操作与保养手册伸缩臂叉车XC6 3514K（英文版）

Operation and Maintenance Manual
XC6-3514K
Telescopic Handler
XCMG Special Construction Machinery Co., Ltd.

XC6-3514K Telescopic Handler
Foreword
This Operation and maintenance manual contains information and instructions for safe operation and maintenance
of your XCMG machine.
In the interest of yours and bystanders‘ safety as well as to prevent accidents and ensure environmental protection,
you shall:
- Carefully read the included information before use of the machine.
- Familiarize yourself with its content and.
- This Operation and maintenance manual is an integral part of the machine!
- Keep it on the machine at all times for reference!
- In case of damage or loss of this manual it is mandatory to replace it immediately!
Familiarize yourself with applicable safety regulations in your location and this manual as well as with the
machine.
This Operation and maintenance manual is not suitable reference for extensive maintenance and repair work. Such
work shall be performed by XCMG’s service personnel or authorized specialists.
The Operator´s safety is XCMG’s most important point of interest during XCMG’s efforts in designing,
producing and maintaining their products.
Please note that improper application or maintenance may increase the risk of hazards.
Therefore, always operate and maintain your XCMG machine according to the instructions in this Operation and
maintenance manual.
Doing so you will increase the reliability and availability of your machine.
Immediately repair the defective telescopic handler to guarantee the operating safety and environmental
protection.
1-I
Declaration from The Manufacturer:
◆ Only the trained and authorized people can operate and service this equipment.
◆ Operator and relative people must wear necessary safety protection staffs and take necessary safety
measurement.
◆ Don‘t take any operation that is forbidden in this manual under any condition.
◆ Manufacturer can‘t predict all the working environment in which latent danger exists and operation that may
cause danger. If you do the operation that is not mentioned in this manual, please ensure that this operation
will not damage to the operator, other people and this equipment. If you can‘t ensure safety of such operation,
please stop working and consult with XCMG CONSTRUCTION MACHINERY CO., LTD. or its authorized
agent.
◆ The manufacturer will not be responsible for the casualty, injury and damage caused by using this equipment
beyond this equipment purpose and regulations of operator‘s manual.
◆ The accessories licensed by our company or our designated distributors shall be used. The use of unlicensed
accessories may cause safety problems and affect the normal operation and service life of the machine.
XCMG Construction Machinery Co., Ltd. assumes no liability for the damages, accidents and machine
breakdown caused by the use of unlicensed accessories.
◆ The unauthorized restructuring to the machine can cause danger, and manufacturer will not be responsible for
the damages caused by unauthorized restructuring.
◆ Some details shown in the pictures or diagrams in this manual or some optional components listed may be
different from your machine. Other components that are irrelevant to the instructions may have been
removed from the pictures or diagrams to facilitate illustration;
◆ This manual may not include the changes made to the machine due to the improvements and upgrades of the
product design. This may result in the inconsistency between this manual and the machine purchased and
influence the maintenance of the machine. Read and study this manual carefully and compare with the
machine;
◆ For further information about the machine or if you have any questions about this manual, please consult our
company or the machine distributor.
◆ Observe the national and local laws and regulations during the operation, maintenance and repair of this
machine.
CAUTION!
— Before driving on public roads, please check to see if the machine meets the requirements of the local laws
and regulations for road travel and obtain the road travel permission of relevant managerial departments.
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XCMG representative‘s contact data:
Address: West of Guangde Road, Economic Development Zone, Xuzhou, Jiangsu, China
Sales Tel: +86-516-83111320
Sales Fax: +86-516-83111363
Service Tel: +86-516-87560286
Service Fax: +86-516-83111363
Spare Parts Tel: +86-516-87560286
Spare Parts Fax: +86-516-83111363
Technical Service: +86-516-83111320
Post Code: 221004
Service Hotline: 400-110—9999
Web Sites: http://www.xcmg.com/
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Copyright:
Manufacturer XCMG Construction Machinery Co., Ltd.
Date of Issue 202302
Version N°. V01
XCMG Construction Machinery Co., Ltd.©
Any complete or partial reproduction of this document without prior written

Copyright
permission from XCMG is prohibited.
All technical data, drawings, documentation and etc. are subject of copyright.
Data contained in this Operation and maintenance manual meets the current
Update
state-of-the-art
XCMG reserves the right to improve or modify the content, information, diagrams and specifications in this
Operation and maintenance manual at any time and without any notice.
1-IV
Table of Contents
1 About this Document ................................................................................................................................10

1.1 Main purpose ................................................................................................................................... 10
1.2 Product information ..........................................................................................................................11
1.3 Target group(s)................................................................................................................................. 12
1.4 Warning notices ............................................................................................................................... 12
1.5 Symbols and text-structure of this manual....................................................................................... 13
1.5.1 Additional types of text............................................................................................................ 13
1.5.2 Additional information ............................................................................................................ 14
2 Product description ...................................................................................................................................16
2.1 General description .......................................................................................................................... 16
2.2 Intended Use of the Machine ........................................................................................................... 17
2.2.1 Description and general information ....................................................................................... 17
2.2.2 Unintended Use of this Machine.............................................................................................. 18
2.3 Reasonably foreseeable misuse ....................................................................................................... 18
2.4 Forbidden operation ......................................................................................................................... 19
2.5 Limits of application ........................................................................................................................ 20
2.5.1 Impeding factors for intended use............................................................................................ 20
2.5.2 Space boundaries ..................................................................................................................... 20
2.5.3 Time related limits ................................................................................................................... 20
2.5.4 Environment-related limits ...................................................................................................... 20
2.5.5 Permitted environmental conditions ........................................................................................ 21
2.5.6 Environmental protection and disposal .................................................................................... 21
2.6 Residual risks ................................................................................................................................... 22
2.6.1 Environmental risks due to: ..................................................................................................... 23
2.6.2 Personal injury or even death due to: ....................................................................................... 23
2.6.3 Risks of damaging the machine and property due to: .............................................................. 24
2.6.4 Performance and service life reduction due to: ........................................................................ 24
3 General Safety Information and Instructions ............................................................................................26
3.1 Introduction...................................................................................................................................... 26
3.2 Responsible parties .......................................................................................................................... 26
3.3 Detailed tasks and responsibilities ................................................................................................... 27
3.3.1 General requirements for all responsible parties...................................................................... 27
3.3.2 The manufacturer‘s responsibilities ......................................................................................... 28
3.4 Personal protection equipment (PPE) .............................................................................................. 29
3.5 Hazards and risks of injury .............................................................................................................. 30
3.5.1 General precautions ................................................................................................................. 30
3.5.2 Fire and explosion hazards....................................................................................................... 30
3.5.3 Lighting strike .......................................................................................................................... 33
3.6 Safety distance ................................................................................................................................. 39
3.6.1 Power cables ............................................................................................................................ 39
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3.7 How to act in dangerous situations .................................................................................................. 39

3.7.1 If the machine contacts with a power supply line .................................................................... 39
3.7.2 In case of fire ........................................................................................................................... 40
3.8 Safety signs and labels ..................................................................................................................... 42
3.8.1 Introduction.............................................................................................................................. 42
3.8.2 Mandatory signs ....................................................................................................................... 42
3.8.3 Prohibition signs ...................................................................................................................... 44
3.8.4 Warning signs .......................................................................................................................... 45
3.8.5 Rescue signs............................................................................................................................. 47
3.8.6 Fire protection signs................................................................................................................. 47
3.9 Machine-specific signs and labels ................................................................................................... 48
3.9.1 Introduction.............................................................................................................................. 48
3.9.2 Machine-specific warning signs .............................................................................................. 48
4 Safe Operation Guidelines ........................................................................................................................55
4.1 General Safety Rules and Advices ................................................................................................... 55
4.2 Installation and assembly ................................................................................................................. 57
4.2.1 Requirements for installation and assembly personnel ............................................................ 57
4.2.2 Requirements for the Installation Site...................................................................................... 57
4.2.3 Assembly of the Machine ........................................................................................................ 57
4.3 Installation of accessories and other safety instructions .................................................................. 58
4.4 Commissioning ................................................................................................................................ 60
4.4.1 Requirements for Commissioning Personnel........................................................................... 60
4.5 Safety on the construction site ......................................................................................................... 61
4.6 Safety on the construction site ......................................................................................................... 70
4.6.1 Risk in special operating conditions ........................................................................................ 71
4.7 Safety for Children .......................................................................................................................... 72
4.8 Operator‘s Safety ............................................................................................................................. 73
4.8.1 How to board/leave the machine in a safe way........................................................................ 73
4.8.2 In the drivers's cabin ................................................................................................................ 75
4.8.3 Check FOPS/ROPS structure................................................................................................... 75
4.8.4 Starter Battery Handling .......................................................................................................... 76
4.8.5 Jump-starting the engine using auxiliary cables ...................................................................... 76
4.9 Pre-inspections tasks before machine operation .............................................................................. 76
4.9.1 Pre-operation safety rules ........................................................................................................ 76
4.9.2 Location of safety signs on the machine .................................................................................. 78
4.9.3 Daily inspections and visual checks before operation ............................................................. 81
4.9.4 Engine start check-list .............................................................................................................. 83
4.9.5 Engine Starting process ........................................................................................................... 84
4.9.6 Inspection after starting the engine .......................................................................................... 85
4.9.7 Inspection before starting machine operation .......................................................................... 86
4.9.8 Checking and maintaining before and after working ............................................................... 86
4.10 Safe operation of construction work machines ................................................................................ 87
4.10.1 Recommended use for construction work................................................................................ 87
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4.10.2 General hazards........................................................................................................................ 88

4.10.3 Operational hazards ................................................................................................................. 89
4.10.4 Safety rules for towing operations ........................................................................................... 91
4.10.5 Forbidden Operation ................................................................................................................ 91
4.10.6 Risk in special operating conditions ........................................................................................ 93
4.10.7 Optional components/ equipment ............................................................................................ 97
4.10.8 Hazards handling the battery ................................................................................................... 98
5 Operation ................................................................................................................................................101
5.1 General overview of the machine: ................................................................................................. 101
5.1.1 Introduction............................................................................................................................ 101
5.1.2 Basic functional description................................................................................................... 103
5.2 Operating conditions ...................................................................................................................... 104
5.2.1 Operating limits ..................................................................................................................... 104
5.2.2 Environmental Machine limits ............................................................................................... 104
5.3 Control elements - Dashboard - Display overview ........................................................................ 105
5.3.1 Control elements .................................................................................................................... 105
5.3.2 Dashboard .............................................................................................................................. 107
5.3.3 Illumination and signal lamps ................................................................................................ 109
5.3.4 Adjust the steering column .....................................................................................................110
5.3.5 Selection of Traction Force .....................................................................................................110
5.3.6 Selection of Gear ....................................................................................................................110
5.3.7 Traveling Direction Selection ................................................................................................. 111
5.3.8 Traveling Direction Selection .................................................................................................112
5.3.9 Steering Mode Selection .........................................................................................................112
5.3.10 Operations of Joysticks/Switches ...........................................................................................113
5.3.11 Multifunctional Control Handle ............................................................................................. 120
5.3.12 Control Switch Group ............................................................................................................ 122
5.3.13 Rear mirrors ........................................................................................................................... 124
5.3.14 HVAC Controls ...................................................................................................................... 125
5.3.15 Brake and Accelerator Pedals ................................................................................................ 128
5.3.16 Fire Extinguisher.................................................................................................................... 129
5.3.17 Main battery insulation switch ............................................................................................... 131
5.4 ROPS & FOPS Cab ....................................................................................................................... 133
5.5 Illumination.................................................................................................................................... 133
5.5.1 Rear Combination Lamp ........................................................................................................ 134
5.5.2 Light switches ........................................................................................................................ 134
5.6 Operator's Seat ............................................................................................................................... 137
5.6.1 Seat adjustment ...................................................................................................................... 137
5.6.2 Seat Belt ................................................................................................................................. 138
5.7 Engine start and shutdown ............................................................................................................. 140
5.7.1 Starting engine ....................................................................................................................... 140
5.7.2 Engine and Warm up Period .................................................................................................. 143
5.7.3 Jump-starting engine .............................................................................................................. 144
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5.8 Operate the machine ...................................................................................................................... 146

5.8.1 Before operation .................................................................................................................... 146
5.8.2 Getting on Telescopic Handler ............................................................................................... 147
5.8.3 Start of Telescopic Handler .................................................................................................... 150
5.8.4 Traveling of Machine ............................................................................................................. 151
5.8.5 Operation Instructions of Machine ........................................................................................ 155
5.9 Braking and Stop of Telescopic Handler ....................................................................................... 176
5.9.1 Braking and Stop ................................................................................................................... 176
5.9.2 Brake System ......................................................................................................................... 177
5.9.3 Parking and Shutting down the engine .................................................................................. 178
6 Maintenance............................................................................................................................................181
6.1 Safety during maintenance............................................................................................................. 182
6.2 Inspection checks before starting maintenance .............................................................................. 186
6.3 Lubrication and Repair .................................................................................................................. 192
6.3.1 Correct procedures of maintenance and check ...................................................................... 192
6.3.2 Fluid Chart ............................................................................................................................. 193
6.4 Maintenance and lubrication .......................................................................................................... 194
6.4.1 Lubrication period.................................................................................................................. 194
6.4.2 Periodical maintenance .......................................................................................................... 196
6.4.3 Inspection and adding of oil................................................................................................... 199
6.4.4 Precautions for Fuel, Oils, and Fluids .................................................................................... 202
6.4.5 Checking and maintaining components ..................................................................................211
6.4.6 Structural principle and maintenance precautions ................................................................. 229
6.5 Fluids and grease qualities & quantities ........................................................................................ 246
6.6 Special Maintenance Conditions ................................................................................................... 247
7 Faults and Troubleshouting.....................................................................................................................248
7.1 Power System ................................................................................................................................ 248
7.1.1 Engine system ........................................................................................................................ 248
7.1.2 Transmission System ............................................................................................................. 248
7.2 Steering System ............................................................................................................................. 249
7.3 Electrical System ........................................................................................................................... 250
7.4 Braking System .............................................................................................................................. 251
7.5 Hydraulic system ........................................................................................................................... 252
7.6 A/C system..................................................................................................................................... 253
8 Transport, Storage and Protection...........................................................................................................255
8.1 Transport on Public Roads ............................................................................................................. 255
8.1.1 General Requirements............................................................................................................ 255
8.1.2 Transport Requirements ......................................................................................................... 256
8.1.3 Loading and unloading instructions ....................................................................................... 258
8.1.4 Transport Lashing .................................................................................................................. 260
8.2 Lifting the machine ........................................................................................................................ 262
8.3 Driving on the public roads ........................................................................................................... 266
8.4 Parking, Storage and Protection..................................................................................................... 267
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8.4.1 Parking ................................................................................................................................... 267

8.4.2 Daily and short-term storage and protection .......................................................................... 268
8.4.3 Mid-term storage (up to 4 weeks) .......................................................................................... 269
8.4.4 Long-term Storage (Longer than 1 month) ............................................................................ 269
8.4.5 Use preparation after storage ................................................................................................. 270
8.4.6 Oil and Water supplying ........................................................................................................ 271
9 Cleaning ..................................................................................................................................................277
9.1 Cleaning the Machine .................................................................................................................... 277
9.2 The detailed cleaning process ........................................................................................................ 280
9.2.1 Cleaning the driver's cabin ..................................................................................................... 280
9.2.2 Cleaning the exterior of the machine ..................................................................................... 280
9.2.3 Cleaning the engine compartment. ........................................................................................ 281
10 Technical Specifications/Performance Data ...........................................................................................282
10.1 Operating limits ............................................................................................................................. 282
10.2 Overall dimensions and specifications........................................................................................... 282
10.3 Oil capacity .................................................................................................................................... 285
10.4 Nameplates .................................................................................................................................... 285
10.4.1 Machine nameplate ................................................................................................................ 285
10.4.2 Engine nameplate ................................................................................................................... 286
10.4.3 Other nameplates ................................................................................................................... 287
10.5 Emissions ....................................................................................................................................... 287
10.5.1 Engine emissions ................................................................................................................... 287
10.6 Hydraulic schematics ..................................................................................................................... 288
10.7 Electric schematics ........................................................................................................................ 295
11 Decommissioning and Disposal..............................................................................................................302
11.1 Decommissioning and disposal guidelines .................................................................................... 302
11.2 Disposal ......................................................................................................................................... 302
11.3 Properly disassemble the unit ........................................................................................................ 302
11.3.1 Disassembly personnel: ......................................................................................................... 302
11.3.2 Precautions for disassembly................................................................................................... 303
11.4 Disposal ......................................................................................................................................... 304
12 Warranty .................................................................................................................................................305
1-IX
1 About this Document

