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英文版-XC6-3514 Telescopic Handlers Operator's Manual
英文版-XC6-3514 Telescopic Handlers Operator's Manual
Operator’s Manual
1
Foreword
XC6-3514 telescopic forklift loader is one multi-purpose lifting and handling machine that
integrates the stability and high efficiency and is applicable for handling of various materials.
The telescopic forklift loader is of unique structure, with the working device arranged on the
front. The working device includes telescopic boom and floating forks. During the lifting
operations, the wing-shaped outriggers arranged on the front of the frame provide powerful
support to the machine to significantly improve the working stability. The telescopic forklift
loader is an ideal high-efficiency loading and handling machine for modern industry,
construction industry, and agriculture and is applied in urban construction, power and airport
projects, municipal construction, rural residence, and construction projects engaged by various
construction teams.
This operation and maintenance manual is prepared to help the users better understand and
master this machine and fulfill the operations and maintenances of the machine. This manual
describes the safety precautions and technical specifications of the telescopic forklift loader and
Before the publication of new operation and maintenance manual, this manual shall prevail
for the operations and maintenances of XC6-3514 telescopic forklift loader and other materials
It’s welcome for the users to timely feed back any problem detected during operations for
2
Contents
1. Safety..............................................................................................................................6
1.10. Coolant................................................................................................................23
1.11. Battery.................................................................................................................24
1.17. Tires....................................................................................................................27
3
1.26. Parking of Machine.............................................................................................37
2. Technical Specification...............................................................................................41
3. Operations....................................................................................................................46
3.1. Introduction.........................................................................................................46
4
3.18. Storage of machine............................................................................................121
4. Maintenance...............................................................................................................122
4.1. Introduction......................................................................................................122
4.9 Lubrication.......................................................................................................151
5
1. Safety
1.1 Safety Warning Signs
The safety warning signs are indicated on the machine, on the safety signs, and on
the important safety information at other places. Upon sight of this sign, please
abide by the instructions specified in the safety information and keep alerted
defined as below:
Danger
Danger: It denotes imminent danger. The negligence will lead to serious injury or death.
Warning
Warning: It denotes potential danger. The negligence will lead to serious injury or death.
Caution
Caution: It denotes potential danger. The negligence will lead to minor or medium injury.
“Caution” is used to denote the related safety precautions against the unsafe operations that
probably lead to personal injuries. “Danger” denotes the most serious dangerous issues.
“Danger” and “Warning” safety signs are arranged near the specific dangerous places. The
6
1.2 Identifications of Machine
1 XCMG roduct model 2 Parking shift 3 Read the 4 Fasten seat belt 5 Guard against
identification identification manual rollover
6. Guard against electric 7 Interlock logic 8 Operation 9 Energy curve 10 Energy curve
shock identification identification 1 identification 2
11. Product model 12 Fuel tank 13 Escape 14 Mind Your Hands 15 Customer
identification 1 identification identification identification service hotline
identification
16 Observe Energy Curve 17 Guard against 18 White bar 19 Periodic 20 Power master
identification Door Collision maintenance switch
7
identification identification identification
21 Power master switch 22. Product 23 Body 24 Product nameplate 25 Rivet 4×10
identification 3 model reflective
identification 3 sticker
8
G direction A direction
rotation Radiator
B direction F direction
rotation rotation
Telescopic boom
9
41 Distance 42 Distance 43 CHASSIS NO.
identification 1 identification 2
1、11、18、22、28、29、34.Product XC6-3514,XCMG
model identification
7. Interlock logic
10
8. Operation identification
11
15. Customer service hotline
identification
12
24、25. Product nameplate
13
31. Lifting point identification
14
37. Boom cylinder lock identification
Front wheel:
38 and 39 Tire pressure identification
Rear wheel:
15
through visual inspection.
16
1.3 General Safety Precautions
Please read and get familiar with all safety precautions, otherwise it will lead to occurrence
Only the trained personnel with corresponding qualification are allowed for operation and
If feeling physically uncomfortable or sleepy after taking medicine or after driving, do not
operate this machine. Otherwise, it will lead to your judgment error and possibility for
occurrence of accident.
Before repairing the machine, please hang a label "No operation” or similar information to
Under Repair
No Operation
Do not wear loose clothing or jewelry or have long hair. They will probably be blocked or
entangled into control system or motion parts to cause serious injury or death.
17
During the operations and maintenances of the machine, please wear a cap of hard material,
The use of goggles, safety glasses, or face mask can protect your eyes against the injury of
high pressure fluid during the maintenance of battery and against the injury of splashing
chipping during running of engine and use of tools. Please wear a face mask while disassembling
a spring or elastic part or adding electrolyte to the battery. Wear a safety helmet or goggles
18
While working under high noise, wear appropriate acoustic protection device, such as ear
cap or ear plugs, in order to prevent the acoustic harm by high noise.
Ensure that all protective plates and cover plates on the machine are fixed on the machine.
Ensure that the machine, especially the instrument panel, passage, and ladder, is free of
fragments, oil sludge, tool, and irrelevant things. Properly place the loose articles, such as lunch
While checking an open oil tank or water tank, guard against the ingress of foreign material
into the system parts. Before uncovering a cap, empty your cloth pockets and take special cares
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Understand the gesture signal and the signal source of the working site and take signal only
While disposing hazardous substances, such as lubricating oil, fuel, coolant, solvent, filter,
battery, or other substances, please abide by relevant local laws and regulations.
Take cautions while using detergent and do not use any inflammable (such as diesel and
It’s prohibited to modify the machine without the permission of XCMG, otherwise XCMG
20
1.4 Compressed Air
The compressed air will probably cause personal injuries. While cleaning with compressed
air, wear face mask, protective clothing, and safety shoes. The maximum pressure of compressed
replacing any pipe of hydraulic system, check whether the system pressure is relieved. The
hydraulic oil under high pressure will cause serious injury to the skin if coming into contact with
the skin.
Take cautions while disassembling any hydraulic pipe or connector. When the oil is
spraying out, the relieved high pressure oil will probably lead to sweeping of hoses.
While checking for leakage, wear safety goggles and leather gloves and use a plate or paper
The leakage of high pressure fluid, even in size of pinhole, will probably penetrate muscle
and cause personal injury. If shot by spraying high pressure oil, seek for medical treatment
immediately.
21
1.6 Safe Disposal of Waste Fluids
The improper disposal of waste fluid will endanger the environment and ecology. Abide by
Make sure to properly load with containers the fluids splashed during the checking,
Before opening any fluid chamber or breaking up any fluid contained part, prepare
Use appropriate container while draining any fluid. Do not use a food or beverage
The accumulator must be checked before being charged with nitrogen. It’s absolutely
prohibited to charge the nitrogen if the accumulator has no nameplate, the characters on the
nameplate are fallen or become illegible for its type, the stamped marks are incomplete or
become illegible, or the housing has defect and can’t guarantee operation safety.
The accumulator can only be charged with nitrogen and it’s absolutely prohibited to charge
The nitrogen shall be charged at low speed, in order to prevent bursting the rubber capsule.
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The air valve of the accumulator shall be installed facing upward and must be securely
Never drill any bore on the accumulator and keep the accumulator away from any open fire
or heat source.
The accumulator is one high pressure vessel and shall be replaced and repaired only by
professionals.
Correctly support the machine before operating beneath the working device. Do not support
the working device only by hydraulic cylinder. The movement of control mechanism or leakage
If it’s necessary to remove any shield during repair, make sure to reinstall properly the
The rotating engine blades have a danger of cutting off the fingers. Keep a safe distance or
23
Ensure that there is no foreign material in the engine fan blades. The fan blades will throw
out or cut the tools and foreign things fallen or pushed therein.
Unless otherwise specified, do not conduct any adjustment during running of the machine
or the engine.
If it’s necessary to perform repair procedure during running of engine, do not leave the
machine unattended. Arrange one person sitting in the operator seat and always preparing to stop
the engine.
Do not use a kinked or worn wire rope. Wear the gloves during operations and handling.
Ensure that there is no person in the surrounding area while pushing out the bayonet lock
While hammering any object, ensure that the splashing chippings will not cause personal
injury.
1.10. Coolant
Under working temperature, the engine coolant is at high temperature and is pressurized
and the radiator and all pipelines to the radiator contain hot water or steam so that it will cause
While checking the coolant level, stop the engine and cool down the water filler cap, till the
Slowly loosen the filler cap of cooling system to relieve the pressure.
The coolant contains alkali that will probably cause personal injuries. Keep it away from
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Oil
The hot oil and hot parts will probably cause personal injuries. Keep the hot oil and hot
Before opening the filler cap of hydraulic oil tank, stop the engine and cool down the filler
Slowly remove the oil tank cap to relieve the pressure of hydraulic oil tank and prevent the
Before disassembling any pipe, connector, or relevant part, relieve the system pressure.
1.11. Battery
The smoke emitted by the battery will probably lead to explosion.
The electrolyte is one acidic substance. Keep the electrolyte away from contact of skin or
eye.
While checking the battery, wear the protective goggles and protective gloves.
It will probably lead to fire if the fuel leaks onto a hot surface or an electric unit.
Do not smoke during refueling or in the refueling area or a place with storage of
inflammable.
Clean and tighten all electrode connectors. Check for loose and worn wires each day.
Before startup of machine, tighten loose power supply and repair or replace worn wires.
25
Store fuel and lubricating oil in the containers of corresponding markings, in order to
Place the oil contaminated rags and other inflammables in shielded containers and preserve
in a safe place.
Do not conduct electric welding or flame cutting for any pipe containing flammable fluid.
Before the electric welding or cutting, thoroughly clean all flammable fluids.
Thoroughly clean the flammable materials (such as fuel, lubricating oil, and other
Keep the battery away from open fire and fire spark and do not smoke in the charging place
of battery.
To jump start the machine, make sure to connect the positive (+) cable to the positive (+)
terminal of battery connected with the coil of starter motor and connect the negative (-) cable of
the external power supply to the negative pole (-) of the starter. If the negative terminal of starter
Timely repair any loose or damaged fuel and lubricating oil pipeline or pipe or hose of
hydraulic system. Any leakage will probably cause fire. Please contact an XCMG’s designated
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2. Wear or separation of hose outer layer or exposure of hose reinforcement wire.
Ensure the correct installation of all pipe clamps, protective plates, and insulation caps, in
While disassembling any connecting pipeline of A/C compressor, keep away any open fire,
A first-aid kit must be prepared in the working site. Check it periodically and when
Prepare the telephone numbers of some persons (such as doctor, emergency center, and fire
station) for emergency contact. Stick there contact numbers at the specified place and ensure that
Frequently check and maintain the fire extinguishers. Abide by the operation methods
In event of thunder and lightning, please stay in the cab (if within the cab) or keep away
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1.17. Tires
The maintenance, disassembly, repair, and installation of tires and wheel rims require
special equipment and expertise. Therefore, it’s better to have them repaired and maintained by a
The inflated tires will explode if the internal gas of the tire is heated or combusted, which is
generally caused by the expansion or combustion of gas due to the heating or electric welding of
The explosion of tire is much more powerful than the air deflation and may fly the tire,
wheel rim, and drive parts to be 500m away from the machine, in which the explosive force and
Never close to a heated tire and maintain a minimum distance (at least 15m).(As shown in
It’s recommended to inflate the tires with dry nitrogen (N2). If the tires are originally
inflated by air, it’s recommended to adjust the tire pressure with nitrogen, as the nitrogen can
mix with the atmospheric air. The nitrogen inflated tires can prevent the possibility of explosion,
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as the nitrogen is non-flammable. Meanwhile, the nitrogen helps prevent the oxidation and
Avoid the excessive inflation. The correct inflation equipment and the training for the
operations of equipment are required, as the incorrect equipment or improper use of equipment
The incorrect maintenances of tires and wheel rims will probably lead to burst of tires. This
burst force can lead to serious personal injuries. The maintenance of tires and wheel rims can be
conducted only by trained personnel with use of correct tools and correct procedures. XCMG
recommends inflating the tires with dry nitrogen and adjusting the pressure of tires. This
includes all machines equipped with rubber tires. The nitrogen is one inert gas that will not help
The use of nitrogen (N2) can not only reduce the explosion danger, but also help prevent
the oxidation and rubber aging and prevent the corrosion of wheel rim parts. This is especially
important for the wheel rims to be used for more than 4 years.
