of oil supply, etc.), 3.9 Pulse mode (d=4):
generally greater than 4-8 seconds of the normal This mode is mainly used for PUILES system
operation time of the pressure switch, the operation This mode is to control the lubrication pump to
time of the PDI system for wind power is set to a pulsation (non-continuous) mode of work. Such as:
maximum of 999 seconds, and the gap time is set by pneumatic plunger class and electromagnetic plunger
the manufacturer. lubrication pump, through the control of the air
3.8 Counting mode (d=3) source solenoid valve or drive solenoid power on, off
This mode is used as long as the PRG system that pulse on, off time to achieve the reciprocating
The lubrication system oil supply process is motion of the pump plunger and complete the oil
controlled by the oil supply cycle switch installed on supply process.
the oil distributor. Lubrication pump according to the
controller set the number of cycles to start running, if
the system works properly, the oil distributor on the Attention
oil outlet in turn for oil, when the completion of an
oil supply cycle on the cycle switch sends a signal, IS pump for the time mode (d = 1) or counting
the controller counts once, when the number of oil mode (d = 3)
supply cycle to reach the controller's set value, the
152
ARTICULATED DUMP TRUCK XDA45U Specifications
Ventilation
Before filling with new lubricating grease, when the oil level of lubricating grease tank reaches below the
minimum level, the system cannot work as expected, it means that there is the air cavity in the pump unit
or one of the main pipelines. Now, the system must be discharge.
1 Be sure that the lubricating grease tank has been refueled to the maximum oil level.
Warning
Risk of personnel injury!
2 On the metering block the farthest away from the distance pump unit, remove the plug at the end of
the main pipeline.
Attention
Pressure can persist in the pipeline. Danger, be careful! When the released end is clogging, be sure
that no persons stay in front of the clogging end, to prevent the personnel injury.
3 Turn on the power and press the active forced lubrication button.
4 After the airless lubricating grease flows out from the main pipeline, the discharge is ended.
5 Release the active forced lubrication button and install the end plug.
7 Run the single lubrication cycle continuously for two times to check the system function.
Cleaning
Water under normal pressure cannot pass through the system. The flushing under not too high pressure is
dangerous, so the pump unit should be safe kept. Water ingresses into the system won’t disappear
automatically, and it will cause the running problem. After the high pressure cleaning, the continuous
testing lubrication cycle should be made.
Central lubrication, filter, clean/replacement

Clean or replace the filter every other 4000 hrs.
1 Remove the refueling pipe joint (lubricating grease nipple).
2 Remove the filling filter.
Prompt
There is a nut on the filter, it is unnecessary to undo it when the filter is removed.
Prompt
When there is a hole in the filter, the whole pump must be thoroughly cleaned.
3 The filter shall be thoroughly cleaned by use of diesel oil. Confirm that the filter has no damages.
4 Use the compressed air to dry up the filter.
153
Warning
Compressed air: Do absolutely not directly point to the exposed skin. Please use protective
equipment.
Recommended use of lubricant

Lubricating grease
Recommended lubricating grease
The following requirements are applicable to the lubricating grease used in the concentrated lubricating
system:
● In winter, it is recommended to use special antifreeze lubricating grease(Our
company:L-TARMELA9400-1-17)
● In summer, it is recommended to use the extreme pressure lithium-based grease 0#-2#;
● The lubricating grease may not contain the graphite or PTFE(Teflon);
● The applied lubrication oil is allowed to contain, as maximum, 5 % molybdenum disulfide (MoS2).
154
Specifications
Oil quality and filter element

Quality of filled oil
Filling part Type Specification Capacity Change interval/h
Engine Engine oil API CH-4 SAE 15W/40 (-15℃～40℃) 40L 300
Allison transmission special oil TES 295 (＞

Transmission Lubricant 50L 2000
-40℃)
Water
Antifreeze FD-2A-45℃(can be replaced with Caltex -45℃) 100L 6000
Dispersion
Diesel exhaust Diesel