This chapter includes important information regarding the use of this Operation and maintenance manual.
1.1 Main purpose

This Operation and maintenance manual includes safety, operation and regular maintenance instructions for the
machine. Further documents and manuals may be attached if necessary.
This Operation and maintenance manual supports you in:

- Getting familiar with your machine.
- Reducing probability of risks and hazards.
- Preventing incorrect operation, unintended use and foreseeable misuse.
- Improving your machine‘s reliability and availability.
- Reducing maintenance costs.
−
Following the instructions of this Operation and maintenance manual is mandatory.
- This Operation and maintenance manual is intended for persons operating and maintaining the machine.
- Additionally to it, you shall adhere to rules and regulations applicable at your location.
- It is mandatory to keep this Operation and maintenance manual always available to operators and
maintenance personnel, at the machine. Store it at the designated storage location (see 错误!未找到引用
源。).
- For repair and maintenance supplementary documents may apply (i.e. for the engine), please contact your
XCMG representative for further information.
Figure 1-1:
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Designated storage location of this operation and maintenance manual on the machine is the compartment behind
seat
Before operating, maintaining or repairing any machine part:

- read carefully and master the content of this Operation and maintenance manual.
- learn how to correctly operate and maintain the machine.
- note the instruction for use‘s safety information, the safety signs attached to the machine and how both are
related.
- understand the safety requirements and their purpose.
- The documentation supplied with the machine shall enable the reader to:
- operate the machine safely.
- use it in all permitted situations.
- maintain/service the machine within the required schedules.
−
NOTICE! Please read the Operation and Maintenance Manual.
- To prevent accidents during operation or maintenance, always comply with all the precautions
measures specified in this operation and maintenance manual
 Keep the documentation always complete, up to date and available if needed:

- Do not remove individual pages from the operation and maintenance manual.
- Request any missing or uncomprehensive parts of the operation and maintenance manual from XCMG
after sales service.
- Include new documents supplied as a result of modifications immediately.
- Replace obsolete versions of the operation and maintenance manual by the amended contents.
- The delivered documentation is compiled for the indicated serial number.
- It may not be used for machines of the same series with different serial number.
NOTICE! Please read the Operation and Maintenance Manual.
 Operation and maintenance manual is considered as a construction part of the machine!
1.2 Product information

XCMG produces and delivers high quality products. Your machine and its components have been through
numerous inspections before assembly and delivery, ensuring compliance to XCMG’s high company standards.
You can maintain reliability and prolong availability by following the instructions of this operation and
maintenance manual, by correct use and careful maintenance. Use only genuine XCMG spare and wear parts.
11
Within warranty period, XCMG’s specialists as well as our representatives will help you in repairing or even
maintaining your machine. Please refer to your warranty conditions attached to your purchase contract.
After warranty period elapsed, XCMG will continue to provide our services to you, helping you maintaining the
machine in best condition through its entire lifetime.
 Warranty claims cannot be accepted in case of:
- Operation faults and operations not in line with this operation and maintenance manual.
- Use of wrong consumables.
- Deficient maintenance.
- Maintenance/repair errors by service personnel not authorized by XCMG.
- In case of use of non-genuine XCMG parts.
- In case of not XCMG approved modifications of the machine.
- Resulting damage/defects due to delayed warranty request or repair.
 Follow-up damage is unexceptionally excluded from warranty.

1.3 Target group(s)
This operation and maintenance manual is intended for use by:

- owners;
- all operators;
- personnel conducting maintenance and overhaul or repair of the machine.
- Refer to the Section 3.2 and Section 3.3.
 Make this operation and maintenance manual accessible to all persons who operate or work with this
machine.

1.4 Warning notices

Hazard severity graduation – decrease as follows:
DANGER! Short hazard description!
− Indicates an imminent and inescapable danger that causes certain death if not prevented.
WARNING! Short hazard description!

− Indicates a possible danger that may cause death or at least serious irreversible injuries if not avoided or
prevented.
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CAUTION! Short hazard description!
− Indicates a possible danger that may cause light or moderate reversible injuries if not avoided or prevented.
NOTICE! Short hazard description!
− Indicates a situation that may cause property or environmental damage if ignored.
1.5 Symbols and text-structure of this manual

Indicates a single instruction or a regulation to be observed (e.g. for safety reasons).
 Indicates a complex instruction for action containing several steps or bundled regulations be observed
simultaneously (e.g. for safety reasons). Indicates any information content for the user that does not
require his action.
− additional safety measures for a hazardous task/process
− further detailed explanations to a complex matter
− hazardous consequence(s) due to ignored warnings or previous action(s).
−
1.5.1 Additional types of text
1.5.1.1 Instructions for action
 Structions for action are demanding you to undertake an activity or to carries out a work step.
− Always carry out Instructions for action stepwise and in pre-defined sequence.
 Handling instructions are structured as follows:

− Guideline for one instruction
− Result of action – if required
−
13
1.5.1.2 Lists
— Not-numbered Lists are structured as follows:

− List-Level 1
— List-Level 2
– Numbered Lists are structure as follows:
1. List Level 1
2. List Level 1
2.1. List-Level 2
2.2. List-Level 2
2.3. …
3. (List level 1) …etc.
1.5.2 Additional information
Illustrations only serve for additional or more detailed information and may differ from the actual product or
scope.
1.5.2.1 Figures
- Figures and associated postiton numbers are given in bold in the text.
- Position lines pointing to a certain spot in an image end with:
 A dot, if they denote visible parts
 An arrow, when pointing to towards invisible/indicated direction
1.5.2.2 Dimension unit
− Dimensions are given in metric, ISO units.

−
1.5.2.3 Applicable documents
- Pay attention to additional documents as repair and maintenance documents of equipment that may apply (i.e.
for the engine or other additional equipment installed).
14
1.5.2.4 Accessibility
− Make the contents of this Operation and maintenance manual including the applicable documents available to
all persons who operate or work with this machine.
15
2 Product description
2.1 General description

− XC6-3514K telescopic handler is equipped with high performance parts and is applied with high-strength
structure of innovative technologies to guarantee the stable quality and reliability of the machine. It‘s a really
highly efficient machine.
− This machine can be equipped with diversified attachments, including forks, bucket, hook, and aerial work
platform. No matter for new building, roof, and covering constructions or renovation and repair works, this
product is one essential tool for modern buildings.
−
Figure 1-2: Exterior of Machine
16
2.2 Intended Use of the Machine

2.2.1 Description and general information
 The Intended use defined in this Section is a basic requirement to ensure the safe operation of this
machine or any other one on a construction site.
- This telescopic handler is designed in compliance with recognized standards (i.e.: ANSI B56.6) and
manufactured according to state-of-the-art methods and technologies during its placement to the market.
- The Intended application of this machine applies exclusively to its construction and all purposes its overall
description mentioned above.
- Move the machine with extra care.
- If necessary, ask a co-worker for supervision and marshalling.
- Operate and park the machine only on surfaces capable of supporting its weight.
- Observe the installation and safety requirements specified in the technical documentation at any time.
- Any use disregarding the contents of the documentation of the machine is concidered as ―unintended use‖.
- Intended application of the machine only refers to its installation and the above-mentioned purposes.
- Utilisation is limited to the work areas and conditions of use described in this operation and maintenance
manual.
- Use fences and other barrage equipment to prevent unauthorized access to the work area this machine is used
in (e.g.: by children or other unqualified people).
 Ignoring the rules of intended use defined above may result in the following consequences:
- Life-threatening or other irreversible injuries
- Severe damage to the machine, the assets or environmental contamination which the owner/operator may be
held liable for.
 Loss of warranty and guarantee claims
- The machine may only be operated in enabled setup condition and modes as provided in this operation and
maintenance manual for operation and maintenance.
- Any application not described in this operation and maintenance manual must be authorized in writing by the
manufacturer beforehand.
- Any divergent use without the manufacturer‘s written approval is considered as ―unintended use‖.
- All associated risks, Injuries or damage resulting from improper use or misuse of the machine are the owner‘s,
operator‘s, or user‘s (whoever is in charge) sole liability.
This also applies to unauthorized modifications to the original product.
 Refer to the information in Section, Technical Specification and Performance Data. Comply with this
information completely. Compliant intended use requires all the following conditions to be met:
- Install all protective devices properly and verrify their correct function.
- Provide and carry out all maintenance and repair tasks according to the specifications prescribed in this
operation and maintenance manual.
- Only assign maintenance or repair tasks to maintenance personnel according to their respective skills and
knowledge.
- Comply with all contents of this operation and maintenance manual to ensure safe operation of the machine at
all times.
- Also apply all valid local, national and international safety regulations not stated in this manual.
17
- Only use the opperating supplies described in this operation and maintenance manual.
- Always take all the technical data and their limit values listed in this operation and maintenance manual into
account (including the machine model and its respective maximum loads) to prevent any obvious personal
injuries or erquipment damage.
2.2.2 Unintended Use of this Machine
 The machine is not intended to be used:

- as transport vehicle for persons),
- on unstable surfaces (e.g.: uneven ground with potholes, dug pits or steep slopes),
- in areas with explosion hazards, and
- areas with insufficient ventilation (i.e.: within closed spaces).
 Any use other than described as intended in this section is not authorized by the manufacturer and is
beyond the legal limits of his liability.
2.3 Reasonably foreseeable misuse

- Reasonably foreseeable misuse includes the use of machinery in a way not mentioned in the operation and
maintenance manual, but which may result from readily predictable human behavior.
- This includes any undeclared application or type of misuse listed in this manual.
- Basically, state-of-art-technologies can anticipate and prevent several of these "foreseeable misuses", but not
all misuses can be managed by technology alone.
- Misuse or improper use of the machine may lead to severe injuries or death and consequently to expiration of
the warranty!
- The machine operator and /or owner will be held fully responsible for all damages caused by any ―unintended
use‖ of their machine.
- Any use that is not described in this operation and maintenance manual is considered as ―unintended use‖.
 Reasonably foreseeable misuse is considered as - but not limited to:
- Failing to abide by, or imntentionally ignoring, the regulations prescribed in this operation and maintenance
manual.
- Operating the machine while the operation and maintenance manual is either lost, incomplete, or not available
in the contractually agreed language.
- Operating the machine by uninstructed or unqualified personnel.
- Operating the machine while ignoring safety requirements applicable at your area of work.
- Exposing the machine to physical quantities exceeding its limits defined by the manufacturer in its technical
data (e.g.: ambient work temperature, ASL-altitude, carried load, surface restrictions during operation (e.g.:
Lateral and transversal surface gradient))
Refer to Section 10: Technical Specifications/ Performance data

− Reflexive actions during operation (e.g: due to imminent danger or startle).
− Transporting materials and/or passengers in an unintended manner.
− Towing loads.
− Place items and additional weight on the work guardrail.
18
− Operating the machine from the control unit on the ground while people are on the platform.
− Operating the machine without being buckled-up properly.
− Removing of bypassing the protection equipment.
− Perform maintenance or repair tasks while the motor is running or the machine is (still) unsecured.
− Operating a machine that is not functioning properly.
− Moving the machine at low vision without a supervising coworker.
− Attaching any interchangeable equipment that may unbalance the machine without the manufacturer‘s written
declaration of approval.
− Skip or delay the maintenance intervals or ignore other related instructions
− Skip or delay repairs and activities meant to prevent or to detect damage.
− Improper maintenance or repair work.
− Use of unapproved spare parts.
− Carrying out unauthorized structural modifications to the machine.
− Cleaniuung the machine with inappropriate high-pressure cleaners and/or use inappropriate cleaning agents
and other devices.
− Transporting the machine without properly securing it on the transport vehicle.
− Parking or storing the machine unsafely (on uneven or britle ground) or facilating unothorized access (leaving
it unlocked or forgetting the ignition key inside)
− Using Open fire or smoking while handling flammable materials (i.e.: when refueling.)
2.4 Forbidden operation

 Operating the machine without clear knowledge of the machine functions! Learn and
undersatand all functions of the machine before the first operation.
− Operating the machine is forbidden in case it doesn‘t work as to be expected or hasn't been correctly
maintained.
− To carry out tasks or actions which will unballance the machine.
 In particular, it is forbidden:
− To use the machine to push other object.
− To change or disable the machine components, affecting the safety and stability.
− To use components with different weight or specifications to replace the components affecting the machine
stability.
− To use tyres or air tyres with different specifications to replace the original tyres. The wheel weight is critical
to the stability.
 The original tyre shall be used. Use of other types brands to replace the originally used
standard tyres need approval from XCMG.
− To use any additional equipment to increase the maximum extension length.
− Do not board or leave the platform in any way while it is raised or lowererd.
 Without prior approval of the manufacturer, it is forbidden to carry out any modifications or upgrades
to the original machine.
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2.5 Limits of application

2.5.1 Impeding factors for intended use
− Scope of application (refer to section 4.2).

in accordance with the operator‘s experience and knowledge of the machine (industry, commerce, private,
public sector)
− Intended use (refer to section 2.2).
(refer to specifications in the operation and maintenance manual)
− Unintended use
(refer to Section 2.2)
− Reasonable Foreseeable Misuse
( refer to section 2.3)
− Various steps within the product life cycle
− (i.e.: assembly, commissioning/delivery, set up, regular operation, cleaning, maintenance & servicing,
appropriate disposal)
− The operator’s skills, experience and knowledge
Operator, maintenance personnel in terms of training, experience, skills
− Inexperienced/more vulnerable people
− Vulnerable groups (e.g.: apprentices, pregnant women, volunteers, disabled persons with health conditions)
− Collateral damages
unrelated to the company
(e.g.: employees from other companies, visitors etc.)
2.5.2 Space boundaries
− Safety ranges/distances during movement/deployment

− Safety boundaries for people during installation and maintenance
− Material supply/removal
− Working places/area Interfaces
2.5.3 Time related limits
− Limits of the service period of the whole machine or specific components

− Recommended inspection, maintenance and repair intervals
2.5.4 Environment-related limits
The following environmental factors define the limits for the safe operation and the performance of the
machine:
 Environment-related limits (restrictions due to specific environmental conditions)
− weathering,
− altitude,
20
− slope inclination, steepness
 Energetic limits
− Types of energy
− Quality of energy
− Supply/discharge- Interfaces
 Material limits
− Supply/discharge- Interfaces
− Starting materials/auxiliary opperating supplies, waste products.
2.5.5 Permitted environmental conditions
 Take environmental conditions into account to ensure the safe operation of the machine, improve
its reliability and lenghten its life span.
CAUTION! Never exceed the values listed on the data sheet!

− Maximum ground loading.
− Lateral or the longitudinal inclinations.
Only operate or park the machine on ground stable enough to carry its maximum applicable load.
Environmental temperature influences the behaviour of the machine, especially its acceleration,
deceleration and stopping.
Check and adjust all the operating fluids of the machine (viscosity, amount of fuel, hydraulic oil, coolant
antifreeze, etc.) to your local weather conditions.
Avoid replacing the battery at temperatures below 0°C. of the machine.
2.5.6 Environmental protection and disposal
− Comply with the local environmental proctection rules and regulations.