Warning: The necessary training must be taken for the operation personnel of inflation
equipment, otherwise the incorrect tire inflation technique will cause personal injuries.
Do not set the pressure of tire inflation equipment to be higher by 1 .4 kg/cm2 than the
Check and adjust the inflation pressure of tires after the tires are sufficiently cooled down.
Notify all other personnel away from the dangerous area (surrounding area of wheel reducer).
The pressure of nitrogen inflated tires is same with that of air inflated tires. XCMG
recommends choosing inflation pressure of tires depending on the working condition of the
The tire inflation pressure listed in the table is the inflation pressure under normal
temperature.
Front/rear wheel
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front/rear wheel(kPa)
While driving the machine under frozen temperature, the tire pressure originally under
18~21ºC will vary greatly. The tires inflated to normal pressure under normal temperature will
have insufficient inflation pressure under frozen temperature. The insufficient pressure will
If the cab is damaged by falling object or due to rollover, its strength will be impaired so
that its normal function can’t be met. In such case, please contact a XCMG’s designated dealer
Even if the ROPS is installed, the effective protection can be provided only when the
operator fastens the seat belt. Make sure to fasten the seat belt during the operations of the
machine.
It’s prohibited to conduct drilling or electric welding inside or outside the cab, in order to
If the modification of cab is required due to certain cause, please consult with XCMG to
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1.19. Precautions for Accessories
Make sure to install and adjust by relevant qualified personnel. The operation personnel
must be trained and conduct operations and maintenances strictly as per the operation manual of
the accessories.
During the installation and operations of the accessories, please read the manuals and
brochures of relevant accessories and the related information of accessories specified in the
manual.
The incorrect installation of accessories or optional parts will not only cause safety issues,
but also have adverse influence on the operations and the service life of the machine.
Do not use any accessories not approved by XCMG. The use of non-approved accessory
will probably cause safety issues, which will impair the normal operations of the machine and
It’s prohibited to modify any accessory without permission, otherwise all consequences
XCMG will not be liable for any damage, accident, or machine damage arising from the use
of non-approved accessory.
the machine. In addition, all damaged parts shall be repaired and all loose bolts shall be
tightened.
Get on or off the machine only from the locations with ladder or handrail. While getting on
or off the machine, face towards the machine, hold the handrail by hand, and step the ladder to
maintain three-point contact (two feet and one hand or two hands and one foot).
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It’s prohibited to jump off the machine.
It’s prohibited to get on or off the machine during the running of the machine.
It’s absolutely prohibited to take any operating lever as handrail while getting on or off the
machine. While carrying a tool or other thing, do not get on or off the machine. Instead, hoist the
Before entering or leaving the cab, ensure that the machine is completely stopped and
reliably parked. While getting on or off the machine, always keep three-point contact with
handrail and ladder footstep. As shown in the figure, do not use an operating lever or steering
wheel as handrail.
Understand all control systems and the purposes of instruments and indicator lamps.
Understand the rated carrying capacity, speed range, braking and steering characteristics,
Bear in mind that the rain, snow, ice, gravel, and soft road will change the working capacity
of the machine.
Study the safety signs on the machine (Danger, Warning, and Caution) and other signs.
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1.22. Understanding Your Working Area
Whenever possible, understand the area you are ready to work in advance. Please check the
position of slope, open trench, fallen or hung object, soil condition (soft or hard), pond and
swamp, rock and stump, embedded foundation, root pillar, and wall border, buried garbage or
filled border, hole, obstacle, mud and ice, traffic volume, heavy dust, smoke, or mist, and
accurate locations of buried or hung electricity, gas, telephone, water, sewage, and other utility
pipelines. If necessary, please have them marked by the public utility companies and close or
good operating state. Keep all other personnel around the machine away from the working site.
Before getting on this machine, thoroughly remove the sludge and tiny sands from your
shoes.
Check all structural parts and covering parts for presence of collision impact and damage.
Check all safety protection devices (such as doors, shields, and covers) for correct
installation and guard them against damage of motion parts. Any damaged device shall be timely
repaired.
Check the hydraulic system for presence of oil leakage and check the hoses and pipes for
presence of wear.
Check electric harnesses for presence of wear or rubbing damage, check the fuses for
Check the engine and fuel system for normal oil/fuel level and timely drain the water or
Replace all damaged or missing parts and fulfill the necessary lubrication works as per the
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Remove all loose articles from the cab, as the loose articles will probably influence the
Ensure that all windows of the cab are clean and the wiper can function normally.
Adjust seat to appropriate position and check the seat belt and seat belt fastening devices for
presence of damage. Replace the seat belt once it’s in service for 3 years.
Ensure that the lighting system of the machine works normally and the working site is
sufficiently illuminated.
Under Repair
No Operation
Ensure that the operator already sits in the seat and fastens the seat belt securely before
Before starting the engine, ensure that the hydraulic operating lever is at position HOLD
Start the engine only within the cab. It’s prohibited to start the engine by short circuiting the
starter motor, otherwise starting the system by bypass will damage the electric system of the
machine.
After the start of engine, observe the pressure gauge, instruments, and warning lamps to
ensure that they are functioning normally and their readings are within the working range.
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Observe and carefully listen the inside of the machine for presence of malfunction. Upon
detection of malfunction or abnormality, immediately stop the engine and solve the malfunction
The exhaust gas of engine will cause illness or death. If it’s necessary to start the engine in
an enclosed or poorly ventilated place, open the doors and windows to ensure sufficient
ventilation, in order to prevent gas intoxication. If it still can’t provide sufficient ventilation after
the doors and windows are opened, it’s necessary to install fans.
Ensure that all windows, lamp shades, and rearview mirrors are clean and properly fix the
Adjust the position of rearview mirrors to provide a best visual field for the operator sitting
Clear all obstacles from the driving path of the machine. Take cautions against the
Ensure that the horn, reversing alarm, and other alarm devices of the machine function
normally.
Operation of Machine
Before driving on a public road, please check whether the machine conforms to the local
road driving laws and regulations and obtain the road driving license from relevant
35
administration department. While driving on public roads, please abide by the local road traffic
regulations.
Before driving the machine, make sure to verify the surrounding safety and ascertain your
Keep a correct sitting posture on the seat. The operations of machine by sitting in the seat
It’s prohibited to carry other person, unless the additional seat, safety belt, and rollover
Before starting official working, slowly drive the machine to an open field and check all
Upon detection of any machine item (such as noise, vibration, smell, incorrect indication of
instrument, air leakage, and oil leakage) needing repair during the operations, immediately report
The dust, heavy rain, and heavy mist will dim the sight line. Keep the windows, mirrors,
and lamps under clean and good state. In event of reduced visibility, slow down and use
appropriate lighting.
While driving or operating the machine in an area with poor visibility or in a crowded area,
please appoint a signaler. Keep the signaler within the visual range and coordinate the hand
signals.
Avoid all conditions that probably lead to rollover of machine. The machine will probably
roll over while working on a hill, bank, or slope. The machine will probably roll over while
Drive the machine up or down a slope straightly and do not make turn or drive laterally on a
To prevent rollover of machine or damage of working device due to overload, make sure to
36
Take special cautions while working near a high voltage grid. Before the machine starts
working in a working site with a possible danger of touching power cables, consult the electric
power company and check whether the determined operation is feasible as per the relevant
Touching the power cables will cause serious accidents or injury/death. Keep all parts of the
machine away from power cables. Check the above space of the machine and understand the
sufficient clearances between power cables and machine and the ground. If possible, it’s better to
cut off the power supply. If impossible, appoint a signaler for guidance.
1. Warn all other personnel not to touch the machine and keep away from the machine.
2. If it’s possible to separate the touch, change the operation leading to touch with high
voltage power supply and drive the machine away from dangerous area.
3. If it’s impossible to separate the touch, stay in the machine, till the electric power company
cuts off the power cables and notify you that the power supply is cut off.
4. If it’s really necessary to leave the machine in event of extreme case (such as fire) due to
touch of high voltage power supply, do not walk out the machine step by step. Instead, jump off
the machine with your feet together whenever possible and do not touch the ground by hand.
Then, jump with your feet together, till you are a safe distance away from the machine and
power supply.
If it’s necessary to park the machine on a slope, block the wheels by stop blocks to prevent
Do not park the machine on a construction road. If it’s necessary to park in such places,
make sure to use flags in daytime and use signal lamp or flasher lamp in nighttime to alert other
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After the machine is parked, lower the bucket onto the ground.
Shift the hydraulic operating lever to neutral position and shift the gearshift operating lever
to neutral gear.
Keep the engine idling for further 5min to gradually cool down.
Before leaving the machine, lock all devices by key. Withdraw the key and carry it with
you.
Before lowering the working device, ensure that there is no person around the machine.
Preservation of accessories
Preserve the accessories and tools safely, in order to prevent serious injury or death due to
falloff. Keep all playing children and bystanders away from preservation area.
works. Clean the working ground, wipe away the fuel, lubricating oil, and water, and pave sands
or other absorbing material on slip ground. Keep clean and dry the working area.
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During working, the accessories or apparatuses are generally located on low ground. If it’s
necessary to operate on or beneath any hoisted mechanism or accessory, please support the
Disassembly of machine
Abide by the relevant national and local regulations on the weight, length, width, and height of
Use ramps of appropriate size, sufficient strength, low angle, and appropriate height. Ensure
conduct the electric welding in a place with appropriate equipment. During welding, the
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1. Before the welding on the machine, make sure to turn off the power master switch and
disconnect the connectors of instrument system, otherwise it will burn the units on the
instrument panel.
2. Remove paint from the area to be welded, in order to prevent the generation of harmful
gas.
4. It’s prohibited to weld in a place near rubber hoses or electric wires or on a pressurized
pipe.
7. Clear all flammable materials and make sure to prepare fire extinguishers in the
working site.
deposited grease, oil, and fragments, and keep clean the engine compartment, radiator, battery,
40
While flushing the machine by high pressure water, take cautions to keep away from the
shot of high pressure water and keep dirt and sludge away from splashing into eyes.
Do not spray the water directly to the sensors, connectors, and instruments of the electric
system. The ingress of water into electric system will lead to danger of operation failure.
41
2. Technical Specification
2.1. Diagram of Overall Dimensions
42
Center distance of load 600mm
Model CA395142S
Drive
system
Shift number 2
Gearbox
Speed ratios for forward gears 4.286/1.359
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Maximu
m 28°30′32″ on outer side and 40° on
Front steering drive steering inner side
axle angle
Speed
18.46
ratio
Model CA394934S
Maximu
m 28°30′32″ on outer side and 40° on
Rear steering drive
steering inner side
axle
angle
Speed
18.46
ratio
Tire specification 15.5-25-16PR L-2E
Tires
Tire pressure Front tires 525kPa Rear tires 325kPa
44
Regulated
pressure, 3
MPa
Luffing cylinder, mm Ф90/Ф190
45
2.4. Table of Fuel/Oil/Fluid and Capacity
Caution: The user shall adjust the appropriate fuel/oil/fluid timely depending on the air
temperature.
46
3. Operations
3.1. Introduction
This chapter is intended to learn how to operate the machine efficiently and safely and
guide the operator step by step. Please fully read this part from beginning to end.
Before starting the machine, sit in the driver seat and get familiar with the arrangement of
cab. Understand all operating levers, switches, instruments, buttons, and pedals with reference to
this manual, instead of by own guess. In event of anything unclear, please consult with a XCMG
dealer.
The operator shall always understand the things occurred inside and outside the cab. The
If you are already familiar with the operating levers, switches, and instruments, practice
how to use them. Drive the machine to an open space and keep away from crowd. Attempt to
feel the machine and its operations and controls to the greatest extent.