Exhaust Must meet the requirements of GB 29518/DIN
fluid (DEF) 40L -
70070/ISO22241
reservoir Fluid
(DEF)
Diesel fuel tank Diesel fuel 0#(>4℃); -10#(>-5℃); -35#(>-29℃) 530L -
Hydraulic oil Hydraulic

BP AUTRAN 4 10 hydraulic oil 250L 4000
tank oil
Hydraulic oil
Brake Oil Mobile Delvac Synthetic ATF (＞-40℃) 140L 4000
tank
Drive Axle Gear Oil SAE 80W/90 GL-5 165L 1000
Mechanical
Extreme pressure lithium grease No.2 (summer),
lubrication Grease 30kg -
No.1 (winter)
parts
Air
Refrigerant R134α 950g -
conditioning
system
Suspension Hydraulic
Mobile Delvac Synthetic ATF （＞-40℃） 2×4.3L 4000
System oil
Filter element and replacement cycle
Filter element Replacement interval/h

Air filter safety cartridge Replacement interval 500 hours. Alarm that the
main filter element is cleaned, every 6 times the
Air filter main cartridge
main filter element is cleaned or every 500 hours
155
(whichever comes first), both filter elements are

replaced at the same time.
Oil and water separator cartridge 300
Machine filter 300
Diesel filter 300
Diesel particulate filter 4500
Engine
Transmission
Oil Filter 1000
Breather 2000
Cab
FEFF008 Cab supercharger filter element 6000
Air Conditioning
Air conditioning filter 1000
Hydraulic system
Filter element Replacement cycle/h
Breather (working tank) 1000
Breather (brake oil tank) 1000
First warranty 1000 hours, then change every
Return oil filter (working oil tank) 2000 hours.
When the alarm prompts, replace directly
First warranty 1000 hours, then change every
Return oil filter (brake oil tank) 2000 hours.
When alarm prompt, replace directly
Oil suction filter (working oil tank) First warranty 1000 hours, then change every
2000 hours
Oil suction filter (brake oil tank) First warranty 1000 hours, then change every
2000 hours
Cooling oil pot filter element 1000
(1) When the filter is prematurely clogged alarm, then it must be replaced.
(2) The suction filter element must be checked at the same time as each hydraulic oil change.
156
Engine
Engine
Manufacturer Mercedes-Benz, Germany (Benz)
Model OM471LA.E5/1
Type In-line 6-cylinder, supercharged intercooled, EGR and
EGR cooler, multi-point electronic injection,
DOC+DPF+SCR exhaust aftertreatment technology
diesel engine
Displacement 12.8L
Cylinder bore stroke 132mm×156mm
External dimensions L × W × H (mm)/ 1336×1043×1215

Full load minimum fuel consumption 192g/kWh
Weight 1071kg
Power 390kW /1600 rpm
Torque 2600 N.m / 1300~1600rpm
Maximum speed 2140rpm
Power Definition EWG-R120
Emission standards Off-Road EU Stage 5
Technical specifications In accordance with engine type code: D471.945

Standard low idling speed 500rpm, minimum idling
Idling speed
speed 450rpm
Air filter
Type Donaldson's new PowerCore® air filter with
primary filter and safety filter secondary filter,
electronic alarm
Cooling fan
Type Hydrodynamic coupled ring fan
Quantity 1
Thermostat
Start open temperature 81℃
Fully open temperature 89℃
Relative pressure of expansion tank pressure 1.4~1.6 bar
cap
157
Power transmission
Gearbox
Manufacturer Allison
Type Automatic planetary gearbox, 7 forward gears, 1 reverse
gear
Name 4800ORS
Drive Axle
Name Front Axle Middle Axle Rear Axle
Manufacturer Kesseler Kesseler Kesseler
158
XDA45U Articulated Dump Truck Performance Parameters

Category Item Unit Parameter
Overall length mm 11070
Overall width of the machine mm 3950
Overall height of the machine mm 3846

Dimensional
Front center wheelbase mm 4450
parameters
Middle and rear wheelbase mm 1940
Wheel center Front wheel mm 2600

distance Rear wheel mm 2600
Total vehicle mass kg 75000

Weight
Rated load capacity kg 41000
parameters
Unladen vehicle weight kg 34000
Front axle kg 17000 (50%)