− Dispose of all materials (packaging, replaced maintenance and wear parts, cleaning agents, residual fluids,
etc.) according to the local environmental prevention regulations by using the locally available recycling
systems.
− Turn the maschine off whenever it is not needed.
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2.6 Residual risks

 Operational safety is ensured by following the instructions provided in this manual and observing the
warning signs labeled on the decals of the body of the machine.
 Foreseeing all possible hazards involving the machine is near to unfathomable. However, the residual
risks that were already known when designing this operation and maintenance manual should all be
mentioned inside of it. This includes especially those which:
− Have a significant impact on both the functionality of the machine and the opperator‘s health.
− Have a highly enough probability of occurrence.
 The Set-up work may require a disassembly of the protective equipment by the customer, resulting in
miscellaneous residual risks and potential hazards every operator must be aware of.
DANGER! Dangerous hazards during machine operation!
− Automatic motion sequences of the machine during operation, persons can be crushed in a life-threatening
manner.
− Install and approve the function of crane protective devices before to commissioning.
− Never enter the protective area during automatic operation.
DANGER! Danger due to electric shocks!
 Electric shocks may cause fatal injuries or death.
− Stop the maschine with the emergency stop before doing anything else.
− Use the main disconnection device to de-energize the machine before to any repair, set-up, or maintenance
work.
− Secure the machine against inadvertent activation.
− Close off the main disconnection device and put-up warning signs.
WARNING! Danger of slipping, skidding or falling!
 Weather influences (wetness, snow, ice, frost, dirt) may make the treads, walkways, and handrails
slippery, which can lead to:
− Serious injuries or even death of workers
− Up to heavy damage to the machine
22
 Contamination of the road due to leakage (fuel, hydraulic oil, etc) may lead to fatal accidents:
− Remove traces of oil or fuel on sight thoroughly.
− Mind the weather conditions when walking on the machine, (e.g.: frost, wetness, or dirt).
− Only access or bord the machine through approved walking/treading areas.
− Observe all safety signs and labels.
− Replace damaged safety signs and labels immediately.
WARNING! Danger of burns!
 Contact with surfaces of heated components may cause serious burns!

− This applies to the exhaust systems, the engine and the respective gearboxes in the boom‘s turntable and the
machine.
− Let the components cool off before touching them.
− Stay focussed when working close to heated components.
 Residual risks are likely to happen in the following situations:
2.6.1 Environmental risks due to:
− Misuse or wrong operation (see above).

− Superflous generation of noise and exhaust gas by keeping the engine running needlessly.
− Use of unsuitable consumables, wear and spare parts.
− Insufficient maintenance and/or repairs.
2.6.2 Personal injury or even death due to:
− Ignoring the local guidelines, requirements, and directives of Occupational Health and Safety.
− Misuse or wrong operation (ignoring the content of this operation and maintenance manual).
− Improper machine transportation, (Use of unsuitable transport means or lack in securing measures.
− Continuing work with worn out parts (e.g: delay in, or deliberate refusal to replacing them.)
− Operation under influence of medication, drugs, alcohol, or any other substance impairing the fitness for
work.
− Operation of the machine by unqualified people (e.g.: due to lack of required knowledge or taining, or due to
a physical handicap preventing safe operation).
− Dirty or damaged warnings on the machine, including slippery substances on the access areas (steps, handles,
etc.), unreadable or damaged safety decals and operation elements.
23
− Insufficient securing of the machine when parked, maintained, serviced, or repaired.

− Insufficient safety precautions at the work area.
− Insufficient use of personal protective equipment.
− Smoking and/or using open fire when handling flammable substances (i.e.: The engine fuel or oil during
refueling).
− Refueling while engine is running or spilling fuel over hot surfaces.
2.6.3 Risks of damaging the machine and property due to:
− Misuse or wrong operation

not complying to the guidelines of this operation and maintenance manual.
− Operation of the machine in or on inadequate environment (on structures with insufficient load-bearing
capacity or not bearing vibration impact during operation).
2.6.4 Performance and service life reduction due to:
− Misuse or wrong operation (see above).

− Extended idling (i.e.: keeping the engine runing needlessly).
Figure 2-3 Take note of the local Occupational Health and Safety regulations.
24
Figure 2-4 Take note of safety precautions and devices installed at your site.
Figure 2-5 Use P.P.E refer to local Occupational Health and Safety regulations.
25
3 General Safety Information and Instructions
3.1 Introduction
To prevent personal injury or property and/or environment damage observe and respect the safety instructions
stated in this Section.
Take note of and comply with all safety instructions.
3.2 Responsible parties
This operation and maintenance manual defines the various stakeholders as follows to enable a better distinction
of their respective professional purposes and their relationships to each other:
a) Manufacturer: The producer of a certain kind of unit(s) or machine(s) (i.e.: XCMG)

b) Dealer: a partner and official reseller of machines produced by a manufacturer
c) Owner: A person, company or other entity using machines he or she bought from a manufacturer or a
reseller
d) User: any party making use of a product of XCMG. This group may include manufacturers, owners,
operators, and maintenance personnel
e) Operator: A person officially authorised to operate a machine who has been instructed or trained to do so.
f) The maintenance personnel
g) Lessor: A person or party lending machines to a construction company or a project manager to carry out his
project.
h) Lessee: The party borrowing machines or other tools from a lessor to carry out their task, project, or mission.
i) Agent: A company representative whose tasks are the support of company customers.
 The manufacturer, as well as the Dealer
− Is a natural or juristic person/entity responsible to deliver products (i.e.: machines) and their accesories in a
technically safe and operational condition;
− supports the product‘s performance, maintenance and repair in all periods of its life cycle;
− supports the operational state of the unit via a worldwide maintenance and repair service;
− offers training for the owner‘soperation and maintenance personnel as a service.
 The owner:
− is a natural or juristic person/entity who owns permanently or temporaryly a (set of) machine(s), with legal
rights, duties and responsibilities, and:
− either: uses those purchased or lent machines to manage a job on a work or construction site (e.g.:
Construction Company)
26
− or: generates sales merely through the distribution of these machines ( e.g.: Reseller or renter).
 The operator:
− a natural person in charge for a specific job/ project and the respectively needed machine, (eg.: an individual
specialised in installing, adjusting, operating, maintaining, cleaning, repairing, or transporting the machine) or
− a driver, who is able to move a macjhine, but does not necessarily knbow all of its functions (comparerd to a
trained/instructed operator).
− a company that operates technical equipment, ( e.g.: juristic user/entity)
 Maintenance Personnel/Service Provider:
− The natural person(s) responsible for the proper function of the machine and all processes affecting it (i.e.:
maintenance, overhaul, repairs, testing, control adjustments, modifications, etc.)
3.3 Detailed tasks and responsibilities
3.3.1 General requirements for all responsible parties
 Any responsible party involved should be committed to:
− Making use of and complying with all instructions stated in this operation and maintenance manual to ensure
safe operation
− Notifying all involved parties of any safety-related defects observed on the machine.
− Checking the machine for damage and malfunctions every day before operation and notify the responsible
XCMG-branch or their supervising manager on any defects.
− Wearing PPE as recommended or required st their work site/area.
− Operating any machine correctly, meaning according to the intended use and the parameters prescribed in this
operation and maintenance manual.
− Stopping work with a machine immediately if its safe operation is not or no longer guaranteed.
− Repair/maintain the machine appropriately before any further operation in case of defects.
 Only qualified and authorized personnel shall conduct the operation, transport, and maintenance of
this machineQualified persons shall meet the following minimum requirements:
− be at least 18 years of age,
− possess the physical and mental abilities to perform the assigned tasks
27
− be able to read and understand the technical documentation of construction machinery (i.e.: this manual)
 Having knowledge of:
− accident prevention
− performing first aid,
− all applicable occupational safety regulations.
 Be sufficiently trained/instructed for the assigned tasks, including:
− Possessing a valid driving license for machines, if legally required.
− Being versed with at least the basics of machines operation and effects.
− Marshalling machines shall only be performed by instructed personnel with confirmed skills. (Ensure
acknowledgement upon the meanings of all hand signals between the marshaller and the driver).
3.3.2 The manufacturer’s responsibilities
− is responsible for delivering a machine and its accessories in a technically safe and operational condition.
− supports the product‘s performance, maintenance and repair in all periods of its life cycle
− ensures the operational state of the unit via a worldwide maintenance and repair service
− offers training for the owner's operation and maintenance personnel as a service
28
3.4 Personal protection equipment (PPE)
 Take note of safety precautions at your site
Figure 3-1 Personal protection equipment is recommended and possibly mandatory at your site.
(Wear PPE when working on any machine as required.)
PPE may include:
− Safety helmet to prevent injuries possible due to moving/slewing machine parts, falling objects, or flying
particles/parts
− Safety goggles when in contact with corrosive and/or highly pressurised liquids, the chance of flying particles,
loose parts or dust
− Respiratory protection/breathing masks in case of dangerous gases, vapor, smoke or dust in the working
environment
− Hearing protection when working very close to the machine/on the platforms and roof recommended also
for a driver working with opened windows
− Must not reduce the operator‘s attention in communication with the environment
− Protective gloves when handling or sharp materials or carrying heavy loads by hand
− Safety shoes when working on areas where heavy objects might fall or sharp ones may may on the ground
− Special protective clothing to prevent burns, chemical burns, or cutting injuries in respected work places
− Boldly-colored or reflective clothing when working at night or if recognition by other personnel is needed.
29
3.5 Hazards and risks of injury
3.5.1 General precautions
 Before putting the machine into operation, check the following:
− The indicators and warning lights of the machine are all off (except the usuals after turning the ignition key)
− The machine works does not make any weird sounds and the controls work propperly
− The immediate vincinity is free from any obstacles or people.
 During operation, observe the followings:
− Do not enter unsafe areas with the machine
− Do not reach into the range of action of other machines
− Keep all hatches, hoods and openings closed when moving
3.5.2 Fire and explosion hazards
− Before refueling or filling with hydraulic fluid, shut off the machine and secure it against self restart.
− When refueling via a tank supply line, make electrical compensation between the machine and the refueling
machine.
− wipe any spilled fuel off the machine immediately with a suitable cloth.
− bind any fuel spilled on the ground with binder.
− Dispose of used binders safely according to local regulations for environmental safety.
− Do not use booster sprays containing ether-solvents to start the engine.
− Do not store or use flammable liquidsor cleaning agents close to the machine.
− Do not store flammable materials (e.g.: rags or clothing) near the engine.
30
Safety sign Related Hazards
− Danger of fire and danger of explosion due to easily flammable opperating supplies or
gas mixtures resulting from these.
− Avoid using or causing open fire, naked flames or electrostatic discharges while
handling flammable materials or fluids!
− Observe handling-specific and situation-specific safety notes.
− Dusty environments and improper handling of the machine withion these hazardous
areas (e.g.: dust formation on surfaces) leads to:
− Increased risk of fire.
— Increased risk of dust-explosion
− Prevent dust formation through technical or organizational measures.
− Shorten both cleaning and maintenance intervals.
— Observe the following safety measures:
− Keep a fire extinguisher ready
− Have an operational fire extinguisher available at all times.
− Make sure to know how to use it in case of an emergency.
− Do not hang any transparent knickknack on the window glass to prevent fire dude to
focussed sunlight.
− Keep the engine free from inflammable deposits and soils (oil buildup, leaves, pine
needles, coal dust, waste)
− Before to refueling or filling with hydraulic fluid, shut down the machine and secure
the engine/machine against unintentional restart!
− When refueling via a tank supply line, make electrical compensation to avoid
electrostatic charging between the machine and the refuel unit.
− Immediately wipe spilled fuel off the machine with a suitable cloth.
− In case that oil is spilled on the ground or floor, use the binder to collect it.
− Dispose of any used binder safely and in an environmentally friendly manner.
− After refueling, remove the fuel supply line from the machine and close the fuel tank
again.
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− Only commission the machine as described in this operation and maintenance manual.
− Do not use booster sprays containing ether-solvents to start the engine.
− Do not store or use flammable liquids in the vicinity of the machine.
− Do not use flammable cleaning agents to clean the machine.
− Do not place flammable materials such as rags or clothing near the engine/electric
motor.
− Regularly check all protective covers, cables and wire brackets or completeness and
tightness.
− Ensure that loose cables or lines are firmly re-installed.
− Check all hydraulic lines regularly (at least once a year) for damage and leaks.
− Replace damaged hydraulic lines immediately.
− Do not smoke near the battery.
− Close the cover of ashtray to extinguish the match and cigarette butt
− Ensure that there are no open flames or sources of.
− Check regularly the electrical machine of the machine by qualified personnel.
− No open fire when handling flammable materials.
— Perform an emergency call
− First Aid Measures
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3.5.3 Lighting strike
WARNING! Lightning Strike hazard!
 Electric shock from lightning!
− Contact with a direct or indirect current flow caused by a voltage flash-over or step
voltage can be fatal.
− Fall hazard when working at heights.
− It can also cause a total loss of control, damage to the electronics or to local welding
spots on supports, especially on the swing ring.
 Observe handling-specific and situation-specific safety notes.
 Observe the following safety notes:
− Do not operate the machine during a thunderstorm!
− The charge is channeled through the machine and into the ground
− Always stay away from large, free-standing metal parts (e.g.: machine) during a
thunderstorm.
− Machines without direct contact between steel structure and ground must be grounded.
− Evacuate the machinein the case of fire.
 Measures after experienced storm strike:
− Inspect the electrical machine of the machine by qualified personnel
− Thoroughly inspect the machine by paying attention to any damaged cable, hose or
rope.
 Check machine for leaks of fuels or supplies
− Inspect the operational capability of the control systems of the machine
− Contact XCMG for after-sales service.
— First Aid Measures
− Provide Emergency call
33
WARNING! Injury from Mechanical Parts
 Mechanical actions due to moving machinery! When operating the machine,

numerous hazards and situations can arise that can cause life-threatening
injuries.
− Switch off the machine and power supply!
− Wear suitable PPE.
− Only work on non-moving parts.
− Do not reach into areas with moving machine parts (e.g.: drive shafts, drive belt, fan,
etc.).
− Examples of mechanical impact:
− Standing under a suspended load.
− Danger of being drawn in by moving drive units or machine parts.
− Danger of falling when working without safety gear.
− Danger of crushing due to unsecured components such as doors or sliding elements.
 First Aid Measures
− Provide Emergency Call
34
WARNING! Hazards and Injuries from Hydraulic Devices
 Leaking of hydraulic oil under high pressure!
 Leakages in hydraulic lines can cause injuries to skin, destroy tissue and can
cause blood poisoning due to the high pressures involved.
− Repairs to hydraulic machines may only be carried out by qualified technicians with
specialized knowledge and experience of hydraulics.
− Make sure that the whole machine is pressure-free before start.
− Never attempt to locate the leakage point with your hand or other parts of the body
− Damaged hydraulic components must be replaced immediately with original XCMG