At last, do not complete the learning of the manual hastily to ensure the complete
understanding of the contents of the operation manual. Only the carefulness and deliberation can
leave the machine. It’s recommended to occasionally stop the machine and fulfill the checking
All checking items are related to the working capacity of the machine and some of them are
related to your safety. Ask your service engineer to check and correct all problems.
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d. Clean all safety labels. If missing or illegible, immediately replace with new one.
2. Checking of damages
Check the rubber for presence of cutoff and puncture by sharp object. Do not operate the
5. Ensure that all instrument panel interfaces are sealed and safe.
Caution: If the filler caps and instrument panel are fitted with a lock, it’s recommended to lock
them, in order to prevent theft or other destructions.
Warning
It’s extremely dangerous to walk or operate beneath the lifted boom. The falloff of boom or
Before these checking items, make sure to fully lower the boom. If you are not familiar
with the machine, ask an experienced operator to help you lower the boom.
If no one can help you, study this manual till you know how to lower the boom. Of course,
before these checking items, ensure that the parking brake is already applied.
The burst of machine tire will probably cause injury or even death to you. Do not use
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3.3 Seat Control
The seat can be adjusted to meet your comfort needs. The correctly adjusted seat can relieve
the operator’s fatigue for comfortable operations and controls. During the driving of the
machine, the seat can be adjusted by leaning the seat backrest with your back to completely
Warning
Cushioned seat
Caution: The seat can be adjusted only when the operator already sits in the seat.
a. Horizontal adjustment
b. Vertical adjustment
c. Sitting height indicator. Refer to vertical adjustment.
d. Backrest angle adjustment
e. File bag
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3.4. Seat Belt
Caution: If the seat belt is locked before the tab is locked into the buckle, completely retract
the seat belt and retry. In event of sudden pulling of seat belt or sudden inclination of
machine, the inertial device will be probably locked. In such case, gently and slowly pull out
from the retractor.
a. Sit correctly in the seat and fasten the seat belt as described.
b. Hold the middle portion of belt shown in the figure and pull forcibly to lock the seat
belt.
Warning
If the seat belt fails to lock during the checking of normal functioning, do not drive the
The failure to fasten the seat belt will probably cause you to be thrown or even thrown
out of the machine or crushed. Make sure to fasten the seat belt during operations of the
machine. Make sure to fasten the seat belt before starting the machine.
If the seat belt is damaged or worn or if the machine just encounters an accident,
timely replace with new seat belt. Replace at least once every 3 years.
Warning
Upon detection that the seat belt can’t be locked during the checking of normal
functioning, do not start the machine. Repair the seat belt immediately or replace.
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Release of seat belt
Warning
Push down the button C and pull out the tab A from the buckle B.
Adjust the seat belt to ensure that the belt crosses over your upper hip instead of your
stomach.
1. Depending on the required distance, pull down the toggle switch along the belt.
a. To increase the length of belt, pull the end E till an appropriate length is reached.
b. To reduce the length of belt, pull the end F till an appropriate length is reached.
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Arrangement of Cab
Caution: The arrangement of cab adopts the figure of one typical model. In event of any
difference, please refer to the related contents in the manual.
Steering wheel
Gearshift lever
Angle gauge
Instrument panel
Load table
52
3.5. Driving Control, Switches, and Instruments
Driving Control
Steering wheel
Rotate the steering wheel towards the desired steering direction. Please be noted that the
machine is of four-wheel drive mode.
Inclination adjustment
After sitting in the seat correctly, adjust the angle of the steering column to the most
comfortable position.
Rotate the lever A counter-clockwise to loosen the steering column. Pull or push the
steering wheel to a position appropriate to you. Rotate the lever A clockwise to clamp the
steering column.
Warning
Check and ensure that the steering column is clamped in place. Do not attempt to
adjust the steering column during driving.
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Accelerator pedal
Depress the pedal to increase the engine speed and release to enable the return of pedal and
reduce the engine speed. Do not depress the pedal while the engine is idling.
Brake pedal
Depress the brake pedal to slow down or stop the machine. While driving down a slope, use
The stop lamp will turn on when the brake pedal is depressed. Do not drive the machine,
Function
Gear selection
When the machine is stopped, ensure that the direction selection lever is at neutral position
The machine can move at any gear, depending on the ground condition.
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Warning
Do to shift the gear when the forklift truck is in driving state, and whether shift from
the high-speed gear to the low speed gear or shift from the low speed gear to the high speed
gear, the forklift truck will produce a greater traction force difference, so that you have a
major injury, and even death, while damage the forklift truck. If need to shift the gear,
please be sure to adjust the driving and reverse gear to the neutral position, and parking
the forklift truck, after that you can shift the high speed gear and low speed gear.
Warning
Operating the direction selection lever during the driving will probably cause serious
injury or even death to you and others. The machine will not change the driving direction
Before operating the direction selection lever, stop the machine and select forward (F),
reverse (R), or neutral (N). Lift and move the direction selection lever to the designated position.
High/low gears can be operational in both forward and backward driving. There will be warning
sound when the reverse (R) is selected. The engine can be started only at neutral gear.
There is a retention position of gearshift lever at forward, reverse, or neutral position. Pull
the gearshift lever towards you to depart it from the retention position.
a. Stop the machine and depress and hold the brake pedal.
b. Drop the engine speed to idling state.
c. Select a new driving direction.
d. Release the brake pedal and depress the accelerator pedal to drive away.
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If the parking brake is applied, when rotating the gearshift lever from the neutral gear, the
Horn
The horn button is located on the middle of the steering wheel. Push down the button to
sound the horn. The horn is operational only when the starter switch is position ON.
turn off the indicator lamp. This function is operational only when the starter switch is at
position I.
turn, turn off the indicator lamp. This function is operational only when the starter switch is at
position I.
3. Instrument indicator
Turn the operating lever once away from your direction, and the indicator light is on. The
function only takes effect when the start switch in the I position.
function only takes effect when the start switch in the I position.
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Starter switch
The starter switch is controlled by the starter key. It has four positions. The key can be
O The engine will be stopped if the key is rotated to this position. Before stopping the
engine, ensure that the gearshift lever is at neutral position, the attachment is already lowered
I When the key is rotated to this position, all electric circuits are connected with the
battery, except the lamp and 4- type hazard warning lamp circuit (the lamps and the hazard
warning lamp circuit is permanently electrified). Upon release from the position II or III, the
starter key will return to this position. At -6ºC, the warning lamp 5 will turn on to indicate
that the multi-branch heater at the cold start entry is already started.
Caution: If the engine fails to start continuously, do not operate the starter motor
continuously for more than 10s. If the engine is ignited, but is not completely started, do not
operate the starter motor continuously for more than 40s. Make sure to leave at least 2min
cooling time for the starter motor between two consecutive starts.
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Cab lamp
Push down one end of the unit a to turn on the cab lamp. Push down the other end to turn
Before leaving the machine for a while, ensure that the cab lamp is already turned off.
Drive by two-wheel drive mode whenever possible during driving. Drive by four-wheel
drive mode only when the traction force is restrained on soft and uneven roads.
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Combination Instrument
1. Voltmeter
It indicates the voltage of system
2. Rear axle center position indicator
When the two rear wheels alignment, the indicator light is on.
3. Front axle center position indicator
When the two front wheels alignment, the indicator light is on.
4. Low oil pressure indicator
When the engine oil pressure is lower than 1bar, the indicator light is on, and at the same time
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8. Indicator of Low Brake Pressure
When the brake pressure is lower than the value set, the indicator would be on.
9. Charging indicator
When the generator is normal, the indicator lamp is off. Under normal circumstances,
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14. The left support leg indicator
When the left support leg landing, the indicator is on.
15. The right support leg indicator
When the right support leg landing, the indicator is on.
16. Alarm Indicator of Low Oil Level
When the oil level in the diesel is lower than the setting value, the indicator would be on,
reminding the driver to refuel.
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3.6. Operating Levers
Warning
The operations of the machine from the outside will probably cause injury or even death to
you and others. Operate the machine only when sitting within the cab correctly.
Boom/driving of machine
Operating the boom during driving will probably cause accidents and lose your complete
control on the machine. Therefore, it’s absolutely prohibited to operate the boom during driving.
Danger
Overhead Power Cables
It will probably cause electric shock if your machine or attachment is too close to the power
cables. Observe the working area for presence of power cables before starting the working. If
yes, contact your local power supplier and inquire which safety measures shall be taken.
Meanwhile, understand the requirements of local laws and regulations on the operations near
power cables.
After you understand the safety measures to be taken in the working site and understand the
Warning
Ensure there is no obstacle above before lifting the boom. Keep a sufficient safe distance
from all power cables. Contact local power company to obtain safe procedures.
Release the boom operating lever immediately after the boom is completely lifted. Holding
the operating lever at the lifted position will lead to slow lag of the attachment.
The functions of operating lever/switch vary on different machines. The labels nearby
indicate the functions of operating lever/switch. Before the operations, check the label to
The operating lever is fitted with spring that can automatically return it to central position.
The action of the corresponding hydraulic cylinder depends on the movement distance of the
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operating lever. The farther the movement is, the faster the action of the hydraulic cylinder is.
The hydraulic cylinder will hold at original position, until the operating lever or switch is
operated.
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Single-Lever Control
Lifting/lowering of boom
A Lift
B Lower
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Extension/retraction of boom
C Extend
D Retract
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Reverse forward/backward of attachment
E Forward
F Backward
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Frame Leveling (swinging)
Warning
When the swing arm is higher than the horizontal position, it is
forbidden to control the frame leveling (swinging).If the machine is not at a
horizontal level, the swing arm is forbidden to be operated.
Warning
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Control
You and others may be hurt and dead in the case of operation outside
the machine.You only can operate the machine when correctly sitting the
cab.
Before the loading and unloading, the leveling can be carried out for the
machine from one side to the other side by the frame leveling (swinging) control
Before the hydraulic cylinder is moved by operating the switch again, the
When the angle of swing arm is 10¡ã greater than the horizontal level, the
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Before the swing arm is operated, the banking indicator A is used to check
the horizontal level of machine. When the banking indicator turns to zero (0¡ã),
Turning left/right
E: turn left
F: turn right
Control of outrigger
Warning
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It is not allowed to pile minces in the holes between the cylinder and the
outrigger.Remove all minces and clean it.
The position from the machine to the side is indicated by the banking
indicator A installed in the cab. Before the swing arm is operated, the banking
indicator is used to check the horizontal level of machine. When the banking
indicator turns to zero (0¡ã), the machine is in the horizontal level condition.
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If the machine can not be adjusted to the horizontal level status at a certain position, it shall
Ensure the outriggers are laid down, and support the machine at the same time. The swing
arm is not stretched if not necessary. Before the machine is operated, it is necessary to
The outrigger of the machine can not be withdrawn if the swing arm can not be withdrawn
completely. If the arm is withdrawn completely, the indicator of arm withdrawing turns on.
D: Lay down
E: Withdraw
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3.7. Load Diagram
The safe working load (SWL) of machine depends on the extended boom length and the
lifted angle.
It's really important to ensure that the machine is fitted with following types before the
Caution
The load diagram shown in the figure is only one example. Do not use it to look up
the load limit of your machine. Before lifting or placing a load, observe the load
diagram within the cab of your machine.
The safe working loads under different extended lengths of the boom are described in the
The load diagram describes how long and how high can the boom be extended, provided
that the safe working load is not exceeded. Each model has a load diagram for standard forks and
an additional load diagram for outrigger or frame leveling (swing) operation. When the boom is
equipped with different attachment or accessory, there will probably have other load diagram for
operations.
The load diagram in this manual is taken for reference only. Before lifting or placing a load,
make sure to observe the load diagram within the cab of your machine.
Check the applicability of relevant load diagram for irregular attachment or accessory. At
appropriate locations, the load diagram describes the part number A for the related attachments
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or accessories. If you are not sure about the correct load diagram to be used, please contact your
Caution
The limits on the load diagram are based on the condition that the machine is
level and stationary. Do not lift or extend the boom during movement of the machine.
Before driving under loaded condition, fully retract the boom and lower the boom as
low as possible.
1. Determine the accessory equipped on the boom of your machine and turn over to select
from gravity center of the load to the vertical surface of forks is no more than
600mm(20in).