No load
Mass Rear axle kg 17000 (50%)
distribution Front axle kg 22,500 (30 %)
Full load
Rear axle kg 52,500 (70%)
Engine type /engine Benz OM471
Engine power rating kW /rpm 390/1600

Power
Maximum Engine Torque Nm/rpm 2600/1300
parameters
Drive type / 6×6
Tires / 29.5R25
Maximum driving speed km/h 51
Minimum passage circle radius mm 9275

Driving
Max. climbing degree % 45
parameters
Max. steering angle ° ±42
Min. ground clearance mm 530
Loading height mm 3272

Operating
Lifting time s 12
parameters
Lifting angle ° 70
Fuel tank L 500
Hydraulic oil tank L 300
Brake oil tank L 200

Maintenance
Motor oil L 40
capacity
Coolant L 100
Distributor box L 11
Drive Axle L 165
Cargo Flat pack m3 19.5/20.5

compartment
2:1 stacking m3 25/26
volume
159
XDA45U shape diagram

Production unit: Xuzhou Xugong Mining Machinery Co., Ltd
Address: China. Jiangsu. No.169, Heping Avenue, Xuzhou, China
National unified customer service hotline: 400 - 110 - 9999
Service phone: 400 - 110 - 9999 0516 - 83113333
Fax 86 - 0516 - 83113222
Zip code: 221004
Website: http://www.xcmg.com
Version number: June 2021 edition
All rights reserved. Infringement will be investigated.

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ARTICULATED DUMPTRUCK

XUZHOU XUGONG EXCAVATOR MACHINERY CO., LTD

Control console Hydraulic oil tank Fuel tank

Quality frame Battery box Rear side of cab

L/R sides of body

Accumulator Left and right suspension Right box

Rear of frame Left and right side of cargo box Engine

1 Lift Handle Caution Label

2 Lifting handle signs

When the lifting handle is located at this position,

When the lifting handle is located at this position, the

When the lifting handle is located at this position, the

3 Apply parking brake warning sign

4 Logo marking of hydraulic oil

5 Hydraulic oil refill warning mark

6 Explaining identifiers of hydraulic oil refueling

8. Hydraulic system high pressure hazard

9 Cargo compartment crush warning sign

10 Wheel deflection and squeezing warning sign

11 Power switch warning sign

12 Battery cable warning sign

13 FOPS, ROPS warning sign

This identifier is located on the rear of driver seat in cab.

14 Accumulator High Voltage Warning Label

This identifier is located on the wall of energy

15 Accumulator filling hazard label

16 Suspension cylinder hazard signs

17 Falling prevention safety signs

19 Lifting and tieing signs

20 Hooking point sign

21 No-tread safety sign

22 To avoid scalding injury warning sign

Cab and control device

1 Blowing Air 8 Key Switch 15 Longitudinal 22 OBD

Combination keyboard CAN failure

1 High and low beam indicator

3 Longitudinal differential lock indicator

Failure voltage, in which case

When the transmission When the oil level is

This light is When the hydraulic oil

When the oil level is Hydrau

brake. Release the fluid red light will come on.

er or engine torque <50%,

DEF DEF (Diesel Exhaust

AdBlue fluid level Indicator light

DEF indicator flashes at 1Hz.

Torque limiting indicator on for a long

Torque is gradually reduced to 75%.

AdBlue level 5% DEF indicator flashes at 1Hz.

Torque limiting indicator changes from

Torque reduced to 50%.

Maximum speed limited to 60% of rated

DEF indicator 1Hz flashing.

Torque limiting indicator 1Hz flashing.

AdBlue level 2.5% Long red engine light.

Engine speed reduced to idle speed.

Torque reduced to 20%.

DEF indicator 1Hz flashing.

Torque limiting indicator 1Hz flashing.

AdBlue level=0% Engine red light 1Hz flashing.

Engine idle speed.

Torque limiting at 20%.

Failure detection Indicator light

Problem fault DEF indicator 1Hz flashing.