spares
− Check all hydraulic lines regularly (at least once a year) for damage and leaks.
− Replace damaged hydraulic lines immediately.
 Examples of hydraulic energy:
− Tissue damage from high pressure leaks.
− Sepsis from hydraulic oil entering bloodstream.
WARNING! Risk of physical burns
 Contact with hot surfaces and consumables!
− High surface and equipment temperatures can lead to burns or scalding.
− Always wear suitable protective gloves when working on hot components.
35
− Only carry out work on the machine after it has cooled down and is stopped.
 Examples of burns and scalding:
− in contact with the entire drive machine.
− on engine exhaust parts.
− on hydraulic pumps or motors
− on electric components
− engine cooling radiator and pipes
WARNING! Chemical burns
 Contact with corrosive and chemical consumables!
− Acids and bases cause chemical burns to skin and tissue, and blindness if they come in
contact with the eyes.
− Acids and bases will damage clothing.
− Replace damaged battery immediately.
− Wear safety goggles and protective gloves when replacing battery.
− Wear safety goggles and protective gloves when working on the battery.
− Do not smoke near the battery.
− Ensure that there are no open flames or sources of ignition (e.g.: electrical equipment)
near the battery.
− Do not short connect the battery terminals.
− Do not place conductive materials on the battery.
− Replace discharged battery immediately or charge battery in heated area
 Examples of chemical burns:
36
− Chemical burns from handling acidic consumables.
− Chemical burns from leaking battery acid.
WARNING! Asbestos dust hazard
 Contact with the asbestos dust!
− If too much asbestos dust in the air is breathed, it is possible to suffer a lung cancer.
− Use the dust filtering masks, when there is asbestos dust in the air.
− Follow the rules, regulations and the environment standard at the work place.
− Do not allow other personnel to come close to the machine during operation.
− Operate the machine in the upwind position if there is asbestos dust in the air.
− Do not use the compressed air to reduce the dust.
WARNING! Poisoning and Suffocation Hazard
— Inadequate ventilation or fresh air!
− Poisonous vapors or other atmospheres hazardous to health can lead to poisoning or

suffocation.
 Observe handling and situation-specific safety notes.
37
− Only operate machine in well-ventilated areas
− Use breathing apparatus when working with hazardous materials.
− Regularly replace filter of respiratory mask
 Examples of intoxication and choking:
− Engine exhaust gases contain carbon monoxide and other hazardous gases.
− Machine is used in areas where hazardous substances are present, and contact with
hazardous gases is a possibility.
WARNING! Environmental Risk
 Risk of damage to the environment caused by pollutants!
— If their release is not controlled, fuels, oils, cleaning agents, coolant, etc. can enter the
ground or rivers and cause environmental damage.
− In the event of leakage of fuel or operating consumables, rectify the causes

immediately.
− Eliminate leaking fuels or opperating supplies immediately with binders.
− Dispose of used binder safely and in an environmentally friendly manner.
− When disposing of fuels or opperating supplies, observe national disposal regulations.
− If necessary, clarify the disposal with the local authorities.
− Use a suitable container when draining fuels or fluids.
− Sump is sufficiently large, dense and chemically resistant to the corresponding fuel or
hydraulic oil.
− Do not mix fuels or operating consumables when draining.
− Store or dispose of fuel or operating consumables separately.
38
 Examples of hydraulic energy:
− Leakages in the operating machines.
− Refilling consumables incorrectly.
 First Aid
— Notify the emergency services/authorities of any large amounts leaks of environment

endangering substances!
3.6 Safety distance
3.6.1 Power cables
 Start working only after explicit approval or confirmation of the shutoff of the power supply lines by
the responsible authority.
− Treat the power lines as live until shutoff has been confirmed in writing by the responsible authority.
− Pay attention to distances between power supply lines and working position.
− Involve nd consult a second person for observation If necessary.
− Break the operation off in case of doubt.
3.7 How to act in dangerous situations
3.7.1 If the machine contacts with a power supply line
 First response
− Remain calm.
− Alert the relevant power supply company.
− If the control machine is still functioning:
− Move the machine out of the danger area.
39
− Leave the machine.
− Never touch any live parts of the machine when touching the ground.
− Jump in a direction that avoids any contact with live parts.
− Jump to a safe distance from the machine and land on both feet at the same time.
− Land on both feet at the same time with legs closed (do not straddle).
− Never hold on to the machine or any live parts.
− Jump away on both feet with both legs pressed together.
− While jumping away, keep well clear of any live parts.
 First Aid
− Alert Emergency Services
− Leave the personnel rescue to the professionals!
− Assure medical attention after electrical accidents. The person affected may experience
symptoms of an irregular heartbeat sometime after the accident.
3.7.2 In case of fire
 First response
− Incorrect behavior in case of fire
− Danger of backlash!
− Even if the fire appears to be extinguished, leaking fuel or oil coming in contact with
hot components may reignite
− Shut off the engine.
− Alert the emergency services.
− Move people out of the danger zone,
− Perform first aid if required
− Only start to fight the fire if there is no risk to your personal safety.
40
 Fire Fighting
− Regard Fire Classes Requirements:
− Appropriate extinguishers must be used!
− If unsuitable extinguishers are used, they may be ineffective or even lead to additional
hazards.
 Use extinguishers matching the fire class (see symbols below)
− Fire extinguishers are subject to national regulations!
− Take fire extinguishers on the machine off the holders
− Make it ready for operation.
− Fight the source of the fire with several short bursts.
− While fighting the fire, ask personnel to alert the fire brigade.
 Class of Fire and Reliable Extinguish Agents
Class of Fire − The assignment of extinguishing agents to fire classes prevents risks and damage
through a wrong extinguishing agent:
A = Solid organic materials (as wood, paper, cloths etc. …)
− Extinguish by using: Water, ABC-Powder
B = Liquids and liquefying materials (as Gasoline, Wax, White Spirit Solvent etc. …)
− Extinguish by using: BC-Powder, ABC-Powder, CO2
C = Gases and other vapors (as Propane, Butan, Natural gas etc. …)
− extinguish by using:
− Shut-off Valve, BC-Powder, ABC-Powder, CO2
D = Flammable Metals (as Aluminium, Magnesium, Lithium…)
− Extinguish by using: Metal fire powder, Dry sand
41
First Aid
− Alert emergency services
− Only experts rescue the personnel!
3.8 Safety signs and labels
3.8.1 Introduction
 Make sure to understand all safety signs contained in this operation and maintenance
manual and the safety symbols related to the machine.
− Keep safety signs clean, undamaged and readable.
− If any safety sign is missing/damaged, contact XCMG Construction Machinery Co., Ltd. immediately to have
them replaced.
− Do not hesitate to contact an XCMG agent for any other ambiguity or issue as well
3.8.2 Mandatory signs
 Mandatory signs enforce behavior preventing or reducing a risk to health or safety.
Common mandatory signs
Description Signs Description
Wear ear protection Wear eye protection
Wear safety footwear Wear protective gloves
42
Wear protective clothing Wear a face shield
Wear head protection Wear a safety harness
Wear safety belts Read operating operation and

maintenance manual
43
3.8.3 Prohibition signs
 Prohibition signs forbid behavior likely to cause a risk to health or safety.
Common prohibition signs
Description Prohibition Signs Description
Smoking prohibited Fire, open ignition sources and

smoking are prohibited
Pedestrians prohibited Forbidden for ground

conveyors
Access for persons with No access for unauthorized

pacemakers or implanted personnel
defibrillators prohibited
Entering the area prohibited Switching prohibited
Do not lift load No climbing for unauthorized

personnel
High-pressure cleaning
prohibited
44
3.8.4 Warning signs
 Warning signs indicate potential risks or hazards (ISO 7010)
Common warning signs:
Description Warning Sign Description
Warning of non-ionizing Warning of obstacles on the ground

radiation
Warning of fall hazard Warning of slipping hazard
Warning of electric voltage Warning of suspended loads
Warning of hot surfaces Warning of automatic start
Warning of crushing hazard Warning of crushing hazard when

falling
Warning of hand injuries Warning of counter-rotating rollers
Warning of being hit by Warning of crushing hazard from

moving parts when staying above
within the range of action
Warning of crushing hazard Warning of getting rolled over

from above
45
Warning of getting rolled Warning of getting drawn into

over winches
Warning of dangers through Warning of hazards through battery

pressure container charging
Warning of dangers through Refer to operation and maintenance

hydraulic oil manual
46
3.8.5 Rescue signs
 Rescue signs mark the locations of first aid equipment and emergency exits.
Common signs
Description Rescue sign Description
First Aid Place where to find a first aid kit or similar
Emergency exit (door) Door useable to exit in case of emergency (alarm may turn on
when opened; do not misuse)
Emergency exit (window) Window to escape in case of emergency. Use the

mallet/hammer nearby to smash open
3.8.6 Fire protection signs
 Fire protection signs mark the location of fire alarms or fire extinguishing equipment
Common fire protection signs:
Description Fire protection Sign Description
Fire extinguisher Fire Alarm
47
3.9 Machine-specific signs and labels
3.9.1 Introduction
− Be sure to read and memorize all safety instructions in this operation and maintenance manual and
maintenance and all safety signs and symbols associated with the machine.
− Ensure that the safety signs and symbols remain legible. If one is missing, damaged or unrecognisable, have it
replaced immediately.
− If you have any questions, contact an XCMG representative or XCMG Fire-fighting Safety Equipment Co.
Ltd.
3.9.2 Machine-specific warning signs
The overview list below shows all stickers attached on machine.
− Replace any damaged or lost decals immediately.
− Find the list of exact part numbers in the spare parts list included among the documentation.
 Refer to Overview-Table in Section 4.8.2
− Please get familiar with all safety labels (refer to Section 3.8).
− Ensure that you can see all the safety labels clearly.
− If the words of a safety label are unclear, clean the label or replace it.
− If the illustrations of a safety label are unclear, replace them.
− Clean the safety labels with cloth, water and soap.
− Do not clean the safety labels with solvents, gasoline or caustic chemical agents!
− Solvens, chemicals can make the labels loose, cause them to fall off.
 If any safety label is damaged or lost, it must be replaced immediately.
 If the part to be replaced has a safety label, ensure that the part to be replaced with also has the safety
label.
− Contact your XCMG service partner if you need any support.
48
View A rotation View B rotation View D-E rotation
Radiator View C rotation View F rotation
49
Figure 3-2 Position of the decals
No. Labels Description
Take cautions to observe the energy curve.

PN: 404204236
1 This special notice is intended to remind the operator of
observing the energy curve during the operation of the
machine.
Location: Within the operator‘s cab.
50
Mind your hands

PN: 404204226
2 Take caution not to crush your hands while opening or
closing doors or windows.
Location: Operator‘s cab internal bracket.
No treading
3 PN: 801969642
Location: On front and rear mudguards.
Electric shock hazard

4 PN: 404204234
Location: Cab internal bracket.
Tip-over hazard
PN: 404204229
5 Read the operation manual to guard machine against
tip-over.
51
Fasten seat belt.

PN: 404204231
6 Do not jump off the machine in event of machine tip-over.
Please fasten seat belt.
Read operation manual

7 PN: 404204237
Location: Inside of cab.
Power master switch

PN: 404204573
8
Power master switch label. The system voltage is 24V.
Location: This label is under the cab.
Limit reminder
PN: 404204230
9
Pay attention to the door limiter.
Location: Left side within cab.
52
Guard against door collision

10 PN: 404204232
Location: Left side within cab.
Fan cutting hazard

PN: 404204221
11 The rotating fan has a cutting hazard. Touch the fan only
after the stop of the machine.
Location: At the radiator within the hood.
No standing on attachment
PN: 404204228
12 Do not stand or lean against the attachment or its
accessories.
Location: This warning label is affixed on the top of engine
hood.
Thermal hazards
PN: 801903051
The engine, engine oil, exhaust pipes, the radiator and
13 coolant can cause burns.Keep in mind this warning when it
is necessary to approach or to work near these surfaces.
Location: This warning is located on the top of the engine
hood.
53
Safe spacing
PN: 404202634
14 Please keep a specific safe spacing to the boom and
attachment.
Location: Front and rear of telescopic handler.
Placement and movement support

PN: 404204235
15 Please install or remove the support device as per the
instruction of the label before and after the use of safety
handle.
Location: Right rear side of telescopic handler.
Boom cylinder lock

PN: 404204636
16 Before stopping the machine for checking and repair, please
make sure to lock the boom luffing cylinder by safety
handle.
Location: Left and right sides of engine hood.
54
4 Safe Operation Guidelines
4.1 General Safety Rules and Advices
 Take note of the operation and maintenance manual of your machine.
 Take note of:
− the safety instructions, rules and regulations applicable at your areasite.
− the protective devices installed on your machine or available at your site.
− the Personal Protection Equipment required for your next task.
 Before starting any process described in this Section 4, note down all local emergency phone numbers,
including:
− doctors,
− ambulances,
− hospitals and
− fire departments
Figure4-1 Reminder of the the importantce to follow safety rules and regulations
Comply with any additional regulations, standards and laws that may apply in your area or at your jobsite.
Wear all the PPE required/recommended at your work site or for your specific job depending on the
situation (e.g.: reflective vest, gloves, safety glasses, safety shoes)
Dust masks may be required in dusty, dry or confined environnements!
Learn about and comply with the rules and regulations applying at your area.
55
Figure 4-2 Figure 4-3
 In case of driving on public roads, follow local road traffic regulations including driving rules and
condition of the machine.
 In case additional documents related to the safety of the machine and its operation, they must be kept
together with this operation and maintenance manual.
 Ensure safety-related systems are fully operational and undamaged at any time.
 Check the tightnes of all bolts and nuts before beginning your work.Take note of all the emergency
equipment closest to your usual work site/area (i.e.: emergency phone lines, fire extinguishers, first aid
kits, defibrillators, etc.)
 In case any equipment is incomplete, missing or damaged, contact your assigned XCMG service agent
immediately to have it replaced.
Figure4-4 emergency Equipment
56
4.2 Installation and assembly
DANGER! Risks and hazards during installation or assembly
 Any kind of operating the machine may result in life-threatening hazards for the operator, co-workers
or other bystanders, as well as risks of property damage!
− Follow the safety rules presented hereafter to minimize these hazards.
4.2.1 Requirements for installation and assembly personnel
 Installation or assembly will only be carried out by local XCMG agents or authorized personnel
istructed by them.
 Always keep the basic PPE on you (e.g.: helmet, gloves, safety shoes) to protect your co-workers and
yourself from unexpected dangers, especially during the assembly/installation process.
4.2.2 Requirements for the Installation Site
− Carry out an installation or assembly process on flat and solid ground, suitable for the size and total weight of
the machine at its full load.
− Use lifting appliances of sufficient capacity to instal/attach heavy machine components.
4.2.3 Assembly of the Machine
The scope of installation mostly depends on the size and complexity of the machine
Smaller units are usually already fully assembled when delivered.
For bigger units, the delivery is alwas suited to the shipping – in most cases determined by the customer.
The following situations are possible:
− All-in-one delivery (ready for immediate use)
− Refer to the installation and assembly documentation supplied with the machine to ensure safe and proper
setup.
57
4.3 Installation of accessories and other safety instructions
 Installation for the accessories
− When installing the optional parts or accessories, please contact the XCMG distributor in advance. Any
injury, accident or product fault caused by using the accessories or parts without approval from XCMG will
be unrelated with this company.
 The window glass for the driver’s cab
− If the front windshield in the driver‘s cab crushes, the equipment attached may contact and hurt operator‘s
body directly!
− Stop operation and replace the front window glass immediately.
 FORS and ROPS
− The different types of guards are used to protect the operator.
− The machine and the machine application determine the type of guard that should be used.
− Install FOPS (Falling Object Protective Structure), ROPS (Rollover Protective Struucture) or window
protection devices/guards to protect the cab and the operator from falling stones or flying objects during the
work on the construction site, in a mine, tunnel, dell or mellow and humid surfaces.
− The FOPS/ROPS structures (if equipped) on your machine are designed and type-tested and certified for the
intended safety (in accordance with the ISO ISO 3471: 2008、ISO 3449-2: 2005 standards)!.
 Delivered FOPS/ROPS guards on the machine cannot be dismantled at someone free will!
− The cab without or with damage FOBS/ROPS devices do not provide expected legislation safety for the
operator.
− If any plastic deformation or damage appears on any part of the FOBS/ROPS structure (e.g., affected by
rolling, falling object or dumping), contact the XCMG or XCMG representative and let the authorized
professionals to replace the structure.
− Check the base plate of protection devices on corrosion or damage. If found any, contact the XCMG or
XCMG representative and let the authorized professionals to do the repair.
− Equip appropriate hoisting tools to take down the original protection device carefully and save it safe or hand
it over to some specially assigned person.
− Repaired or new FOBS/ROPS to be installed by authorized professionals.
58
 Modification without approval
− Approve any modification by XCMG in advance! Contact the XCMG service or XCMG representative.
− For any injury, accident or product fault caused by modification without approval from XCMG, the
XCMG-company will not be liable.
 Removal of counterweights/ attachments
WARNING! − Hazards from sudden move!
− Removal of counterweights or front-end equipment from the machine affects the stability of the machine!
− This will result in its sudden machine move that may cause serious injury and even death.
Figure 4-5 Lowering bucket and installed stopper blocks on wheels
 In order to avoid machine stability, first
− lower the working device at the ground,
− keep the machine straight and
− put the stopper-blocks under the machine front and rear tyres
 Then remove counterweights or change another working device!
 Safety in the workplace
 Before operating, check the work area thoroughly for dangers.
− Check the ground in the workplace and decide the safest operation method.
59
− Do not operate the machine in places with a risk of collapse or falling objects.
 If there are water pipes, gas pipes or high voltage electrical wires buried under the workplace,
contact the site contractor to mark their positions.
− Take outmost care operating in hot and dry areas! Dry cottage roofs, dry leaves or grass may cause a fire.
NOTICE! Damage of workplace!