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Caution: The center of the load is not always the gravity center of the load Y. It’s really
necessary to find out the gravity center.
3. After making clear the weight of the load, look up the load diagram to find out the
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In this zone, the left boundary B and the top boundary C indicate the stability load limits of
the machine under your load. Do not operate beyond these boundaries while lifting and
Warning
There are two working statuses for the type of machine, namely, outrigger support
and withdrawing. When checking which load diagram is used, it is necessary to identify the
suitable working status. Please select correct load diagram, or it may cause the machine
overturned and personnel injury, even death.
4. After the forks are forked into the load, before the lifting, observe the readings of angle
gauge and boom length indicator. Find out the same readings on the load diagram.
On the diagram, you can see the lines that vary along with the readings of boom angle and
boom length in the colored zone. Find out the intersection point between the lines of your
readings. If the point is within or on the right side of the maximum load zone, the load is within
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If the point is above or on the left side of the zone, do not attempt to lift the load again.
Withdraw the forks, retract the boom, and attempt once again. Even if the boom is fully
retracted, the angle and extending readings of the boom may still be beyond your maximum load
5. When the forks are loaded with a load, retract the boom before lifting or lowering the
boom. This can reduce the instability danger of the boom. While moving the boom,
observe the readings of the angle gauge and the extending indicator of the boom. Keep
6. Before placing the load, use the load diagram to find out how far your machine needs to
be from the load location. The load must be placed without going beyond the left or top
The safe working loads at different positions of boom are described in the load diagram
within the cab. The boom is integrally fitted with boom angle indicator and extending
indicator. The extending length of boom is indicated by number B in unit of meter. The
angle of boom is indicated by indicator A in graduation of degree.
Always look up the load diagram within the cab before lifting or placing a load. Refer to the
load diagram.
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Warning lamp
Important: It’s recommended to use flashing warning lamp when the machine is
traveling on public roads. In some regions, driving the machine without warning lamp is
illegal. Please abide by the local traffic regulations.
Two types of yellow or amber beacon kits, namely magnetic disc type and telescopic type,
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3.8. Before start of engine
Caution: If working in a high temperature or low temperature environment, please read the
operation manual for working under high temperature or low temperature environment.
Caution: If the fuel in the fuel tank or any other system is used up or out of supply, make
sure to add sufficient fuel before restarting the engine.
1. Apply the parking brake when the machine is finally stopped. If not applied, apply the
parking brake now.
Danger
Before lowering the attachment onto the ground, ensure that the machine and all
personnel nearby are not in the dangerous zone. The personnel on or near the machine
will probably be crushed by the attachment or fall off from the machine.
2. The attachment shall be lowered to the lowest point before the engine is stopped. If not
lowered to the lowest point, restart the engine and lower the attachment to the lowest point.
Then stop the engine and perform step 3.
3. For the safety of you and others and the service life of the machine, please fulfill the
thorough checking before start of engine.
a. If the machine is driving outside and the thorough checking is not completed, please refer
to section Before Entering Cab. Of course, the detailed daily checking as specified in the
maintenance schedule shall be completed.
b. Remove dirt and waste from the cab, especially from the pedals and the operating shaft.
Warning
Keep clean and dry the control part of the machine. The slip of your hand or foot
will probably lead to out-of-control of machine.
c. Wipe dry the oil and mud from the steering wheel and operating levers.
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Warning
The unstable things will fall off to probably hit you or roll beneath your feet. You
might be knocked unconscious or be blocked by operating parts to cause out-of-control
of the machine.
e. Throw away all unsafe things from the cab, such as lunch box and tools.
f. Check the damage state of ROPS/FOPS structure. Always contact and consult a XCMG
dealer for repair of any damage. Make sure that all bolts are correctly installed and
reasonably reinforced.
g. When necessary, check the bolts around the cab for looseness and missing and repair
timely.
h. Check the damage and wear extent of the seat belt and its devices.
Warning
If the seat belt is damaged or seriously worn or the machine ever encounters an
accident, timely replace with new seat belt. Replace the seat belt once every three
years.
Lamps, warning lamps, horn, indicator lamps, all switches, turn indicator lamps, hazard
warning lamp, and windscreen washer and wiper (if equipped).
4. Adjust the seat for you to drive the machine comfortably. You may lean against the seat
by your back to fully depress the brake pedal. Please refer to section Seat Control.
5. Adjust the driving devices so that you can operate the steering wheel and operating levers
comfortably.
6. The correct setup of rearview mirrors can provide a good visual field for you within the
cab.
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1. Before starting the machine, carefully read and abide by the operation and maintenance
manual.
2. Before starting the engine, make sure to apply the parking brake of the whole machine.
3. Before starting the machine, make sure to install and use the battery fuse. Refer to the
section Operations of Battery.
Caution: If the engine fails to start, do not run the starter motor for more than 10s. If the
engine is ignited, but is not completely started, do not run the starter motor for more than
40s. Wait for at least 2min interval between two consecutive starts.
5. Once the engine is started, release the engine key. The key will automatically return to
position “IGN”.
Warning
Do not use diethyl ether or other liquid to assist the cold start. The use of such
liquid will probably cause explosion and injuries or damage the engine.
7. Once the engine is started, check whether all warning lamps are turned off. Do not
accelerate the engine till the low oil pressure indicator lamp turns off. The earlier
acceleration of engine will probably damage the turbine unit due to insufficient lubrication.
Check whether the audible alarm sounds.
Caution: This is a normal symptom that the engine noise is relatively high under cold
environment. It can achieve normal noise by adjusting the fuel injector nozzle to meet the
requirement.
Caution: If any warning lamp turns on during running of engine, stop the engine for
checking as soon as possible to ensure safety.
8. Turn on the hydraulic device, in order to ensure the normal functioning of each system
and help the preheating of hydraulic system. Do not operate any accessory before the
hydraulic oil reaches the normal temperature.
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9. The operation of the boom has three phases:
If the boom fails to extend normally after three phases, check the hydraulic cylinder for
normal retraction. Before start of machine, correctly check the boom by phases.
Caution: The new engine requires no run-in. This engine shall be running normally shortly
within one period. Following the running of the engine, it probably leads to the accelerated
oil consumption due to piston and cylinder bore. In any case, do not leave the machine
unused for a long time (for instance, preheat the machine under unloaded condition for a
while).
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3.10. Traveling Preparations of Machine
While traveling outside or in a parking lot, abide by the local traffic safety laws and
regulations.
Important: Always abide by all relevant local laws and regulations while traveling on
public roads.
1. Fully retract the boom. Lower the boom sufficiently and then lift slowly. Tilt backward
the attachment carrier, till the root point A is off the ground by 300mm (12in).
Caution: Some nations require folding the forks while traveling the machine on public
roads.
Warning
The forks are really heavy. Take cautions to separate and fold the forks.
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When the boom is at traveling position, install ropes to the lifting points on the boom and
frame.
2. If other optional attachment is installed, ensure that the safety requirements of the
optional attachment are met.
If the machine is traveling with the bucket, the bucket tooth protective plate must be
installed.
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Caution
4. Adjust four wheels to linear alignment and select two-wheel steering mode. Do not select
crab steering or four-wheel steering while traveling on public roads. Lock the steering mode
selection lever.
5. Some regions legally require turning on the warning lamp while traveling on public roads.
Check and ensure that the lamps of all circuits are functioning normally.
Warning
Hillsides
This forklift truck is provided with a high speed gear and low speed gear. However, it is not
necessary to use a high speed gear to overload the engine, such as in the mountains. High speed
gear is only used for the forklift truck transition and operation in high speed gear can result the
Always keep the machine under control during the movement of the machine. Always keep
alerted against the obstacles and the possible occurred danger moments.
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Do not get off the machine during movement of machine.
Do not shift to neutral gear while driving down a slope, as the machine can’t be completely
controlled and the sliding will damage the transmission of the machine.
Slopes
Under loaded condition, drive forward to drive up a slope and drive backward
to drive down a slope.
Select a necessary gear before driving down a slope. To drive down a slope, use the gear
same with that used to drive up the slope. Do not conduct gearshift on slopes.
Use the brake while driving down a slope, in order to prevent the over-speed and downslide
of the machine.
If entrapped in mud, shift to 1st gear and align forward the front wheels.
Take special cautions during steering. Ensure that your visual field is not obstructed from
the rearview mirrors. Ensure that the road is free of obstruction before the steering. Ensure that
the alarm functions normally so that all personnel nearby can hear it clearly.
Caution: To adapt to different operating environment, the machine is fitted with all kinds
of steering alarms. The types of the alarm are probably controlled by some local laws and
regulations and the alarm can be applied only in some specific fields. Please correct use
the reversing alarm.
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Warning
It will probably cause grinding injury if the machine starts rolling and you attempt to
get off the cab. Do not attempt to jump off the cab when the machine starts rolling.
Please stay within the cab and fasten the seat belt.
Operation procedure
After the preheating of the machine and the parking brake test are completed, operate as per
Caution: This manual provides the locations of switches and operating levers.
Important: Please bear in mind that the driving mode will probably remain temporarily at
previous mode and restore current mode till the rear wheels are aligned forward.
Warning: The rear seat of the machine will swing out during four-wheel steering. Please
check carefully before steering.
Warning
Gearshift
Do to shift the gear when the forklift truck is in driving state, and whether shift from
the high-speed gear to the low speed gear or shift from the low speed gear to the high
speed gear, the forklift truck will produce a greater traction force difference, so that you
have a major injury, and even death, while damage the forklift truck. If need to shift the
gear, please be sure to adjust the driving and reverse gear to the neutral position, and
parking the forklift truck, after that you can shift the high speed gear and low speed gear.
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Operating the gearshift lever during the driving will probably cause serious injury or even
death to you or others, as the machine will probably move suddenly without any warning. Please
Warning
Reversing
The high speed reversing will lead to occurrence of accidents. Do not reverse the machine
at full accelerator and highest gear. Always drive safely depending on the working environment.
c Under braked state, operate the gearshift lever to select forward or reverse.
Caution: When the parking brake is applied, if the gearshift lever is shifted to forward or
reverse, there is a warning lamp indicating that the parking brake is applied.
e After the parking bake is released and the safety is guaranteed, release the brake pedal and
depress the accelerator pedal to slowly move the machine.
Warning
Failure of Engine/Steering
If the engine or steering fails, stop the machine as soon as possible. Do not operate further
f While checking the steering and brake, please drive the machine slowly. When the control
or brake of the machine is malfunctioned, do not operate the machine, even if the
malfunction is not confirmed or considered by you.
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3.12. Braking and Parking
1、 There is no danger or threat to park the machine on a dry level ground.
Parking
The incorrectly parked machine will probably move without the operator. Please abide by
the relevant instructions in this manual for correct parking of the machine.
2、 Slightly release the accelerator pedal and depress the brake pedal to stop the machine
successfully. Depress and hold the brake pedal, till the machine is completely stopped
(step 3 and step 4).
Caution: The parking brake can’t be used to slow down the traveling speed, unless in event
of emergency. Otherwise the braking efficiency of the parking brake will be reduced. If the
parking brake is used in event of emergency, replace with new brake lining.
3、 Sufficiently pull up the parking brake handle. Ensure that the parking brake indicator
lamp turns on. Release the brake pedal.
Warning
4、 Shift the gearshift lever to neutral gear. Ensure that the operating levers are in place and
that the brake indicator lamp turns off.
Danger
Before lowering the attachment onto the ground, ensure that the machine and all personnel
nearby are not in the dangerous zone. The personnel on or near the machine will probably be
5、 Retract and lower the boom and level the forks closing to the ground.
Caution: Do not leave the machine when the boom is sufficiently lifted and extended,
otherwise it will cause permeation of hydraulic oil from one hydraulic refilling valve and
cause partial out-of-phase of boom, which will lead to destruction of boom pipeline system
during retraction of boom.
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Warning
Hydraulic cylinder
The efficiency of the hydraulic cylinders will be influenced if the dusts thereon are not
removed. Periodically remove the dusts from the surrounding area of the hydraulic cylinders.