− Do not break or damage any pipe and wire buried under the workplace.
− Unauthorized persons are not allowed to enter the working area!
− Provide necessary warning and protective measures around the area.
− Before moving or operating in the shallow water or on the soft ground, check the tyres, working area, the
depth and the flow rate of the water.
4.4 Commissioning
4.4.1 Requirements for Commissioning Personnel
 Commissioning will be carried out only by istructed personnel authorized by XCMG or their local
representatives
− The comissioning shall be carried out according to the process check-list and – when completed – will be
countersigned from both the customer or his representative and the leading commissioner.
− For further details on the safety during this process, refer to the recommendations given in Sections
DANGER! Hazards during machine operation!
− Any operation of the machine may cause danger to the life of the operator, his co-workers or other bystanders,
as well as risks of damage to property!
− Be careful! Not respecting the basic safety rules presented hereafter – serious injuries or death casualties
and/or significant property damage will result!
− Retrieve the ignition key to prevent unauthorised operation or unintended delf-moving of the machine.
− Check the protective devices‘ condition regularly.
 Never dismantle protective devices on your own
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− Remove any mud/oil remains on your shoes and soles to prevent slipping while operating the machine.
− To prevent distractions, do not use cell phones a radio or earphones while operating the machine.
− Do not take any flammable or explosive materials with you on the machine.
− Do not use any worn-out or damaged tools to prevent injuries or unsatisfactory results.
− Check the fire extinguisher regularly and have them replaced/refilled if needed.
− Remember how to act in case of a fire and ensure all field personel is up to date on their emergency training
(refer to Sections 3.5.2, Section 3.7 i.e. 3.7.2)
4.5 Safety on the construction site
Note: The manufacturer can‘t directly control the applications and operations of the machine. Therefore, the
safety issues listed in this manual are not exhaustive. The user and the operator shall be responsible for abiding by
good safety specification. Electric hazard
Figure 4-6
− This machine is not insulated and also can‘t provide the protection against contact or current.
− Make sure to check the power cables before lifting the boom.
− Please maintain the spacing to the electric circuits, equipment, and any live (Exposed or insulated) component
as per the minimum approach distance (MAD).
Voltage range (Relative phase) Minimum approach distance (MAD)

0~50KV 3m
>50KV~200KV 5m
>200KV~350KV 6m
>350KV~500KV 8m
>500KV~750KV 11 m
>750KV~1,000KV 14 m
Note: This requirement shall apply unless the owner’s, local, or government regulation is more stringent.
61
− The movement of the machine and the swing of electric circuits are allowed.
− Maintain all machine parts and the machine occupants and their tools and equipment by at least 3m spacing to
any >50,000V electric wire or equipment. Increase the spacing by 0.5 for every increment of 30,000V or less.
− The minimum approach distance can be reduced based on the voltage of the protected circuit if the insulation
barrier is installed to guard against contact. Such barrier shall not belong to any part (or accessory) of the
mechanical mechanism. The minimum approach distance shall be reduced to the distance within the design
working dimension of the insulation barrier. This decision shall be made by the competent personnel based on
the owner‘s, local, and governmental practice requirements on the operations near live equipment.
DANGER!
− It‘s prohibited to operate the machine or personnel within the minimum approach distance (MAD). Assume
that all electric components and circuits are electrified.
 Hazard description
− Please refer to corresponding load chart for other related load requirements.
Figure 4-7
− Never use any attachment, unless the appropriate load chart approved by the original equipment manufacturer
(OEM) is affixed on the machine.
− Understand how to correctly use the load chart within the cab.
− Do not exceed the rated lifting capacity.
− Ensure that the ground condition is enough to support the machine.
− Pay attention to the load swing and the dangerous lateral load probably caused by the wind.
− Maintain the machine by at least 0.6m from any ground hole, fall head, obstacle, fragment, concealed hole, or
other potential hazard.
62
Figure 4-8
− Lift the boom only when the frame is horizontal (0 degree), unless otherwise specified on the load chart.
Figure 4-9
− Do not level the machine when the boom/attachment is >1.2m above the ground.
Figure 4-10
− Always maintain appropriate tire pressure. If the appropriate tire pressure can‘t be maintained, this machine
will probably tip over.
Figure 4-11
− Always fasten the seat belt.
63
− Always keep your head, arms, hands, legs, and other body parts within the cab.
Figure 4-12
 If the machine starts to tip over:
− Do not jump.
− Get ready to sit on the machine.
− Please fasten the seat belt.
− Grasp the handrail tightly.
− Keep away from the impact point.
 Non-hung load
Figure 4-13
− Do not drive the machine with the boom lifted.
 Hung load
Figure 4-14
64
− Fix the hung load to restrain movement.
− The weights of all rigging (Such as sling) must be taken as one part of the load.
− Do not attempt to compensate the swing of load by leveling the frame.
− Approach the heaviest mass center part of the load to the attachment.
− Lift the load vertically and do not drag the load.
 During traveling with hung load:
A. Start, drive, steer, and stop the machine slowly, in order to prevent the swing of the load.
B. Do not extend the boom.
C. Do not lift the load over the ground by >300mm or lift the boom in excess of 45°.
D. Do not exceed the walking speed.
 Traveling hazard
Figure 4-15
− The steering characteristic differs depending on the specific steering mode. Before the traveling of the
machine, sufficiently identify the setting of the steering mode.
− Do not change the steering mode during traveling. Change the steering mode only under stationary status of
the machine.
− After the change of steering mode each time, visually check the wheels for correct alignment.
− Ensure a sufficient space behind the machine and in front of the front forks during the steering of the
machine.
− Pay attention to and keep away from other personnel, machinery, and vehicles within such areas. Please use a
visualizer if a clear vision field is not available.
− Ensure the clear vision field in the surrounding environment and the normal functioning of the horn before
moving the machine.
− During driving, retract the boom, keep the boom/attachment as low as possible, and meanwhile maintain the
visibility of rearview mirrors and the maximum visibility of the traveling vision field.
− Always pay attention to the traveling direction.
65
− Before driving the machine beneath any obstacle, make sure to carefully check the boom height and ensure
that the location of the attachment/load is enough to keep away from the obstacle.
− Only use the front wheel steering mode (If the multiple steering modes are provided) during high speed
traveling.
− The machine equipped with solid or foam filled tires is inappropriate for excessive off-road condition or
long-distance traveling. If the excessive off-road condition or long distance traveling is required, it‘s
recommended to use a machine not equipped with solid or foam filled tires.
 Load lowering hazard
Figure 4-16
− Do not hang the load to other part of the fork or fork carriage. Only use the specified lifting point.
− Do not combust or drill on the forks.
− The forks beneath the load must be symmetrical with respect to the center of fork carriage and be spaced as
large as possible.
− Lifting of personnel
Figure 4-17
− Only use the approved personnel work platform for the lifting of personnel. Before operation, make sure to
look up the load chart within the cab. If you are not sure of the load chart, please contact the local XCMG
dealer for help.
66
Figure 4-18
− Do not drive the machine by the cab when there is any personnel on the work platform
 Cab hazard on a slope
Figure 4-19
 To maintain sufficient traction force and braking capacity, please abide by following procedure during
traveling on a slope:
− Under no-load condition, drive the machine with the forks facing towards downslope direction.
− Under loaded condition, drive the machine with the forks facing towards upslope direction.
− Please refer to the corresponding load chart for other related traveling requirements.
− To prevent the overspeed of engine and drivetrain during downslope traveling, please downshift and when
necessary use the service brake to maintain low speed and do not coast downslope in neutral gear.
− Avoid driving through a steep slope or a slope with unstable surface. To avoid machine tip-over, do not drive
through any steep slope in any case.
− Avoid making turns on a slope. Never use the ―Inching‖ function or coast in neutral gear during downslope
traveling.
− Do not park the machine on a slope.
67
No. Label Description
Pinch point and crushing risk
1 Please keep away from moving components during running of engine.
2 Keep away from steering wheels, frame, and other objects.
3 Keep away from the area beneath boom.
4 Keep away from boom hole.
68
5 Keep arms and hands away from attachment tilting cylinder.
6 Keep hands and fingers away from fork carriage and forks.
7 Keep away from other personnel during operations.
Select appropriate handrails and equipped steps to enter into the cab.
Always maintain three-point contact while getting on or off the cab.
Never grasp any joystick or steering wheel while getting on or off the
8
cab.
Do not leave the machine before completing the machine stop
procedure.
Do not carry any passenger, otherwise the passenger will probably

9
fall off from the machine to cause death or serious injury.
Chemical hazards
Do not operate the machine in any enclosed area without appropriate

ventilation measure.
10 Exhaust port Do not operate the machine in any dangerous environment, unless
approved by XCMG and the site owner, otherwise the spark of the
electric system and the exhaust gas of the engine can probably result
in explosion.
Inflammable fuel
69
Do not refuel or repair the fuel system near any open fire, spark, or
11 smoking material. The engine fuel is inflammable and can result in
fire accident and/or explosion.
Hydraulic oil
When the engine is running or the hydraulic system is under
pressurized status, do not attempt to repair or tighten any hydraulic
hose or part.
Stop the engine and relieve the residual pressure. The liquid in the
12
hydraulic system can penetrate your skin under sufficient pressure.
Do not use your hands to check for leakage. Use a hard paper board
or paper to check for leaking point. Wear gloves to guard both hands
against the liquid spray.
4.6 Safety on the construction site
DANGER! Hazards related to Construction Site
 The hazards on the site may lead to personal injuries or even death, as well as attlerant property
damages!
− Inspect the site and take necessary safety measures before stating any work.
− Comply to all local regulations and safety guidelines applicable in work area.
CAUTION! Hazards due to unstable ground
− Different operations (as vibratory, rattler operation) on different soils increase the stability requirements for
the surface and surrounding structures
 Check construction Site
− Investigate the surrounding work place environment before starting operation.
− Be alert to possible unexpected conditions that can result in dangerous accidents.
− Be familiar with the terrain and ground condition of the working place, choose the safest working method.
− Make the ground of working place firm and level before starting operation.
70
− For dry sandy area reduce dust by spraying some water on the ground before work.
− On a public roads, assign a traffic director or set a perimeter around the work site and post warnings and
caution signs surrounding the work site.
− Provide good and effective ventilation before working indoors to avoid risks from waste or exhaust gas.
− Some water pipes, gas pipes, and power supply cables may be buried under the ground.
− Involve site contactor to properly mark the positions of any underground lines to avoid damaging these pipes
or cables.
− Before working in shallow water or passing through a sandy bank:
a. inspect the water floor, water depth and velocity of f l o w - stream.
b. prevent the driving axle operates in the water.
c. clean out and check lubricating holes after finished work.
4.6.1 Risk in special operating conditions
NOTICE! Be aware of operations at low temperatures!
 Guarantee the safety on your construction site as follows:
− Restrict the access to the construction site to any unauthorized persons according to the local regulations and
best practices
− Obtain information about the latest safety regulations related to your work site.
− Contact your supervisor, your assigned dealer or the local Occupational Safety Authority for more
information. (as this will not be provided in the operation and maintenance manual or any other
documentation of this machine.)
− Keep any bystanders several meters away from the machine before turning it on.
− Keep any bystanders off the vicinity of the machine during operation aswell.
 Recognized regulations in Germany and US for safety in the work-zone:
− German BAuA, RSA 95/ASR A 5.2 Rules. ―Richtlinien für die Sicherung von Arbeitsstellen an Strassen‖.
(Guidelines for the safety in working zone and traffic ways)
− Approve validity and actual status of the regulations at the time you read it.
− In your area and for your specific construction site, other different regulations may apply! Inform yourself by
site contractor!
71
− Ask your supervisor, your dealer or inform yourself, if further reference is not provided in this operation and
maintenance manual.
− Prior to start the machine i.e. do not allow bystanders to be present within 1m radius around the machine.
Send a warning!
DANGER! Be aware of machine operating range!

− The machine stopping distance may significantly exceed stopping distance of other vehicles.
 While the machine is operating, ensure that no persons are no less 10 m in front or behind the machine
on the path of operation.
Figure 4-20 Zone prohibited for bystanders.
4.7 Safety for Children
DANGER! No children allowed on the construction site!
 Children could fall off the machine and be run over or affect its controls
causing unexpected results.
− Keep children away from the working area and always under supervision of
adults.
− Switch the machine off immediately on sight of children entering the working
area.
− Never let children operate any machine!
− Never let children play on the machine or attachments.
− Always check the vicinity of the machine and ensure that there are no children
72
in the area before operating it.
− Before leaving the machine, park it so that it cannot move. When leaving the
machine (e.g.: for breaks or at the end of work), stop the engine, remove the
key.
4.8 Operator’s Safety
DANGER! Hazards on the maschine
− Always get on/off the machine in a safe way!
− Ignoring the basic rules presented hereafter will result in serious injuries or even death and/or significant
property damage!
− Wear the necessary PPE (Refer to section 3.4.)
4.8.1 How to board/leave the machine in a safe way
 Use the steps and the rails to get on/off the machine in a secured way.
 Always hold onto 3 points while boarding or leaving (either 2 hands + 1

foot or vise-versa) for optimum safety.
 Check the entire walking surface (including handrails, steps and the
platform) for any oil, lubrication grease or mud remains and remove
them before operation.
− Always face the machine while boarding or leaving it.
− Never step on the engine without using an anti-slip mat or cover plate.
− Never hold onto any control element when boarding.
 If the machine suddenly starts moving by itself, do not try to jump on it.
 Do not jump on and off the machine, especially while it is moving!
73
 How to get on/off the machine
Figure 4-21 Access the machine carefully.
 How to leave it in a safe way.
− Do not jump of the machine.
Figure 4-22 Do not jump off the cab
74
4.8.2 In the drivers's cabin
 If required, adjust the seat according your needs before starting the engine.
Figure 4-23 Driver's Seat Adjustments
CAUTION! Hazards due to seat adjustment

− Adjusting the seat while driving is dangerous and prohibited.
 Fastening the seat belt is mandatory while operating the machine.
− Refer to Section 5.6 for driver 's seat specific details
4.8.3 Check FOPS/ROPS structure
Figure 4-24 FOPS/ROPS structure
 FOPS/ROPS is mandatory safety equipment, ensure FOPS/ROPS is secured.
75
4.8.4 Starter Battery Handling
− Special care is recommended while handling with the starter battery and/or jump-starting the machine.
− Specific instructions are given in the Section 4.9.8.
4.8.5 Jump-starting the engine using auxiliary cables
− For hazards and safety procedure when jump-starting the engine with auxiliary cables refer to Section 4.9.8.
4.9 Pre-inspections tasks before machine operation
4.9.1 Pre-operation safety rules
 Prior to any pre-operation task, read and understand the safety requirements in instructions stated in
sections 3.4 and 4.1
 Read also hereafter Sections 4.7.1.1 and 4.7.1.2
DANGER! Hazards during machine operation!
 Any kind of operating the machine may bring life-threatening hazards for the operator, co-workers or
other bystanders, as well as risks of property damage!
− Be careful! Not respecting the basic safety rules presented hereafter – serious injuries or death casualties
and/or significant property damage will result!
Figure 4-25 Ensure the functionality of all control elements.
 Check the instruments and confirm the following:
76
− All indicators, including indicator lamps and sound warnings (such as the horn, beacon light, set occupation
light or seat belt-indicator (if installed), etc). are all functioning properly, (none of them should be reacting if
everything seems fine.)
− No error codes are shown on the display display of the machine.
 Keep machine clean, avoiding slippery steps and surfaces.

 Perform regularly recommended maintenance check according the maintenance-schedule chart.
4.8.1.1 Storage bin for operation and maintenance manual
Figure 4-26 Storage bin for operator‘s operation and maintenance manual
 This operation and maintenance manual must stay in the machine’s cabin.
− Store it in the bin behind the operator‘s seat to keep it available to the operator at any time.
NOTICE! Location of operation and maintenance manual

− In case the machine‘s documentation storage bin is locked, be sure to always pass its key together with the
ignition key to the next user.
77
4.8.1.2 Location intended for a fire extinguisher
Figure 4-27 Location for storing fire extinguisher
− A case store a 2 L fire extinguisher is located at the machine‘s rear side
− Keeping a fire extinguisher ready on the machine at all time is highly recommended.
 Inform yourself on the requirements and the availability in your area.
NOTICE! Location of fire extinguisher

Check if the fire extinguisher has the required approvals for your area.
− Follow the requirements of your supplier.
− Read and follow fire extinguishers instructions before using machine.
− Keep then together with this operation and maintenance manual.
4.9.2 Location of safety signs on the machine
− The overview list below shows all labels attached on the machine.
− Replace any damaged or missing label immediately.
− Their respective part numbers can be found in the spare parts list included in the machine documentation.
− Contact your XCMG service partner for any further information or support.
− Refer also to Section 3.9 – for specific meaning of warning signs.
78
View A rotation View B rotation View D-E rotation
79
Radiator View C rotation View F rotation
Figure 4-28 Position of the decals and labels
80
No. Description PN
1 Take cautions to observe the energy curve 404204236
2 Mind your hands 404204226
3 No treading 801969642
4 Electric shock hazard 404204234
5 Tip-over hazard 404204229
6 Fasten seat belt 404204231
7 Read operation manual 404204237
8 Power master switch 404204573
9 Limit reminder 404204230
10 Guard against door collision 404204232
11 Fan cutting hazard 404204221
12 No standing on attachment 404204228
13 Thermal hazards 801903051
14 Safe spacing 404202634
15 Placement and movement support 404204235
16 Boom cylinder lock 404204636
4.9.3 Daily inspections and visual checks before operation
− The scope of inspections the operator is allowed to perform on his own depends on the amount of knowledge
of the machine he has.
− As long as the same person keeps working on the same machine, the scope of inspections can be limited to
basic visual inspection.
− However, the regularity of these must be followed thouroughly to guarantee proper operation.
 When swaping the operating personel or any other situational change not mentioned before, the (newly
appointed) operator shall:
81
− Carry out an extended detailed inspection of the condition of the machine, its protective devices and functions
before starting operation.
− In case the machine has just been under maintenance or repair:
− Confirm its full operationality before putting it back into service.
− Inform yourself on the status of maintenance/repair progress and the results.
 Before starting or resuming work (especially after a longer break):
− Confirm that your Personal Protective Equipment is in good shape and meets the requirements needed for
your job.
− Check the machine for any overlooked or recent damage.
− Also inspect the mechanical connections, including the safety locks and any additionally attached
interchangeable equipment.
− Check for any missing safety split-pin and replace it before resuming operation!
− Lubricate connections according to manufacturer‘s specification if required.
− Check that all safety and protective devices are installed on the machine and are operating properly
− Check tires for wear or damage. Check the air pressure of all tires. Don‘t operate the telescopic handler if
any tire air pressure readings are below the required pressure.
− If the steering pin locking bar is engaged, keep it in the locked position. This way the locked machine
can‘t be moved.
− Verify that all control elements (switches, gear controls, joystics and pedals) are functioning properly.
Clear any debris or grease from operating levers, pedals, and handles to avoid slippage.
− Clear any unnecessary items from the cab, making sure to keep the cab floor clear of any obstructions.
− Have XCMG repair any faulty elements imediately.
− Inspect the remaining amount (level) of all operation fluids used by the machine, including:
a. engine lubrication oil,

b. engine coolant,
c. hydraulic oil
− Refil any if necessary and only use fluids of approved quality. (Refer to Section 6.3.2‖ for further
information.)
− Insert the start-key and initiate the power supply to control system!
 Do not start the engine right away!
 Pay attention to any strange noise or warning signals from the control panel!
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− Check all control functions for failure, abnormal stiffness error any error message popping up. Identify all
warning and safety signs throughout the entire machine.
− Be aware of any dangerous conditions.
− Check the engine compartment.
− Ensure driving belts on engine, alternator and water pump are tightened properly and in good shape before
use.
− Check the watrer separator – Drain any remaining water.
− Clean the air filter. Replace it if damaged.
− Ensure the vicinity around the machine is clear before starting the engine.
− Clean the cab windows and clean all lamps to ensure optimum visual field
− Ensure that the lock bar has been disengaged.
− Before to engine start for safety refer to Sections 4.8.5.
 In case any damage was detected:
− Notify your work site manager or service to enable service department to schedule workflow and more
importantly, order parts required.
4.9.4 Engine start check-list
− Keep people away from the machine during the inspection.
− Remove all obstacles in the area before starting the inspection.
− Check around the vehicle for oil leaks, unusual looseness of machine parts, improperly attached protective
devices and possible damage on any components.
− Check the level of all operation fluids (see top 8 of the check-list in the previous page)
− Check the proper function and orientation of all headlights.
− Check the attaching eyelids and the corresponding safety hooks for wear or damage.
− Verify the main control joystick and revert it to central position if necessary.
 Notify any unusual behaviour of the machine right away and solve them whenever possible to prevent
foreseeable personal injuries or machine failure.
− Ensure that the horn, the motion alarm (if equiped) and other warning or protective devices are set up/working
properly.
− Fix or replace any detected damaged, worn out or torn parts immediately before using the machine again.
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− Attach the safety hook of your harnest to the provided loop provided on the frontal guardrail as soon as you
bord the platform.
 Abnormalities of the machine may not be found out right away after starting the engine, meaning that
personal injury or machine breakdown may occur until then.
 Perform precautionary maintenance and engine warm-up before operation if:
− the machine has not been recently used, or ambient temperature is below the freezing point.
− Start the engine.
− Check for any leaks from the hydraulic components.
− Notice any defects on checks carried out at the roadside.
4.9.5 Engine Starting process
WARNING! Check all protective devices before ignition!
 Optain clearance from the maintenance personel to start the engine.
 Any unapproved ignition may lead to injuries or property damage!
 Never start the engine or touch any part of the machine in the following
cases:
− During maintenance/service/repair by other personnel.
− When a warning sign is hung around the main joystick.
− In the 2nd case, wait for the warning sign to be removed by the placer before operating the machine again.
− Warm up the engine and/or hydraulic oil before resuming operation after maintenance.
− Avoid short-circuiting the ignition machine during the starting process.
− Right after start-up, check the meters and monitor instruments for abnormal values or warning sounds.
− Make sure that all protective devices are in place to prevent accidents during operation
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4.9.5.1 Engine cold-start
NOTICE! Preheating the engine and hydraulic system
− Preheating prevents a sluggisch response of the controls or other machine parts.
− Not practicing preheating increases the risk of accidents and/or damage to the components of the machine.
 If the batery’s electrolytes are frozen, do not charge it or start the engine with auxiliary power, as
either may cause a fire or explosion.
− Dissolve the battery‘s electrolyte is before either charging it or starting the engine with auxiliary power.
4.9.5.2 Cold weather precautions
WARNING! Possible hazards on frozen ground!
 Frozen ground is slippery! It also becomes soft when thawing, posing a hazard of tip-over for the
machine.
− Take extra care when moving the machine in freezing weather.
− Beware of the machine tilting or become buryed when entering deep snow areas.
4.9.6 Inspection after starting the engine
− Make sure that no person or obstacle is within the vicinity of the machine.
− Check if the instruments on the dashboard for any unusual values after the start-up.
− Check for unusual sounds, vibrations, abnormal heat emissions or peculiar smells.
− Fix any abnormality on the spot to prevent serious injuries and/or damage to the machine during work.
 Check if all components respond properly without delay, including:
− The moving and steering functions of the machine .
− Any oil or fuel leaks
− Sound the warning horn to alert people in the area before starting to use the machine.
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4.9.7 Inspection before starting machine operation
WARNING! Imminent hazards before operation
− Always look around for people or obstacles close to the machine

before operating or moving it.
− Double check the range of action when the boom is stretched out.
− Sound the horn to alert other people working in the nearby area.
− Ask a signalman to supervise your movements when you need to turn

or swing the machine.
− Keep a safe distance to people, other machines or other property

around you during the process.
4.9.8 Checking and maintaining before and after working
 Checing before working
− Radiator water level.
− Oil levels inside the engine oil pan.
− Oil levels inside the fuel tank, hydraulic reservoir, and transmission.
− Seal of each oil hose, water hose, air hose, and their connectors.
− Battery connections.
− Reliability of the service brake and parking brake.
− Flexibility of each control lever.
− Tire inflation.
− Fasten loose rim bolts, axle bolts, and other screws.
 Checking and maintaining after the working
− Check fuel level.
− Check oil level and cleanness of the oil pan. If oil is found over-leveled and diluted, cause should be
determined and fixed.
− Check for leakage from hoses and connectors.
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− Check the fastening, sealing and overheating of transmission, torque converter, hydraulic pump, steering
devices, axles and brake calipers.
− Check fastening of all pins and bolts on wheel rims and transmitting shafts.
− Empty the radiator when the environmental temperature is below 0°C (except when using antifreeze).
− Check brake liquid level.
− Clean the oil-water separator and drain the water in the air tank.
− Lubricate each grease point as required in the time schedule.
− Reasonable inspections and maintenance are necessary to your machine.
− Be careful not to cause any accident or hurt yourself.
− If something abnormal is found during your inspection, mark it first and fix it after all the checking items.
− When inspection is carried out with the boom raised, make sure that it cannot fall down.
− Do not check or maintenance near flame.
− Do not smoke.
− A fire extinguisher must be at hand.
4.10 Safe operation of construction work machines
4.10.1 Recommended use for construction work
 To avoid possible injuries or mechanical damage due to unexpected shocks, self-provoqued movements
or extensive vibrations:
− Select the appropriate machine(s) with only the required equipment and ancillary devices necessary for the
purpose or task given to you.
− Use the machine(s) exclusively according to their intended use.
− Make sure to read, understand and follow all recommendations described in this Operation and maintenance
manual.
− In case of recent faults, confirm with the maintenance personel that the necessary repairs and maintenance
have been properly completed before reusing the machine.
− Reverify the tire pressure and the condition of the brakes, steering gears and all related components after
maintenance or repairs have been performed on them.
− Operate the machine with care to avoid ecessive abrasion of the parts and keep the frequency of repairs to a
minimum (e.g.: when steering, braking, accelerating, changing gears, or moving the work equipment.)
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− To properly stop the previous action, always return the joystick to the neutral position before proceeding to
the next step.
− Adjust the speed of the machine to the quality of the ground to reduce the hazards of both injuries of the
operator and damages to the machine due to its exposure to possible vibrations.
− Avoid driving over obstacles or through rough terrain. Bypass any of these whenever possible to minimise the
impact of unexpected shock movements on the machine.
− If compulsed to drive through/over them, slow down and proceed with great care.
− When working on a construction site, include the maintenance of the ground into the project‘s schedule to
increase the safety during machine operation.
− Keep moderate speed when traveling longer distances (e.g.: on public roads)
 Keep the ground on your working perimeter in optimum condition as follows:
− remove any large rocks and other obstacles in the way;
− plug ditches and potholes;
− even the ground regularly and thouroughly.
4.10.2 General hazards
DANGER! Beware of hazards for life and property!
 Take utmost care in any step and refer to Section 4.8.3 for further essential pre-inspection information.
 Ignoring the following safety rules will cause life-threatening hazards for the operator, nearby
co-workers, bystanders or severe equipment damage.
− Follow the safety instructions acurately to prevent injuries and material damages:
− The graphical symbols on the controls indicate their respective functions.
− Memorise or refresh all their purposes and functions before beginning operation for the first or resuming after
a longer break.
− When released, most control elements will automatically return to their centered neutral position, causing an
immediate stop of the executed function or command.
− Check your surroundings before rotating the boom. Operate the levers carefully.
 Uncontroled movements may cause physical injuries or mechanical damages. Avoid it at any time!
 Especially the boom poses a dangerous threat to bystanders if moved unexpectedly.
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 Do not lean out or keep the hands out the window while working. Accidental movement of the machine
can cause physical injuries. Avoid it!
4.10.3 Operational hazards
DANGER! Beware of fatal injury hazards
 Ignoring any of the following rules or advices may cause life-threatening hazards for the operator,
nearby co-workers, bystanders or high material damage.
− Avoid any sudden, uncontrolled movements for the same reason.
− Inspect the machine before to any operation, especially if you did not take part to the installation process of
the machine or the equipped interchangeable equipmet.
− Refer to the safety instructions in Section. 3.5 for detailed information.
− Install only interchangeable equipment authorized by the manufacturer.
− Verify the installation of any interchangeable equipment before operation.
− Avoid lifting the interchangeable equipment while driving a slope downhill.
− Do not drive across slopes or protective walls.
− Make sure enough space is available to stop the swing process, especially while on a slope.
DANGER! Tripping and falling hazards!
− Ensure that all doors are closed and secured in the correct position before operating the machine.
− Use two hands and one foot or two feet and one hand at any time while boarding/leaving (a steady
3-points-contact is mandatorry).
− Keep your feet steady while on the platform to avoid accidents.
− Do not bring any additional items to extend your reach (e.g: ladders, boxes, steps, planks, etc.) onto the
platform.
− Remove any oil, mud, etc. from your soles to prevent slipping.
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DANGER! Tip-over hazard!
− Inspect the road‘s condition before starting to drive.
− Keep the machine within the inclination limits given in the technical data sheetto avoid tip-over.
− Keep the platform down to the base when driving on or close to a slope, or on any other form of uneven, soft
ground.
− Confirm to be on a firm, leveled and smooth surface before elevating the platform or driving with the boom
extended.
 Before driving onto surfaces with limited space and sustainabilty (e.g.: bridges, trucks, building roofs,
platforms, containers etc.), verify if they can sustain the maximum weight of the machine.
− Keep any electric items (e.g.: cables) away from the machine.
− Use cranes, forklifts or any other equipment suitable to stabilize the machine.
DANGER! Impact and crushing hazard!
− Assign a supervisor to monitor your movements and warn you from unseen hazards when driving it hrough
areas with limited vision (the blind spot beneath the plaform).
− Keep any bystandards at least 1.8 m (6 ft) away from the machine during operation.
− Adapt the driving speed to the ground‘s quality/conditions (e.g: congestion, visibility quality, presence of
slopes and the steepnes, presence and exact location of persons in the vicinity, and any other conditions that
may cause collisions resulting in personal injuries or property damages.
− Be aware of the braking distances of the machine in all driving speeds and weather conditions.
− Always switch from to low speed before stopping the machine to avoid mechanical damages.
− Only use low speed while driving the machine on a slope, in confined areas (e.g.: caves or buildings) or when
reversing.
− Prevent bumping into obstacles, or having them interfering with operating controls or endangering the
workers.
− Ensure that all personel (i.e.: operators of other machines in the vicinity, co-workers on the ground closer to
the platform or walking on nearby structures or buildings under construction) are aware of the MEWP's
presence.
− Disconnect the power of any cranes overheading the platform to ensure safety of the worttkers operating it.
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− Place roadblocks around the platform to keep other workers in the vicinity from standing, or walking right
beneath it.
4.10.4 Safety rules for towing operations
DANGER! Hazard during towing operations
 Any movement involving heavy loads, especially towing defective machines, involves many
unmanageable variables and unforeseable hazards for the operator, co-workers and other bystanders,
as well as the environment!
− Towing ropes may tear at any time due to overload or abrasion! Be careful during the entire process!
− Restrict the access to the area between the towing machine and the towed machine to any person during the
whole process.
− Wear leather gloves when handling steel ropes.
4.10.5 Forbidden Operation
DANGER! Life-threatening hazards of forbidden operation!
 Operations mentioned hereafter always will result life-threatening hazards for or major property
damages, therefore are prohibited.
 Not respecting these rules will inevitabily lead to irreversible injuries and major damages to the
machine.
4.10.5.1 Hzards preventive measures when parking the machine
1. Drive the machine to a safe spot with flat and firm ground.
2. Retract the boom completely and lower it down to the chassis, with the platform facing the rear of the
machine, in suspension above the axle.
3. Make sure all maintenance panels and doors are closed and latched.
4. Remove all remaining loads from the platform and let the engine idle for 3–5 minutes to cool down the
engine.
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5. In the ground control box, turn the the console selection key switch to the central (off) position and the
power/supply switch down (off position). Don‘t forget to take the key with you.
6. Cover the platform‘s console to protect nameplates, warning signs, and operating controls from
weathering influences
4.10.5.2 Peventing risks due to surfaces with poor bearing capacity
− Place the machine on a firm and evenly flat supporting surface (see Table 4-2 for ground bearing capacity)
and ensure the sides of the machine will not sink during operation, to avoid tipping over.
Maximum tire load (Single tire) 6500kg
Ground pressure 1.18kg/cm²
Reference table for ground bearing capacity
S/N. Soil type Ground bearing capacity
(kg/cm²)
Natural soil:
1
Sludge, peat, and wetland 0
Non-compacted soil:
2
Construction debris 0–10
Non-cohesive soil:
3
Sand, gravel, rock, and mixture 20
Clayed soil
a. Mixture of clayed silt and topsoil 12
b. Powdered coal, composed of coarse clay and few clay 13
4 c. Pottery clay, composed of plastic clay and filler
Hard 9
Half-solid 14
Solid 20
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S/N. Soil type Ground bearing capacity
(kg/cm²)
d. Mixed granule ground (mixture of clay, sand, gravel, and