Before leaving or stopping the machine, close all hydraulic cylinders to minimize the weathering
corrosion.
6、 It’s recommended to increase the engine speed to 1000r/min and unload for 2~3min
before stop. This can cool down the turbocharger.
7、 Before leaving the machine, please ensure that all switching devices are already turned
off. If necessary, leave the hazard warning lamp and the side lamp on. Withdraw the
key.
8、 Use the handrail and foot ladder to get off the machine. When leaving the machine,
close and lock all windows and two doors. Ensure that the all filler caps are locked.
Warning
Make sure to use the provided handrails and foot ladder to leave or enter the cab or driving
shed. Face towards the machine while entering or leaving the machine. Ensure that the foot
ladder, handrails, and bottom of your shoes are dry and clean. Do not jump off the machine. Use
the handrails, instead of any operating lever of the machine, to enter or leave the machine.
9、 When the machine is not to be used for a long time after one working cycle, please take
away the battery (if equipped) if no lighting is needed. Battery isolator\
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3.13. Operation Instructions of Machine
Introduction
This section can tell you the methods and techniques for safe and effective operations of the
machine.
Your machine can be applied in various conditions. Therefore, in all cases, the driver must
determine the operation manual and the working conditions depending on the actual situation, in
We provide the most useful information with deep sincerity. XCMG accepts in a
responsible way the suggestions, opinions, statements, viewpoints, clear conclusions, and
Ensure that you have passed sufficient training and believe that you are capable for
The carefulness, well training, and rich experiences are your magic keys for safe and
effective operations of machine. Lacking of experiences or carelessness will make your driving
dangerous. Do not threaten your life or others due to your irresponsible driving.
Danger
The influencing factors for the stability of machine include driving mode, load type,
elevation and reach of boom, ground condition, and wind speed and direction. Before the
operations, it’s the operator’s responsibility to evaluate the wind direction and speed and
load scale. Before the operations, it’s operator’s responsibility to evaluate the terrain,
ground roughness (bear in mind that the roughness is different between wet and dry
Before starting the operations, read and understand the load table of this manual and
the boom manual. Ensure that you can correctly control the machine before the actual
operations.
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Use a load of standard weight for testing. Do not use any unknown load, unless you
Read and understand this part. Use the load diagram and boom indicator before operating
this machine. Practice continuously, till the operations are correctly understood.
Firstly practice the operations of flat loads and, after the flat loads can be operated safely
The machines covered by this part are equipped with standard fork attachment. Please
Before using any attachment, take the possible safety influence of attachment into
consideration. When the attachment is equipped, the gravity center or the overall dimensions of
the machine may vary, which will probably influence the stability of the machine. Therefore, pay
attention to the safety of ground operations and the safe distance from the power cables.
Pay attention to the maximum wading depth of this machine. If the water is too deep, the
water will enter into the engine, axles, and cooling fan to damage the machine.
The operation regulation shall be properly considered before starting any operation not
covered by this manual. You may contact a XCMG dealer, who will serve you with pleasure.
Read the part Safe Operations in the preface and the following information:
Safety Rules
At the control or motion device part of the machine, do not wear loose clothing or jewelry.
Wear the protective clothing and labor protection articles as per the working conditions or local
Ensure that the place for the placement of load can carry the load safely.
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Make clear the direction and keep calm during driving. If the load is too large to block the
Pay special attention to the level condition of the ground during driving. Refer to the part
The stacking height of the loads shall not be higher than the forks.
The driving speed shall depend on the driving conditions. Drive at low speed on moisture,
Drive with care on bump roads, as it will probably bump off the load.
Risk evaluation
operator’s responsible to prepare appropriate operation regulation for the safe operations of the
machine.
It’s of great importance to fulfill correct risk evaluation and ensure effective safety
If you don’t know how to handle specific works, please contact a XCMG dealer, who will
During the risk evaluation, some factors below shall be taken into consideration as
Important: The correct risk evaluation is originated from the well training and rick
experiences. Never neglect your life or others.
Basic knowledge:
In the loading/unlocking area, the working area shall be enough to accommodate the
machine body and outriggers (if equipped). It’s unnecessary to operate the machine in a narrow
space.
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The working area shall be hard enough to carry the machine and load without clear
deformation. The ideal condition is that the working area can accommodate two machines and its
specially, the operator may handle with well training and rick experiences. If equipped, the
The traveling path shall be solid and reliable and its gradient shall be no higher than:
These data can be used only for normal driving mode of the machine, namely the boom is
retracted, the root of the forks is more than 500mm (20in) above the ground, and the machine is
not speeding. It’s necessary to restrain the loads of certain shapes, especially on lateral slopes.
Personnel:
Among the personnel for this operation, who is better trained? Who is better experienced?
Who is better competent for this operation? Are they well rested? The driving under ill or fatigue
Machine:
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Do the tires for fulfillment of operation have sufficient pressure? Are they under good
Load:
How large is it? A large surface area will be influenced by wind speed.
Is it a shape load? Where is its gravity center? An unbalanced load is difficult to handle.
Loading/unloading area:
Is it level? The careful consideration shall be given if its gradient exceeds 2.5% (1:40).
Is there more than one direction to access the load? If possible, avoid crossing over any
slope.
Is the ground solid? Can the ground carry the weight of machine under full load?
Is the ground really rough? Is it harmful to the machine, especially to the tires in event of
emergency?
Is there any obstacle or dangerous article nearby? Such as fragments, large pits, and electric
wires.
Is the operation space enough? Is there the accessing of other vehicle or personnel during
the working of the machine?
Crossing path:
Is the ground solid? Can it provide sufficient traction force and braking force?
How about the steepness of the slope (upslope/downslope/lateral slope)? It’s really
dangerous to cross over a slope. Is it possible to make a detour?
Weather:
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How strong is the wind? A strong wind is harmful to the stability of the loaded machine,
especially when the surface area of the load is large.
Safety warning:
Warning
Carefully check the working site before starting the machine for operations. The
stacked materials near the working site will collapse once being impacted by the machine,
which will probably cause injury or even death to you. Check the dangerous factors that
may cause out-of-control of the machine (including pits, fragments, log, and steel blocks).
Dander
Without permission, it’s prohibited to lift anyone in the high air or stand on the non-
protected forks. The violation will probably cause serious injury or even death.
Caution
Driving the machine too fast or the over-high load will probably lead to rollover of the
machine. During the traveling of the machine, keep the load close to the ground.
Under loaded condition, do not drive the machine too fast. Drive with care on bumpy
roads.
Warning
The high slopes and earth ditches will probably collapse. It’s probably dangerous to park
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Safety railing
It’s probably dangerous to leave the machine unattended in a public place. In a public
place, if the environmental visibility is reduced, setup a safety railing in the working are to
Caution
Make sure to understand the weight of load before lifting the load. Firstly check the
stability of the machine, even if the load is to be lifted only for centimeters. If feeling that
the machine is unstable, immediately lower the load. While lifting or extending the boom, if
feeling that the machine is unstable, lower and retract the boom.
The load shall not exceed the values indicated on the load diagram (Refer to the load
diagram and boom description in the manual).
Caution
During loading/unloading, if the ground is not solid, it will probably lead to rollover of the
machine and cause serious injury or even death to you. Before the loading/unloading,
ensure the leveling of the ground. Whenever possible, do not carry the load on a non-solid
ground.
Dander
It will probably cause electric shock if your machine or attachment is too close to the
power cables. Observe the working area for presence of power cables before starting the
working. If yes, contact your local power supplier and inquire which safety measures shall
be taken. Meanwhile, understand the requirements of local laws and regulations on the
After you understand the safety measures to be taken in the working site and
understand the laws and regulations, make sure to abide by these requirements.
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Caution
Driving the machine too fast or the over-high load will probably lead to rollover of the
machine. During the traveling of the machine, keep the load close to the ground.
Under loaded condition, do not drive the machine too fast. Drive with care on bumpy
roads.
Make sure to understand the weight of load before lifting the load. Firstly check the
stability of the machine, even if the load is to be lifted only for centimeters. If feeling that
the machine is unstable, immediately lower the load. While lifting or extending the boom, if
feeling that the machine is unstable, lower and retract the boom.
The load shall not exceed the values indicated on the load diagram (Refer to the load
During loading/unloading, if the ground is not solid, it will probably lead to rollover of
the machine and cause serious injury or even death to you. Before the loading/unloading,
ensure the leveling of the ground. Whenever possible, do not carry the load on a non-solid
ground.
Spacing of forks
The load will probably fall off if the spacing between forks is not incorrect. With
respect to the load, the forks are always correctly placed. Before the lifting, ensure that the
The load on single fork will fall off. It’s prohibited to lift the load by single fork.
Unloading
It’s prohibited to unload the load from the forks by suddenly stopping the machine.
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Warning
Do not exceed the load grade of the forks. The forks will probably break to cause loss
Warning
Maintain a correct pressure for the tires and prevent the lateral instability of the
machine. Daily check the tires for damage trace, cut, and piercing object. These detects will
probably lead to pressure loss of the tires.
Caution
When the machine is started or idled for more than 5 minutes, first need to turn the
steering to charge the accumulator, then the machine can work normally.
The maximum carrying capacity is described in the performance part of the machine
(Technical Specification). The carrying capacity of the forks for this machine must be equal to or
If the carrying capacity of the machine differs from that of the forks, the smaller value shall
Important: All lifting equipment, including the forks and its equipment, shall be
periodically checked and tested by qualified personnel, in order to guarantee their
performances.
Some nations probably require checking at least once every half year or one year. To
guarantee the safety, the local laws and regulations shall prevail.
If you have any questions, please further consult with local XCMG dealers.
Regular Loads
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Caution
Load and unload on a solid and level ground. Take cautions against possible dangers,
Warning
Before lifting or handling a load, ensure the weight of own braking load.
Never exceed the safe working load of your machine. Do not exceed the lifting angle
and the limit extending length indicated in the load diagram within the cab. Observe and
use the load diagram and boom indicator (in the operation part).
Take cautions to separate or stack the fork bodies, as the forks are really heavy.
Loading
1. Separate the fork bodies as far as possible, depending on the size of the load.
2. Place the forks at horizontal position and fully retract the boom.
3. While closing to the load slowly, keep four tires forward and do not form any angle.
Stop the machine and keep a sufficient space for movement of boom. Apply the parking
brake and shift the transmission to neutral gear.
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Caution: If the load is on a high platform, it’s necessary to lift the boom so that the machine
can close to the load sufficiently.
4. Extend the boom or move the machine to insert the forks into the load. Stop the machine
when the attachment comes into contact with the load. Check the extending
length/lifting angle of the boom and ensure they are within the limit.
Warning
If the machine starts to become unstable when starting the lifting of load, immediately
5. Lightly lift the load, tilt backward, fully retract the boom, and lower the boom to the
traveling position.
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Unloading
Caution
Load and unload on a solid and level ground. Take cautions against possible dangers,
Warning
Before lifting or handling a load, ensure the weight of own braking load.
Never exceed the safe working load of your machine. Do not exceed the lifting angle
and the limit extending length indicated in the load diagram within the cab. Observe and
use the load diagram and boom indicator (in the operation part).
1. Slowly close to the center of unloading area, keep four tires forward, and do not form
any angle. Ensure not to exceed the load limit indicated in the load diagram.
2. Apply the parking brake and shift the transmission to neutral gear.
3. Place the load at a position slightly above the required position. While stacking box
loads, ensure that the loads are stacked straightly and squarely. For better stability,
stagger the topmost row of load.
4. Lower the load to the required position and ensure that the load is level.
5. Carefully withdraw the forks. Depending on the height of the load, it’s necessary to lift
or lower the boom while withdrawing the forks.
6. After withdrawing the forks from the load, fully retract the boom and lower the boom to
the traveling position.
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Irregular loads
Important: While handling irregular loads, take special cautions to operate the boom and
attachment.
1. Find out the gravity center of the load. For a properly packed load, the gravity center is
probably marked on the box.
2. Properly place the machine to ensure that the gravity center of the load is at the
symmetric center between two fork bodies.