rock)
Hard 15
Half-solid 22
Solid 33
Uniform solid rock:
5 a. easily broken or decomposed 150
b. Non-fragile 300
Artificially compacted road:
a. Asphalt road 5-15
6 b. Concrete:
1) General concrete (grade BI concrete) 50–250
2) High strength concrete (grade BII concrete) 350–550
4.10.6 Risk in special operating conditions
NOTICE! Be aware of operations in special conditions!
− Special operating conditions may have impact to the service life of machine, machine functions and finaly
safety of machine operation!
− Not respecting the safety steps and notices presented hereafter – can reduce the machine service life, may lead
to machine damage and loss of the product warranty.
4.10.6.1 Operating at low temperatures
NOTICE! Be aware of operations in special conditions!
 Not respecting the safety steps for special operating conditions may have impact to the service life of
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the machine, its functions and also the operation safety.
 The loss of the product warranty may result aswell.
 Protective measures must be taken to ensure normal operation under freezing temperatures. The
following inspection can ensure flawless operation of the machine under these conditions.
− Check the cooling system carefully and record any leakage.
− Also verify that the correct antifreeze was added.
− Allways keep the battery at full charge to prevent it from freezing.
− If water has been added into the battery, run the engine for at least 1 hour to enable a homogene mix with the
electrolytes.
− Maintain the engine at its optimum to enable an easy start and operation, despite adverse weather conditions.
− Use engine oil with specifications complying with the ambient temperature.
− Refer to the section ―Lubrication and Specifications‖ in the engine‘s operation and maintenance manual for
further information.
− Ensure that the fuel tank is full at any time and drain any condensate that built-up in the fuel tank each time
before starting operation.
− Remove and service the fuel filter element regularly. Drain any concretions (e.g.: wax), and ensure that the
used fuel‘s solidification point is below the minimum ambient temperature.
− Lubricate the machine completely according to either the ―Lubricants and Maintenance Schedule‖ or the
lubrication diagram on the machine.
− Start the engine to warm it up to the usual operation temperature before load-on operation.
− While in idle state, if there are any dirt or ice deposits on the running gears, heat the machine up to thaw the
frozen impurities before beginning machine operation.
− Operate the hydraulic units with care until the temperature required for normal operation is reached.
− Check all control units and their function status to ensure flawless operation.
− If assisted start becomes compulsory refer to the ―start in cold days‖-section located in the chapter ―Engine
Start‖ in this operation and maintenance manual.
− Clean up all dirt, snow and water on the machine surface to prevent ice coating.
− If possible, cover the machine with canvas and prevent its edges from getting frozeon the ground.
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4.10.6.2 Operations in very hot areas
NOTICE! Overheat due to continuous operation in hot areas!
 Not respecting the safety steps for special operating conditions may have impacts to the service life of
the machine, its functions and its safe operation as well!
— Monitor the engine‘s temperature and stop the machine regularly to enable a cooldown
whenever needed.
 Dirt inside the cooling system will accumulate faster under high temperatures.
− Change the antifreeze at least once a year to maintain the corrosion resistance properly.
− Flush the cooling system regularly to keep its pipes clean.
− Do not use highly alkaline water to limit the deposit of dirt and rust inside the pipes.
− Check the electrolyte‘s level every day.
− Use less concentrated electrolytes in a high-temperature environment.
− Dilute the electrolyte with a specific gravity of 1.280×103 kg/m3 into that with specific gravity of
(1.200~1.240) ×103 kg/m3. Then charge the battery fully once.
− Recharge the battery whenever the reading of specific gravity reaches 1.160×103 kg/m3
 If stored for a longer time under high temperature, the battery will quickly discharge itself.
− Do not store acidic batteries close to a large number of tires, since the acidic gases will damage the rubber.
− Lubricate according to ―Lubricants and Maintenance Schedule‖ or the lubrication label attached on the
machine.
− When leaving the machine for a longer period, park it in a shelter to prevent exposure to sunlight, dirt and
dust.
− If there is no appropriate covering available, use a canvas to prevent the dust from entering the engine or
hydraulic system.
− Apply corrosion resistant lubricant on the unpainted or exposed areas.
− Protect conductors and terminals with an insulating mixture.
− Apply paint or appropriate antirust materials on damaged surfaces to prevent the rust from spreading.
− Apply paint or appropriate antirust materials on damaged surfaces to prevent further rusting.
 Rust and paint bubbles will build up on the metal surfaces and spots may appear on other components’
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surfaces, too.
 The machine components will corrode faster in a hot and humid climate; especially during the rainy
season.
4.10.6.3 Operations in dusty or sandy areas
NOTICE! Extra precautions in dusty or sandy environments!
the machine, its functions and its safe operation aswell!
 Take extra protective measures when working in dusty or sandy environements.
− Clean the machine with compressed air frequently to keep the cooling system dustfree.
− Wear safety goggles when using compressed air for cleaning.
− When servicing the fuel machine, take extra care to prevent dust or sand from entering the oil circuit.
− Always keep the air cleaner clean an in good condition.
− Check its clogging indicator everyday.
− Prevent dust and sand from entering engine parts and/or components as well as possible.
− Lubricate and service according to ―maintenance schedule‖ or the lubrication diagram attached on the
machine.
− Clean all the lubrication connections before lubricating the machine.
− Sand mixing in with the lubricant will cause the machine parts to wear faster. Keep the machine as sand- and
dust-free as possible.
− Park the machine under a shelter or cover it with a tarpaulin to prevent potential damage caused by
sandstorms.
4.10.6.4 Working in rainy and humid environment
NOTICE! Extra precautions required in rainy, humid areas!
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the machine, its functions and its safe operation aswell.
 Take extra protective measures when working in rainy, humid environements.
− the measures are similar to those for working in hot areas.
− Coat all exposed surfaces with lubricant
− Pay extra attention to damaged or unpainted areas.
− Immediately apply lubricant where paint starts to crack to prevent corrosion!
4.10.7 Optional components/ equipment
 If there are optional components/ equipment, please follow the following information.
− For any special component/equipment contact an authorized XCMG dealer or XCMG Construction
Machinery Co., Ltd.
− Read carefully installation instructions to manage the task by yourself
− Only use optional equipment according to their intended use and range of application.
− To install optional equipment properly read and follow operation and maintenance manual.
− If not trained - do not install any optional equipment on your own. Ask for proffesional support by XCMG
representative.
− Never remove protective devices (FOPS/ROPS) without approval by XCMG Construction Machinery Co.,
Ltd.
 Without proper working protective devices, the machine will lose its conformity according to the
machine directive (2006/42/EG) and all other applicable directives and regulations related to it.
WARNING! Hazards during installation of optional equipment
 Installation of the optional equipment may bring possible hazards and risks for the service staff and
environment.
 Not respecting the basic rules presented hereafter – serious injuries or deaths and/or significant
property damage may result!
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4.10.8 Hazards handling the battery
DANGER! Beware of flammable and explosive hydogen gas!
 Hazards involving the battery
 The battery’s status is defined by the densimeter’s display colour as

follows:
− Green: The batteryis charged and ready.
− Black: The batteryneeds be charged.
− White: The battery needs to be replaced.
− Use protective gloves and goggles when handling battery.
− When charging the battery, beware of the highly flammable and explosive hydrogen gas generated in the
process
− The battery‘s electrolytes contain corrosive sulfuric acid.
 Never smoke or use open fire at any time close to the battery!
 Wash out clothes or skin thoroughly with water if sulfuric acide splashes on any.
 In case sulfuric acid drops in eyes, wash them out with clear water and contact immediately the closest
hospital for treatment.
 Beware of sparks the battery may generate during operation/ handling. Shut the engine off before
starting the maintenance process.
 Carry out the maintenance by keeping the following in mind:
− When disassembling the battery, first start to disconnect the negative (-) terminals (grounding side).
− Do not let tools or other metal objects contact the battery‘s terminals or drop on the battery terminals.
− Before charging, disconnect the battery from the machine and carry it to a well-ventilated place for
re-charging.
− Finally, reinstall the battery in its original position after maintenance.
− When installing the battery, connect the positive terminals first, then the negative terminals (grounding side)
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4.10.8.1 Battery main insulation switch
 Switch the battery OFF in the following cases:
− Not operating the machine for 1 month or longer.
− Maintaining the electrical system.
− Disposal of the battery.
− Replacing the fuse and/or fuse link.
− Connecting the auxiliary cables.
 To avoid damage on the electrical system, do not switch off the battery
while the engine is still running.
− Switch off the disolator switch at least one minute after the engine has been
turned off
− The battery isolator switch is located either on the battery container frame or in
the engine compartment close to the location of the battery.
− Switched off - this switch physically cuts off the DC power supply between the
battery and the electrical system of the machine.
− Cut off the DC power supply.
− (O) (=‖ OFF‖-positisolatorion): => Cuts off the electric supply.
− Connect to the DC power supply: (I): (=ON”-position): Electric current is

provided.
 Switch it ON before starting the engine!
− Cut-off power suply may delete the radio‘s stored data set.
Reset the data in case that happens, if necessary.
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4.10.8.2 Engine start using auxiliary battery cables
WARNING! Explosion hazard in case of to wrong wiring!
 A wrong wiring of the cables will damage the battery and may even
cause an explosion!
 Always wear googles and rubber gloves when handling the batteries and
cables.
 For safety reason, jump-starting the engine using auxiliary cables

requires 2 people:
− When using the battery of a second machine to jumstart your own, do not
short-circuit the two machines together.
− Turn all engines off before connecting the cables to prevent unexpected
movements when supplying power.
 When installing the auxiliary cables, first connect the positive (+) pole.
 When removing the cables, start by disconnecting negative (-) pole

(grounding)ide).
After removing the auxiliary cables, do not let the clamps contact with any metall
tools or any kind of metall pieces.
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5 Operation
5.1 General overview of the machine:

5.1.1 Introduction
− This Operation and Maintenance Manual applies to following models of telescopic handlers.
− Consider the figures as reference supporting the identification of the system and not as photographic images.
In Figure5-1 machines main systems are shown:
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Figure5-1 Main parts of machine
No. Part Description No. Part D-escription
1 Fork 8 Headlamp
2 Boom 9 Rear illuminating lamp
3 Cab 10 Warning lamp
4 Fuel tank 11 Fender
5 Battery 12 Engine hood
6 Hydraulic oil tank 13 Rearview mirror
7 Frame
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5.1.2 Basic functional description
A rough overview over the machines functionl principle is given in the table below(table 5-1):
Table 5-1 Main component
Main systems Content

Engine High-power electronic control engine, air filter, and radiator
Brakes Braking system is used for speed controlling or parking on the flatland or slope
Steering Articulated hydraulic steering, with large oscillation angle.
24V, engine emergency switch, weighing system, electro hydraulic proportional handle,
Electrical system
Rocker switch, display instrument.
Dashboard With multifunction gauge including polychrome display and LED status indicators.
Seat Comfort seat with seat belt with belt application switch and optional slideable.
Gear shift Hydrostatic gearshift
Control lever Electro hydraulic proportional handle
Cab FOPS/ROPS, cold and warm air conditioning, large vision, adjustable steering column
Radiator system Fan controled by hydraulic
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5.2 Operating conditions

5.2.1 Operating limits
NOTICE! Respect environment and operating limits of machine!
 Refer to Section 2.5.4 and Section 10.1
5.2.2 Environmental Machine limits
NOTICE! Environmental Machine Limits!
Altitude: Below 2000m above sea level

Ambient Temperature: -25℃ to +46℃
Ideally solid and flat. slopes up to
Ground situation:
15°upwards are ok
Working
Non-swampy
environnement:
− It is XCMG common QA practice to inspect, prepare and adjust every machine before delivery to authorised
representative or directly to a customer.
− Refer also to steps required during initial start-up process, commisioning and/or the running-in period as
described in Sections 4.2 to 4.4.
Apply available checklist for startup and commisioning!
− Ignoring above guidelines may damage the machines or produce other negative impacts on their performance.
− Guidllines in Sections 4.2-4.4 indicatres a situations that may cause property or environmental damage if
ignored
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5.3 Control elements - Dashboard - Display overview

5.3.1 Control elements
Figure 5-2 Control elements(Top view cab interior)
Figure 5-3 Control elements (Exterior view of cab)
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Table 5-2 Control elements
Components Location - Cabin View
Key Component Remarks