3. Fork/place the load, depending on the type of the load. For regular loads, follow the
procedure for regular loads. For irregular loads, the appropriate chains are probably
required to ensure that the load is safely placed on the forks. Stop the engine before
anyone is allowed to close to the forks.
Caution: If it’s impossible to find out the gravity center of the load, follow the procedure
below: Attempt to load the load at different locations, till it’s considered that the load is
stable on the forks. While attempting to load the load, lift the load only by centimeters.
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Handling of package load
Handle the package loads only after fully understanding how to handle regular loads. The
Lifting
2. Extend the boom, lift lightly, and fork into the load. Then, tilt backward the forks and
place the boom to traveling position.
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Placement
1. Properly place the boom and place the package at the position slightly above the
required position of the package. Lower the boom and tilt forward the forks lightly so
that the front edge of the package lowers onto the ground.
2. Retract the boom and withdraw the forks from the bottom of the package. After being
disengaged from the package, restore the boom and forks to the road traveling position.
Warning
The package will probably fall off the forks. In such case, stop the engine before
anyone is permitted to approach the forks.
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Operations of Bucket
Warning
Before lifting or handling a load, ensure the weight of own braking load.
Never exceed the safe working load of your machine. Do not exceed the lifting
angle and the limit extending length indicated in the load diagram within the cab.
Observe and use the load diagram and boom indicator (in the operation part).
While handling loads on high piles or embankments, remove all hanging objects.
Be aware of the falling objects. The sudden falloff of the protruding materials will
probably bury you and your machine.
Caution
Load and unload on a solid and level ground. Take cautions against possible
dangers, especially during steering and reversing.
Do not load by bucket with the boom extended, otherwise it will probably cause
serious damage to the boom.
Your machine may be equipped with diversified attachments, including bucket. Please refer
to the Attachments. The paragraphs below will introduce some related precautions to you. These
precautions may be incomplete to substitute the appropriate training. Make sure that you are
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While digging the bucket into the material, lift the bucket and at the same time tilt
backward the bucket to sweep upward the material and top up the bucket with material.
Push down the drive dumping switch, which can provide more energy and accelerate the
cycles for the loader. Top up the bucket whenever possible, as a half-full bucket means low
productivity.
During the movement of load, tilt backward the bucket to a position capable of prevention
of leakage.
While loading a soft material pile, start from the bottom of the material and operate from
the front as per the figure to horizontally slide the bucket onto the ground towards the material
pile.
While loading a compact material, start from the top and handle downward.
To move away material from a stock pile, start from the position approximate one bucket
height above the bottom. Once the height of the stock pile is reduced, load from the bottom of
the pile.
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Loading to Truck
Park the truck at the position approximate 45º from the material pile, as shown in the figure.
This can save unnecessary movement. Guarantee a sufficient space to lift the bucket to the
Keep your position against the wind, in order to keep you and your machine away from the
dust.
If the truck body is approximately same with the bucket width, dump the load into the
center of the truck. If the truck body is two times of or longer than the bucket width, dump the
Do not dump the load by sudden movement. Tilt forward the bucket step by step, till the
material is fully dumped. Shake the bucket by operating the operating lever back and forth to
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Operations of Machine on Slopes
Warning
Make sure that you are already trained, get familiar with the operations of machine on
slopes, and understand the possible adverse influences of the slopes and working environment on
the stability of the machine. If you don't understand these practices recommended for actual
While operating the machine on slopes, there are many factors leading to adverse influences
on the stability of the machine and the safety of the machine and operator.
It’s really important and necessary to conduct the risk evaluation for the works to be
handled. Please refer to Risk Evaluation (Operation part). The operator shall abide by all safety
While driving on slopes, abide by the following requirements to guarantee the maximum
traction force.
Drive forward the unloaded machine to drive down a slope and drive backward to drive up
a slope.
Drive forward the loaded machine to drive up a slope and drive backward to drive down a
slope.
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Crossing over slopes
Before crossing over a slope, read and understand the instructions specified in this manual.
Operating the machine on a solid level ground can achieve the maximum stability.
Operating the machine on slopes will reduce the stability of the machine.
To cross over a slope, fully retract the boom and drive slowly at walking speed.
Unless it's really necessary, do not lift the attachment excessively high. When a load is
placed onto the forks, generally the lowest point of the load shall be no higher than 500mm
(20in) from the ground, as indicated by A in the figure. Some loads may hang beneath the forks,
as indicated by B in the figure. In such case, conduct the risk evaluation before suddenly lifting
Bear in mind! Caution! Be careful! Taking unnecessary risks will probably endanger your
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Lifting operations on slopes
Unless the machine is level in width direction (for instance, laterally leveling of the
Warning
Stop the machine and apply the parking brake before any lifting operation.
Lateral stability
To work on slopes, before any lifting operation, make sure that you have taken all factors
that may influence the stability of the machine into consideration. Please refer to Operations of
Machine on Slopes (Operation part) and ensure the lateral stability of the machine in width
direction.
Level the machine by one of the following methods, depending on the model and
For the machine with frame leveling (swing) function, level the machine in width direction
by swing control function, as indicated by B in the figure. Please refer to Frame Leveling
For the machine equipped with outriggers, level the machine in width direction by
outriggers, as indicated by C in the figure. Please refer to Outrigger Control Function (Operation
part).
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To ensure maximum stability of the machine, it’s recommended to operate the machine on a
Important: If the machine can’t be leveled in width direction, before attempting any lifting
operation, make sure to conduct the risk evaluation. Please refer to Risk Evaluation
(Operation part).
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3.14. Operation at low and high temperatures
Low temperature
Take the following preventive measures at low temperature, thus it’s convenient for starting
Important: don’t start the engine via 24V voltage formed by connecting two batteries in
series, otherwise it will burn the induction multi-tube heater and starting motor.
8. Before starting the engine, first remove the snow from engine components, otherwise
the snow may enter into the air filter.
High temperature
Take the following preventive measures at high temperature to avoid the possible damages
of engine.
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7. Check the engine pre-filter periodically (if installed).
8. Check the level of battery electrolyte.
Before towing the machine, ensure that you follow the relevant laws and regulations
yourselves.
Ensure that the towing hook of tractor is applicable for your machine, and keep sufficient
Warning
Check the towing hook and tractor hook ring for wears before each operation.
Any bad connection, worn hook or pull ring can lead to the loss of tractor, injury of
you and others.
During the traction, the machine must be at non-load (no ballast), while it drives with two
wheels.
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Warning
Don’t exceed the specified total weight of tractor or hook limit, otherwise the
machine will be unstable.
1. Check the tractor weight and tire pressure. Its maximum towing capacity is determined
by the type of installed brake system. Calibrate the tire pressure as per the requirements
shown on the cab odometer.
2. Put in the parking brake.
3. Adjust the rearview mirror to achieve the best visual effects of hook-towing area.
Warning
When the machine approaches the tractor, confirm no persons between the
machine and tractor.
4. Connect it to the tractor, and the steps for connecting the tractor to hook shall be
subject the tractor type, regardless of the following procedures to obey:
a. Before the machine approaches the tractor, first check and confirm whether the
positions of tractor and its hook are convenient for connection.
b. If any assistant is available, the assistant must stand near to the machine before
connecting the hook and tractor together.
c. If the machine fails to stop, the assistant can’t approach the tractor or machine, put
in the parking brake, and turn the engine switch to OFF position.
Warning
Before driving to leave, confirm that the tractor hook is correctly connected and
locked.
d. If the tractor has been connected, and Pin A is in correct reliable position, the
operator can’t start the engine before the assistant isn’t far away from the machine and
tractor.
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Warning
Don’t use the rear attachment for towing and braking purpose. If no brake valve
of tractor is installed regardless of tractor braking demands, first contact with your
XCMG dealer.
1. For the operation of attachment, e.g. inclination of tractor, operate H/J as per the
installed machine tools and desired actions.
2. In order to avoid the pollution of machine hydraulic system, first make the tractor
horizontal in case of inclining the tractor before disconnecting the hydraulic working
equipment to drain the hydraulic cylinder oil of tractor.
3. In case of towing the tractor on the highway, select two-wheel drive. Check and
confirm that the indicator shows the activation of two-wheel drive.
Warning
Before driving to leave, confirm that the tractor hook is correctly connected and
locked.
Warning
If the steering system isn’t reset at least once every day, it may lead to the
reduction of its steering effects.
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2. If it’s difficult to steer
3. After driving for over 15 miles (24 kilometer) (two-wheel steering driving)
4. If the two-wheel steering indicator lamp flashes (about four times per second)
Reset the steering system as per the following steps:
1. In case of selecting two-wheel steering, the steering indicator lamp still indicates four-
wheel steering.
Since the sensor on drive axle stops the conversion of steering mode before the rear
wheel is not aligned or outside its normal position, the inconsistency of steering indicator
lamp and switch still keeps for a certain time.
Caution
If its towed distance is too short or its speed is too high, it may damage the
transmission. Don’t tow the machine for over one mile. If a longer distance is required,
it’s best to apply the trailer. Its speed shall not exceed 15mph (25km/h) while it’s
towed.
Apply the rigid hook connection. If the towing chain must be applied, two towing
vehicles shall be applied, one is connected to the front of faulty machine, the other is
connected to the rear of faulty machine, thus its braking power can be supplied.
The towing vehicle must have sufficient tensile force and braking ability to pull
and stop the faulty machine.
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1. Put in the parking brake.
2. Turn the gearshift lever to neutral gear, or put forward/reversing lever in neutral gear.
3. Prepare for the machine driving. Observe the preparations for road driving.
If the engine can’t be started, it may be required to lift the boom up to the position
applicable for transportation and fix the boom. Take the operating steps as per the machine
conditions and different installed hydraulic pipes.
If so, it’s best to contact with your XCMG dealer for help and advices before
performing such work.
It’s required to observe that if the engine can’t be started, more effort will be required to
steer the machine.
Warning
The transportation contractor and driver are responsible for safety
transportation. Any machine, tool or part may move during the transportation, so it
needs to be fully fixed.
Note: before the transportation of machine, it’s required to follow all the regulations
and laws for the regions where you will pass.
Ensure the suitability of transported vehicle. Observe its fixed size (performance part),
and check the fixed size of your machine.
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Warning
Before moving the machine on the trailer, first check the trailer and slope, and
ensure that no oil, grease or snow exists. Remove the oil, grease and snow from the
tires of machine. Ensure that nothing collides against the machine on the slope.
Observe the minimum ground clearance of machine in performance part fixed size.
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1. Retract the boom, and lower it to ground.
2. Move away all the accessories.
3. Turn off the engine, pull out its key, close the windows, leave away from the cab, and
close the doors.
4. Remove all the infirm devices outside the machine.
5. Confirm the non-load weight of machine, and observe its fixed metrics.
Warning
Hoisting equipment
In case of applying the wrong hoisting equipment, you may be injured. Ensure the
good state of hoisting equipment. Ensure that the lifting tools conform to local
regulations, and they are applicable for lifting work, while ensuring the hoisting
equipment is competent for work.
Warning
Communication
Any poor communication may lead to the accident. Let the persons around you
guide how to do it. If you and others work together, ensure that all the applied hand
signals can be understood by all the people. The working area is noisy, so it can’t rely
on language commands.
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3.18. Storage of machine
If the machine won’t be used for a longer time, you must store it properly and correctly
to avoid its deterioration.
1. Clean the machine fully, and remove the corrosive substances from it.
2. Fill up the fuel tank to avoid the formation of condensate on the wall of fuel tank.
3. Park the machine on the firm level ground (it’s best to store the machine under the
shed). Ensure that no machine parks in the position difficult to operate, thus it can avoid
the pull-out of machine in the later period of storage (in case the machine can’t be
started).
4. Stop the engine, retract the hydraulic cylinder, and lower the accessories to ground.
Open the filler cap of hydraulic oil tank, and operate the control lever to release the
residual pressure out of hydraulic pipe.
5. Apply a thin layer of grease or petroleum jelly to each exposed hydraulic cylinder lever.
6. Check the level of all the oil. Refill it if necessary.
7. Check the level and conditions of coolant. Refill it if necessary.
8. Remove or charge the battery, store the battery at warm and dry place, and charge it
periodically.
9. Check the tire pressure. Adjust it properly if necessary.
10. Check the machine for wears or damaged parts. Replace if necessary.
11. Turn the wheels periodically.
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4. Maintenance
4.1.Introduction
Note: please read and understand these operating instructions carefully so that you can
maintain this machine correctly. The correct maintenance is important for ensuring the
safety and extending the service life of machine.
In order to achieve the optimum performance, the design and manufacture of machine
can realize the comfortable work under all the complex operating conditions and
environments, and can save its operating energy. Before the transportation, the machine
must be checked at the factory and dealer’s shop to ensure the realization of the most
appropriate case in your hands. In order to keep such case, it’s very important that the
machine shall be periodically maintained by the recognized XCMG dealer as per the
requirements specified in this manual.
The full details of required maintenance items given in this section can make your
XCMG machine keep at peak efficiency.
The details of maintenance are described on the following pages, and many necessary
maintenance checks can be specially performed only by the trained XCMG persons. This
special work can be only performed by XCMG issuer and maintenance engineer who have
been trained by XCMG. The maintenance work can be fully, safely, correctly and efficiently
finished by them only with necessary special tools and testers.
XCMG often updates and inform all their product developments, performances and
changes of its issuer, so only XCMG issuer can be fully competent for maintenance and
repair of your machine.
Any list of maintenance records or notes can contain the maintenance records to make
a better plan for your maintenance demands. These records shall include the dates,
signatures and your issuer’s seals during each maintenance.
Please remember, if its maintenance is reasonable and correct, not only the stability of
machine but also its price can be increased during the resell.
Owner/operator’s support
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XCMG and dealer hope that you’re fully satisfied with new XCMG machine as well. If
you meet with any problem, you can contact with the maintenance points of your dealer, and
they will help you in time.
After setting the machine, you’re required to report the relevant maintenance names
during the contact with your dealer.
Service/maintenance agreement
In order to make you plan and control the maintenance price of machine better, we
strongly recommend that you make full use of service and maintenance agreement supplied
by the issuers, thus you can make an appropriate adjustment as per the operating conditions
and schedule of your machine.
In order to ensure the performance of machine in the later period, it’s very necessary
for the issuers to perform the initial maintenance and check of machine within one month
after purchasing the machine or 100 operating hours (whichever comes first). It should be
informed of the issuers, thus they can make the necessary arrangement.
Only XCMG issuers can meet the check demands fully, while reaching the test
parameters lawfully required by English Health and Safety Administrative Departments.
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Meanwhile, they can provide the annual check services as per the policy of insurance
company.
Only XCMG issuers can realize the definition of “competent person” through these
necessary tests and checks. It certifies that only the experienced modern engineers trained
by XCMG factory can ensure the considerations to attentive or reliable business level only
by providing the useful data and material support for XCMG issuers.
Replacement parts
We suggest that you supply only XCMG original parts. The parts manual can assist in
your confirmation of parts, which is convenient for purchasing them from XCMG issuers.
The processor is required to know the correct machine model or some serial Nos. of
machine. Observe “Familiar with your Machine” of Introduction.
Introduction
Read and understand these data and relevant publications, which are very important.
Let all the colleagues contacting the grease read them, too.
Hygiene
It won’t create any endanger of grease against your health to apply the functions of
XCMG grease correctly and properly.
However, any excessive or long-time skin contact can consume the natural grease of
your skin, thus it will cause the dry skin or pain.
Low-viscosity oil is more likely so, so it’s required to pay special attention to it while
treating the used oil, because the used oil may be diluted by fuel pollutants.
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Keep the good protection and personal hygiene at any time for oil product treatment.
For more preventive measures, you’re recommended to read the relevant publications
published by local health agencies, while following the points below:
Storage
Don’t put the grease into any open or unsealed container without labels.
Waste treatment
Caution
It’s illegal to pollute the drain pipe, sewer or road surface. Remove all the
overflown liquid or grease.
The used liquid or grease, filters and polluted materials should be treated as per
local regulations. Adopt the approved waste treatment stations.
The used oil should be collected and treated as per any of local regulations. It’s never
allowed to pour the used engine oil into drain pipe, sewer or road surface.
New oil
Except for normal care and hygienic experiences, no other special preventive measures
are required for treatment or use of new oil.
Used oil
In case of treating the used engine oil, the following preventive measures can assist in
protecting your health:
1. Avoid any long-time, large-area or repeated contact of skin with used oil.
2. Apply the barrier cream before treating the used oil. Pay attention to the following
items while removing the engine oil from the skin:
a. Clean the skin thoroughly with soap and water.
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b. Adopt the special brushes.
c. Apply the special liquid soap.
d. Don’t apply the gasoline, diesel or kerosene for cleaning.
3. Avoid any contact of skin with soaked clothes.
4. Don’t store the oily cloth waste in the pocket.
5. Re-apply it after cleaning the dirty clothes.
6. Discard the oil-soaked shoes.
First aid-oil
Eye
If your eyes contact it carelessly, clean it for 15 minutes with fresh water. If your eyes
are still in pain, seek for immediate medical treatment.
Swallow
If the oil is wrongly swallowed, don’t be lured for vomiting, and take the medical
advices immediately.
Skin
If the skin contacts a lot of oil, flush it immediately with soap and water.
Leakage
Apply the sands or locally approved small particles for absorption. Transfer the
accumulated sands or small particles to chemical treatment stations.
Fire
Warning
Don’t extinguish the fire with water when the oil’s fired, otherwise the fire will
extend more quickly, because the oil can float on the water.
The oil or grease can be fired. Extinguish the fire with carbon dioxide, dry
chemical agent or foam. Any firefighter should use the self-contained breathing
apparatus.
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Battery
Warning
The battery can emit the explosive gas. In case of treating or operating on the
battery, don’t smoke. Avoid any spark or flame produced by the battery.
The battery electrolyte contains sulfuric acid. If your skin or eyes contact it, it will
burn you. Please wear the safety glasses, and treat the battery carefully to avoid the
leakage. Any metal object (watch, finger ring, zipper, etc) shall keep away from the
electrode tip of battery. These objects may lead to short-circuit of its electrode and
burn.
After turning all the switches of cab to OFF position, disconnect or re-connect the
battery. In case of disconnecting the battery, first disconnect its ground electrode (-).
Charge the battery at well-ventilated place far away from the machine. Before
connecting or disconnecting the battery, first close its charging circuit. After installing
the battery on the machine, re-connect it by waiting for 5 minutes.
First aid-electrolyte
Reference as below:
If your eyes contact the electrolyte, flush the eyes immediately for 15 minutes with fresh
water, and seek for medical treatment.
If it’s swallowed,
Don’t be lured for vomiting. Take a lot of water or milk, and then drink the milk magnesia,
beaten egg or vegetable oil. Seek for drug treatment.
Clean with fresh water, and take off the electrolyte-soaked clothes. Cover the wound with
disinfected clothes, and then seek for drug treatment.
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Warning signs
Sign Meaning
Safety glasses
Explosive gas
Battery acids
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Pay attention to operating instructions
Caution
Don’t disconnect the battery while the engine is running, otherwise the electrical
circuits may be damaged.
Store the damaged, exhausted battery or fired residues and leaked materials in
the closed acidy box, and treat them as per local waste environmental protection
regulations.
Electrical circuit
Danger
The battery electrolyte is toxic and corrosive. Don’t breathe the gas emitted by the
battery, and it shall keep away from your clothes, skin, mouth and eyes, etc. Wear the
safety glasses.
Caution
Store the damaged, exhausted battery or fired residues and leaked materials in the
closed acidy box, and treat them as per local waste environmental protection
regulations.
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Warning
Battery gas
The battery can emit the explosive gas, so it’s required to keep away from open
fire or sparks. Don’t smoke near to the battery. When the battery is applied in the
closed area or charged, keep it well-ventilated. Don’t check the charging conditions of
battery by shorting its electrodes with metal, aerometer or voltmeter.
Study how to maintain your machine correctly, and follow the correct maintenance and
check methods shown in these operating instructions. If any trouble occurs to your machine,
it must be repaired before the operation or contact with your retailer.
c. Check the hose and steel pipe for oil leakage, twisted wears and damages;
d. Make the patrol inspection of general symptoms, sound and heat, etc of machine.
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4.2.5 Maintenance hints
b. Don’t adjust the control throttle of engine and safety valve of hydraulic system;
c. Protect the electrical elements to avoid any contact with water or steam;
Apply the windshield washing fluid for machine, and ensure the entry of no dirt into it.
Apply the clean oil and lubricating oil, keep the oil or grease container clean, and don’t
mix the sundries into oil or grease.
After changing the oil or replacing the filter cartridge, it’s required to check whether
metal filling or sundries exist in the used oil and filter cartridge. In case of finding out a lot
of metal fillings and sundries, report it to the supervisor, and take the appropriate measures.
c. Connect any ground cable within 1m away from its welded part. If the ground cable is
near to instrument or connector, etc, the faults will occur together;
d. Avoid any seal or bearing between the welded part and ground point;
e. Don’t use any working equipment pin shaft or area around the cylinder as a ground
point.
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a. When opening the access window or oil tank filler for check, it’s important to fall no
nut, bolt or tool into the machine. If any of above parts is fallen into the machine, take it
out immediately;
b. Any unnecessary article shall not be put into the clothes pocket, which can contain only
the articles required for check.
During the operation in dusty environment, pay attention to the following points:
a. Check the dust indicator of air filter to confirm whether it’s blocked, and clean the air
filter at shorter specified intervals;
b. Clean the radiator core frequently to avoid its blockage. Clean the fuel filter frequently
and replace it;
c. Clean the electric appliance, especially starting motor and generator, to avoid the dust
accumulation.
Don’t apply different brands of mixed oil. If it’s required to apply different brands of
oil, all the used oil must be removed from the machine.
When the hydraulic unit is repaired or replaced, or the hydraulic pipe is removed or
installed, the air must be drained out of oil line.
When any O ring or sealed part of sealing gasket is removed, clean its mounting
surface and renew it. Remember to install O ring and sealing gasket;
During the installation of hose, don’t distort or bend the hose into a small-diameter
ring. Thus it can damage the hose and shorten its service life obviously.
4.3.15 Select the fuel and lubricating oil fitting the environment.
The fuel and lubricating oil applicable for ambient temperature must be applied.
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4.3.16 Check of electrical circuit
Warning: if the fuse is frequently burnt or the circuit is shorted, find out its causes and
repair it or contact with XCMG dealer.
a. Check the fuse for damages or capacity unconformity, check the circuit for open circuit
or short circuit, check the terminals for loosening, and tighten any loosened part;
c. For the survey and correction of causes, please contact with XCMG dealer.
Check whether the air volume switch of air-conditioning system is in “Natural Wind”
position or its transfer switch is in “OFF” position. If not, please turn it to its corresponding
position.
Check whether each instrument runs well, and each illuminator, indicator lamp, horn or
wiper can operate normally. If abnormal, please contact with XCMG dealer.
Note: before starting the engine, ensure that any other person except for operator shall not
operate on or near to the machine. Keep the machine always under the control of operator.
c. Reduce the speed of engine to idle speed, and run it for 3 minutes;
d. Turn the starting switch to OFF. Remove the key from the switch (if the maintenance
must be performed at the speed of engine, make someone always at the machine);
e. When no work is performed on the machine, hang a label of “No Operation” on right
control lever.
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4.4.Running-in of new vehicle
It’s important for extending the service life of machine, eliminating the possible
failure and avoiding significant faults to run-in the new vehicle. After the user purchased
this machine, operate on and maintain the machine as per the new vehicle running-in
provisions of these operating instructions, and then this machine can work normally.
b. After each machine startup, first idle it for 5 minutes. The machine shall be started at
stable low-speed small throttle, and then its speed is gradually increased;
c. During the running-in period, make the uniform running-in arrangement by shifting
d. Unless in emergency, avoid any sudden start, acceleration, steering or braking action;
e. It’s best to load the bulky materials during the running-in period. Don’t work too hard
or urgently. During the running-in period, its loading weight shall not exceed 70% of its
rated weight, and its driving speed shall not exceed 70% of its rated maximum speed;
f. Pay attention to the lubrication of machine, and change or refill the lubricating oil and
g. It’s required to observe the transmission, torque converter, front and rear axles, hub,
parking brake as well as temperatures of hydraulic oil, engine coolant and engine oil
4.4.2 Perform the following work after eight-hour new vehicle running-in period.
a. Fully check the bolt or nut of each part for tightness, especially the diesel engine
cylinder cover bolt, exhaust pipe bolt and front/rear axle fixing bolt, rim nut, drive shaft
coupling bolt, diesel engine fixing bolt, transmission fixing bolt, etc;
b. Check the tightness of fan belt, generator belt or A/C compressor belt;
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c. Check the level of transmission oil, drive axle oil or diesel engine oil;
e. Check the fixed connection of each control operating rod or throttle link;
f. Check the temperature and connection of each part of electrical system, power supply
g. Lubricate the pin shaft of working equipment once every 10 hours (within 100 hours
Note: during the check of oil level, check it as per the relevant operating instructions.
a. Fully check the bolt or nut of each part for tightness, especially the diesel engine
cylinder cover bolt, exhaust pipe bolt and front/rear axle fixing bolt, rim nut, drive shaft
coupling bolt, diesel engine fixing bolt, transmission fixing bolt, etc, any of which shall be
once checked;
c. After the running-in period, check, adjust and lubricate each part of machine. Clean
the return filter cartridge of hydraulic oil tank, and check the cleanness of hydraulic oil. If
Note: during the change of transmission drive oil, drive axle lubricating oil or
transmission oil fine filter, it shall be performed as per the relevant operating instructions.
It’s very dangerous for operator or staff around him to maintain the poor machine.
Please ensure that the regular maintenance and lubrication of machine are specified in the
details for maintenance, thus safe or effective operation of machine can be ensured.
Warning
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The repair must be performed by the personnel with professional qualifications
and tools. After confirming the safety of machine, remind you of repair. The machine
shall be parked on firm level ground.
In order to prevent anyone from starting the machine, pull out its starter key.
Before operating under the machine, first disconnect the battery or block the tires.
If you fail to take these measures, you may be injured and even dead.
Except for daily work, the number of machine operating hours is considered in the
details for maintenance. Evaluate the correct maintenance intervals as per the readings of
chronograph, and perform the regular checks. Don’t use the machine required to maintain.
In case of finding out any problem during the regular maintenance check, correct it
immediately.
Corresponding to:
Note: the maintenance is subject to hour or calendar interval, whichever comes first.
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For the details for operation and maintenance
Important: the maintenance is subject to hour or calendar interval, whichever comes first.
Refer to the corresponding calendar.
600
Operation 10 50 100 500 1000 2000
0
Engine
Pre-filter Check □
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Heat radiator Clean □ □ □ □
Transmission, axle,
steering gear
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Front hub bearing Check □ □ □ □ □
600
Operation 10 50 100 500 1000 2000
0
Hydraulic oil
Brake
Electrical appliance
Line Check □ □ □ □ □
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Body and cab
Lifting/unloading/
inclination/ steering cylinder Lubricate □ □ □ □ □
pin
Reflector Check □ □ □ □ □ □
Accessory
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Hydraulic towing hook pin
Lubricate □ □ □ □
(if installed)
Register/certify
1. The initial 100-hour maintenance can be finished only by your XCMG issuers.
2. If the machine works in the hard and severe environment, change the engine oil and
filter every 250 hours.
3. If the fuel contains high-concentration sulfur, the maintenance period of engine oil will
be influenced. For more information, observe the fuel system.
4. In case of frequent operations in the dusty environment, more frequent maintenance is
required.
5. If the engine is difficult to start or its performance deteriorates, the filter will be
renewed.
6. This work should be performed by the professional personnel.
7. After a large drive repair, the temperature of new oil should be near to its normal
operating temperature, the new oil shall be re-changed at this time, thus the dirt entered
during the repair can be taken away. If the dirt still exists in the oil, the oil and filter
shall be re-changed after the next 100 hours.
8. After the repair of hub, the temperature of new oil should be near to its normal
operating temperature, and it shall be re-changed, thus the dirt entered during the repair
can be taken away. In order to remove any impurity, change the new oil again after 100
operating hours. If a new brake plate is installed, it will become especially important.
9. The axle and drive shaft have been lubricated with high-performance grease before
leaving the factory. If the standard grease is applied during the maintenance, its
lubrication period shall be reduced to 50-hour interval, and contact with your XCMG
issuer for more advices.
10. If the option of variable volume pump is available, the machine will be equipped with a
filter. Then you must replace two filters at the same time as per the maintenance detail
period.
11. If the machine operates under the hard severe conditions, check the arm gasket for
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wears every 250 hours.
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Note:
Check the concentration of coolant at least once every year, and it’s best to do before
the cold start.
Warning
The anti-freezing agent may lead to personal injury, and follow the manufacturer’s
instructions while handling the anti-freezing agent.
First dilute the overrich anti-freezing agent before the operation. Apply the fresh water
with its PH value not more than 8.5. If no, apply the deionized water. For more information
on water hardness, please contact with local water suppliers.
The antifreezing agent with correct concentration can prevent the engine from freezing
in winter, and provide the whole-year corrosion protection.
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60% concentration (applied under the extreme conditions)
Important: don’t exceed 60% concentration. In case of exceeding this percentage, its
protection functions will be reduced.
Introduction
Use water or steam cleaning machine, does not allow mud, debris and other loom.
1. In the device will be out of place must be cleaned, as the main job, or a job, the engine
and the whole machine around on the fuel system must be cleaned.
2. When the cleaning is completed, the machine away from the wash area, wash down or
remove something from the machine.
Important: after removing components, there will be exposed to dirt and debris. Cover all
openings before continue cleaning first, and remove the dirt.
Detergent
Avoid the use of high concentrations of detergent - always be diluted detergent according to
the manufacturer's recommendations, otherwise it will lead to damage to the paint.
Always follow local regulations deal with recommendations on the machine to clean dirt
off.
Caution
Do not use water or steam cleaning inside the cab. Because the water or the steam can
damage the plug-in unit type computer, causes the loom not to be able to operate. Use the
brush or the wet cloth for dusting.
Engines and some components may be high-pressure washing system damage, if you want
to use high-pressure washing system to clean the engine, you must take special precautions.
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Ensure alternator, starter motor and all electrical components have shields, not direct high-
pressure cleaning system for cleaning.
Important: Do not put the gun aligning bearings, oil pads, and electricity -related electrical
components, such as engine control units, alternator, and fuel injectors.
Use a low-pressure water gun, foam brush off caking mud and dirt.
Note: the machine after each pressure washing or steam cleaning, need to re- lubrication.
1. The machine parked on a firm, level ground, hang up the parking brake, set the drive in
space, reduce equipment to the ground, and stop the engine.
Important: Stop the engine and wait at least one hour with the engine cooling. While the
engine is running do not try to clean engine parts.
Warning
To avoid burns, dealing with the scorching element is wearing protective gloves. In order to
protect your eyes, use a steel wire brush cleaning element of time wear protective goggles.
Air suspended in the fire flammable particles, such as grass, wood chips, and so on, does not
allow the engine components or support shaft shield buildup. Always check the area, each
time the work shift when the Clean, if needed, more clean-up. To open the engine hood, the
top is free of debris.
When the engine is running; do not clean the engine components. Stop the engine and wait
at least one hour to let the engine cool down.
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b. Do not put directly at the fuel injector nozzle directly cleaning.
g. Electrical connector
h. Ensure alternator, starter motor and all the electrical components have been protected, and
not directly with the high-pressure cleaning system for cleaning.
2. Check all the pins are in the correct position, check that they are safe fastening
positioning element.
3. Ensure that all the steps and hand is not broken, solid and reliable.
7. Check the tires for damage and sharp objects that might have been stabbed in the case.
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Seat belts
Warning
If the machine equipped with seat belts, if damaged or belt worn, or the machine has just
had an accident, then replaced with new. Every three years for a new one.
Check the seat belt signs of worn and stretched. Check the stitch width and no pine damage;
check the buckle assemblies are not damaged, works fine.
Check the seat belt mounting bolts without damage, properly installed and tightened.
Warning
When working in a boom, boom could suddenly fall, resulting in serious injury or death.
Arising before any maintenance work is undertaken under the boom, jib safety rod is
installed.
You must climb up to the machine to install or remove the safety bar. Be careful, especially
machine wet slippery. Before try to climb out the dirt and oil. Do not bleed when the arm, it
will burn you.
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Installation
Before installing, first remove the load on the forks, and empty bucket or equipment.
1. Completely recovered arms (unless extended arm when the need for maintenance).
2. Stop the engine, make sure the parking brake mount, transmission in neutral, pull out the
ignition key.
4. Put the safety lever into the hydraulic lifting cylinder rod around B. Put to the safe
position.
5. In order to prevent the boom slowly slide your finger to pinch the boom to fall on the
safety lever.
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Attention: Careful reduces moves the arm, prevented harms the safety lever. The safety
lever supports to moves the arm weight stops immediately.
Detachment
1. Raises moves the arm, the safety lever does not support the weight.
2. Stops the engine, guarantees the parking brake to hang up, the gear box in the neutral
gear, draws out starts the key.
1. Place the engine on the solid and level ground, making sure the occlusion of the
parking brake and that the transmission is on neutral position. Lower down the accessories
to the ground, turn off the engine and pull out the start key.
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3. Dismantle the hollow bolt connecting the fuel filter and the low pressure oil pipe.
4. Dismantle the bolt connecting the fuel filter and the fixing bracket.
6. To fill to the new filter with clean diesel when replace the filter element, while keep the
filter base clean and apply lubricating oil in the rubber pad.
7. After the rubber pad contact to the base, and then tighten the 3/4 ~ 1 laps, so that it is
sealed.
8. Need to remove the exhaust screw on the filter base, press the hand pump on the
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Change the Element of Fuel Filter of the Engine
1. Place the engine on the solid and level ground, making sure the occlusion of the
parking brake and that the transmission is on neutral position. Lower down the
accessories to the ground, turn off the engine and pull out the start key.
Caution
Do not let the dirt into the fuel system. Perform thoroughly cleaning to the
connection before disconnecting the connection of any part of the fuel system. If some
element is disassembled, for instance the fuel pipe, it is required to equip with the
protective cap and the plug to avoid the entering of dirt. Non-compliance of these
explanations will lead to the entering of dirt into the fuel system. The dirt in the fuel
system will severely damage the fuel injection bubbler and lead to expensive
rehabilitation expense.
4. Use the special wrench of the fuel filter counter clockwise to remove the fuel filter.
5. Before install the new fuel filter, apply the oil evenly to the rubber seals.
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Fuel filter
Fuel filter
4.9 Lubrication
In order to guarantee the loom high efficiency the work, must to the loom regular
lubrication. The regular lubrication may enhance the loom the working life.
The loom must carry on the lubrication after the pressure clean and the steam clean.
Warning
Carries on these work time you need to approach the loom. If possible to reduce moves
the arm, draws out starts the key, separates the accumulator cell. This may prevent the
engine sudden start. Guarantee the parking brake already to hang up.
The raised arm possibly suddenly falls down, and causes the serious injury. Before
work under the raised arm, install well the arm safety lever. Refer to the maintenance
chapter Arm Safety Lever.
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It must be finished with an injection gun. Two-stroke injection gun is commonly
effective. When new grease escapes out of the joint, stop lubricating.
Each lubricated point is numbered in the illustration below. Report each number during
the lubrication. Reinstall the dust cover after finishing the lubrication.
Note: it may be required to lubricate some optional tools more frequently. Refer to the
option of optional tools.
In case of applying XCMG MPL grease, it’s required to lubricate every 10 hours for
50-hour operation.
In case of applying XCMG MPL grease, it’s required to lubricate every 50 hours for
500-hour operation.
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