1 A/C control panel See 5.3.14
2 Horn Button See 5.3.11
3 Radio
4 Emergency stop switch See 5.3.12
5 Combination instrument See 5.3.2
6 Load limiter display screen
7 Electric fan
8 Combination rocker switch See 5.3.12
9 Master joystick See 5.3.7
10 Cigarette lighter (Power socket)
11 Outrigger switch See 5.3.10
12 Key switch
13 Cup holder
14 Washing fluid reservoir
15 Seat See 5.6
16 Accelerator pedal See 5.3.12
17 Brake pedal See 5.3.12
18 Lighting handle See 5.3.11
19 A/C and heater air vent See 5.3.14
20 Electric central control box
21 Door lock
22 Working lamp See 5.5
23 Fixing lock catch
24 Rearview mirror See 5.3.13
25 Interior ceiling lamp switch
26 Rotary warning lamp See 5.5
27 Rear window switch
28 Upper door glass fixing clamp
29 Front windscreen defroster vent
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5.3.2 Dashboard
Figure5-5 Operation monitoring gauges
 Function description
Table 5-3
Table 5-3 Signal and Indicator Lamps (Power-on status) and Functional Descriptions on Combination
Instrument
Display Note (Turn-on status of indicator lamp and

No. Name Symbol
color corresponding countermeasure)
Left turn signal indicator Flash when the turn signal lamp switch is
1 Green
lamp shifted to left turn.
Right turn signal indicator Flash when the turn signal lamp switch is
2 Green
lamp shifted to right turn.
Front axle neutral This indicator lamp turns on when two front
3 Red
indicator lamp wheels are aligned.
It turns on when the engine oil pressure is too
Engine oil pressure
4 Red low or too high for >5s, with a warning tone.
warning lamp
Stop the engine for checking.
When this indicator lamp turns on or flashes,
Engine and emission
the engine or emission system is
5 related malfunction Red
malfunctioned. Please troubleshoot as soon as
indicator lamp
possible.
Rear axle neutral indicator This indicator lamp turns on when two rear
6 Red
lamp wheels are aligned.
This indicator lamp turns on when the engine
Engine malfunction
7 Yellow encounters a minor malfunction. In such case,
indicator lamp
timely solve the malfunction.
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It turns on when the coolant temperature is

Engine coolant
8 Red ≥105 ℃ . Stop the engine for cooling and
temperature warning lamp
checking.
9 Preheater indicator lamp Red It indicates the intake heating status.
Normal status: This indicator lamp turns on

when the machine is powered on and turns off
10 Charging indicator lamp Red after the engine is started. If this lamps fails
to turn off after start of engine, stop the
engine for checking.
Brake pressure warning It turns on when the brake pressure is low.
11 Red
lamp Check and solve the cause.
When the parking brake rocker switch is
Parking brake indicator pressed, this indicator lamp turns on to
12 Red
lamp indicate that the parking brake is applied for
the machine.
It turns on when the air filter element is
Air filter blockage
13 Red blocked. Stop the engine for checking and
warning lamp
treatment.
Low fuel level warning
14 Red It turns on when the fuel level is less than 1/8.
lamp
This indicator lamp turns on when the high
15 High beam indicator lamp Blue
beam is turned on.
Forward gear indicator This indicator lamp turns on when the
16 Green
lamp transmission is in a forward gear.
Reverse gear indicator This indicator lamp turns on when the
17 Green
lamp transmission is in reverse gear.
Neutral gear indicator This indicator lamp turns on when the
18 Green
lamp transmission is in neutral gear.
Left outrigger indicator This indicator lamp turns on when the left
19 Green
lamp outrigger is on the ground.
Right outrigger indicator This indicator lamp turns on when the right
20 Green
lamp outrigger is on the ground.
21 Steering mode display Yellow Two-wheel steering
22 Steering mode display Yellow Four-wheel steering
23 Steering mode display Yellow Crabwalk steering
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5.3.3 Illumination and signal lamps
There are several lamps mounted on the machine, including: front overhead lamp, rear overhead lamp, operation
lamp, front steering lamp, rear steering lamp, instrument lamps and braking lamp, etc.
Following table lists out the bulbs specification for those lamps as below:
Table 5-6
Description Qty Bulbs spec.

Front overhead lamps 4 24V 15W
Rear overhead lamps and operation
6 24V 15W
lamps
High beam 2 24V 75W
Low beam 2 24V 70W
Front and rear steering lamps 4 24V 21W
Braking lamps 2 24V 21W
Rear lamps 2 24V 5W
Top lamp 1 24V 5W
Gauge lamps 1 24V 2W
Clearance lamp 4 24V 5W
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5.3.4 Adjust the steering column
After sitting in the seat correctly, adjust the angle of the steering column to the most comfortable position.
Rotate the handle A counter-clockwise to loosen the steering column. Pull or push the steering wheel to a position
appropriate to you. Rotate the handle A clockwise to clamp the steering column.
Figure 5-8 Steering column
WARNING! Do not adjust the steering column during traveling!
− Check and ensure that the steering column is clamped in place. Do not attempt to adjust the steering
column during traveling.
5.3.5 Selection of Traction Force
Symbol Working condition
It‘s used for loading and unloading of materials

and for other applications requiring accurate
operations and high traction force of machine.
It‘s used for long distance handling or other

applications requiring low traction force. Figure 5-9 Traction Force Selection
Diagram
5.3.6 Selection of Gear
Under each speed mode, two gears are provided at choice, namely gear 1 and gear 2, which correspond to
different speed ranges. Please select the specific gear based on the actual operating need.
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Figure 5-10 Gear Switch
CAUTION! Make sure to operate the gearshifts after the stop of

machine!
− Select the gear only after the machine is stopped completely.
− Start the machine only after your desired gear number is displayed on the instrument display.
5.3.7 Traveling Direction Selection
 FNR and button switch
Figure 5-11 FNR Button
Under the stationary state of the machine, ensure that the transmission is in neutral gear (N) and the lamp N on the
LCD turns on. Ensure that the engine is idling before selecting a traveling direction.
Push forward the thumbwheel to gear F. The forward gear indicator lamp turns on. Depress the accelerator pedal
to drive forward the vehicle.
Push backward the thumbwheel to gear R. The reverse gear indicator lamp turns on. Depress the accelerator pedal
to drive backward the vehicle.
The machine can move in any gear, depending on the ground condition.
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CAUTION! Brake release and engine speed!
− After selecting the driving direction, release the parking brake and then depress the accelerator pedal to drive
the machine.
− Depress the accelerator pedal till the engine reaches a certain speed before the machine can travel.
5.3.8 Traveling Direction Selection
WARNING! It’s really dangerous to change traveling direction

during traveling!
− Selecting the forward/reverse gear during the traveling will probably cause serious injury or even death to you
and others. The machine will change the traveling direction suddenly without any warning. Abide by the
following recommended procedure to correctly select the traveling direction.
Stop the machine before selecting forward (F), reverse (R), or neutral (N) gear. Both high and low speed gears are
operational during both forward and backward traveling. There will be a warning tone when the reverse gear is
selected. The engine can be started only in neutral gear.
Traveling direction selection procedure:
1. Stop the machine and depress and hold the brake pedal.
2. Lower the engine speed to idling state.
3. Select new traveling direction.
4. Depress the accelerator pedal to start the traveling.
If the parking brake switch is pushed down, the parking brake indicator turns on.
5.3.9 Steering Mode Selection
Figure 5-12 Steering Mode Diagram
Steering mode selection Function

The machine is under four-wheel
Four-wheel Shift the steering mode
steering mode and the indicator lamp
steering joystick to position A.
on combination instrument turns on.
The machine is under two-wheel
Two-wheel Shift the steering mode
steering joystick to position B.
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The machine is under crabwalk Figure 5-13 Steering Mode

Crabwalk Shift the steering mode Changeover Diagram
steering joystick to position C.
The steering mode joystick is located on the right side of cab and has three modes, namely A, B, and C. A denotes
four-wheel steering mode, B denotes two-wheel steering mode, and C denotes crabwalk steering mode. Shift the
joystick to position B by default under normal traveling status. To change the steering mode, push the joystick
switch to A or C to complete the changeover of steering mode.
Use two-wheel steering mode whenever possible during traveling. Use four-wheel steering mode only when the
traction force is restrained on soft and uneven roads.
WARNING! It’s really dangerous to change steering mode during

traveling!
− Do not select the steering mode during the traveling of machine, otherwise it will result in serious injuries or
even deaths.
5.3.10 Operations of Joysticks/Switches
 Lifting and lowering (Forward & backward)
Figure 5-14 Joystick (Lifting and Lowering)
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Table 5-7
Description
Lifting:
Pull backward the controller (Direction A) to lift the connected attachment.
Holding:
When the joystick is in default position, the connected attachment keeps still.
Lowering:
Push forward the controller (Direction B) to lower the connected attachment.
 Extending and retracting (Thumbwheel)
Figure 5-15 Joystick (Extending & Retracting)
Table 5-8
Description
Extending:
Push forward the right thumbwheel of controller to extend forward the
attachment.
Holding:
When the right thumbwheel of the controller is in default position, the
connected attachment keeps still.
Retracting:
Pull backward the right thumbwheel of controller to retract backward the
attachment.
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 Tilting (Forward/backward)
Figure 5-16 Tilting of Attachment

Table 5-9
Description
Forward:
Push rightward the controller to tilt forward the attachment.
Holding:
When the joystick is in default position, the connected attachment keeps still.
Backward:
Push leftward the controller to tilt backward the attachment.
 Horizonal swing of frame
WARNING! The failure to abide by following operating requirements is

really dangerous!
− When the boom is higher than the horizontal position, do not operate the horizontal swing control of the
frame. If the machine is not horizontal, it‘s absolutely prohibited to operate the boom.
− Before operating the machine, level the machine by frame leveling horizontal swing control. If it‘s impossible
to adjust the machine to horizontal position, adjust the parking position of machine.
− Do not operate the frame horizontal swing control during movement of machine.
− The failure to abide by these safety rules will be highly likely to cause tip-over of machine.
− Operating 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.
Before the loading and unloading, the frame horizontal swing control switch can level the machine from one side
to other side. Before driving, make sure to use this switch to level the machine.
The hydraulic cylinder will hold at original place, until the switch is operated again to move the hydraulic
cylinder.
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If the boom angle is larger than 10ºwith respect to the horizon, do not operate the frame horizontal swing control.
Figure 5-17 Motion Logic Relations

Before operating the boom, use the angle gauge A to check the horizontal state of the machine. The machine is
under horizontal state when the angle gauge indicates zero (0º).
Figure 5-18 Level Gauge
To use horizonal swing of frame, push downward the switch firstly, and then continue to operate the handle.
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Figure 5-19 Swing of Frame (Joystick Operation)
Table 5-10
Description
Leftward:
Press the controller button and push leftward the controller to swing leftward the
frame.
Rightward:
Press the controller button and push rightward the controller to swing rightward
the frame.
 Multifunction
Push upward the switch firstly, and then continue to operate the handle
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Figure 5-21 Functions

Table 5-11
Description
Multifunction 1:
Push upward the left thumbwheel of controller to realize the own function of
attachment.
Multifunction 2:
Push downward the left thumbwheel of controller to realize the own function of
attachment.
 Control of outriggers
WARNING! Timely remove the sundries!
− Do not allow the accumulation of fragments in the gaps between cylinders and outriggers. Remove all
fragments and keep the gaps clean.
The use of outriggers can improve the stability of machine during lifting.
The lateral position of the machine is indicated by the angle gauge A installed within the cab. Before operating the
boom, use the angle gauge A to check the horizontal state of the machine. The machine is under horizontal state
when the angle gauge indicates zero (0º).
If it‘s impossible to level the machine in any specific position, adjust the parking position of the machine.
Ensure that the lowered positions of the outriggers play a role of supporting the machine weight. Unless it‘s
absolutely necessary, do not extend the boom. Firstly cut off the outrigger control before operations of the
machine.
On this machine, it‘s impossible to retract the outriggers when the boom is not fully retracted. The corresponding
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indicator lamp turns on when the boom is fully retracted and the outriggers are fully retracted.
Figure 5-22 Level Gauge
Figure 5-2 Outrigger Control

Table 5-12
Description
Lowering:
Push downward the outrigger joystick to move downward the
outrigger.
Holding:
When the outrigger joystick is in default position, the outrigger keeps
still.
Retracting:
Push upward the outrigger joystick to move upward the outrigger.
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Figure 5-24 Motion Logic Relations

Table 5-13
Description
The frame can‘t be leveled when the lifting angle of boom is >10°.
The outriggers can‘t be erected or retracted when the lifting angle of boom
exceeds 45º.
The outriggers can't be retracted after the boom is extended.
5.3.11 Multifunctional Control Handle
1. Turn signal lamp (Right)

Push the control handle away from you to flash the right turn
signal lamp and indicate a right turn of machine. At completion
of the turn, turn off the turn signal lamp. This function is
operational only when the starter switch is at position I.
2. Turn signal lamp (Left)

Push the control handle towards you to flash the left turn signal
lamp and indicate a left turn of machine. At completion of the
turn, turn off the turn signal lamp. This function is operational
Figure 5-25 Multifunctional Control Handle
only when the starter switch is at position I.
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3. High beam
When the low beam is turned on, lift up the control handle
towards steering wheel to position I to turn on the high beam
and return the control handle from position I to original
position to turn off the high beam.
4. Overtaking lamp
Lift up the control handle towards steering wheel temporarily
to position II to turn on the high beam.
5. Parking lamp
Rotate the control handle to align the parking lamp symbol B
with D and turn on the parking lamp and rotate the control
handle to align the symbol A with D to turn off the parking
lamp.
6. Horn
The horn button is located on the end of control handle. Push
down the button to sound the horn. The horn is operational
only when the starter switch is at position ON.
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5.3.12 Control Switch Group
Figure 5-28 Control Panel
5.3.12.1 Control of Parking Brake
Control of parking brake Function

On Push the parking brake The parking brake of the
rocker switch towards machine is applied and the
position B. indicator lamp on combination
instrument turns on.
Off Push the parking brake The parking brake of the
Figure 5-29 Parking Brake Diagram
rocker switch towards machine is released and the
position A. indicator lamp on combination
instrument turns off.
CAUTION! Use of parking brake switch!

− The engine can be started only when the parking brake rocker switch is pushed to the position B.
− The machine can start up for traveling only after the parking brake rocker switch is pushed to position A.
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5.3.12.2 Control of Illuminating Lamps and Warning/Indicator Lamps
Control of cab front working

Function
lamp
On Push downward the Two working lamps on front of cab
switch turn on.
Off Push upward the Two working lamps on front of cab
switch turn off.
Figure 5-30 Cab Front Working Lamp
Switch
Control of cab rear working
Function
lamp
On Push downward the Two working lamps on rear of cab
switch turn on.
Off Push upward the Two working lamps on rear of cab
switch turn off.
Figure 5-31 Cab Rear Working Lamp
Switch
Control of boom lamp Function
On Push downward the The working lamp on boom turns
switch on.
Off Push upward the The working lamp on boom turns
switch off.
Figure 5-32 Boom Lamp Switch

Control of rotary warning lamp Function
On Push downward the The rotary warning lamp above cab
switch turns on.
Off Push upward the The rotary warning lamp above cab
switch turns off.
Figure 5-33 Rotary Warning Lamp

Switch
Control of flasher Function
On Push downward the Both left and right turn signal
switch lamps flash.
Off Push upward the Both left and right turn signal
switch lamps turn off.
Figure 5-34 Flasher Switch

Control of wiper Function
A Push the switch to this The wiper stops running.
position.
B Push the switch to this The wiper is running.
position.
C Push the switch to this The washing fluid is sprayed while
position. the wiper is running. Figure 5-35 Wiper Switch
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Control of reversible fan

Function
switch
On Push downward the The reversible fan rotates in reverse
switch direction.
Figure 5-36 Reversible Fan Switch
CAUTION! Routine checking of radiator!

− The accumulated dirt on the radiator will deteriorate the heat dissipation performance of radiator and damage
the engine and hydraulic system.
− Daily check and clean the radiator.
− If there is a great amount of dusts or dirt in the working environment, ensure to increase the cleaning
frequency.
− It‘s prohibited to perform cleaning in an enclosed space.
− While the engine is running, push the rocker switch to position B. After a transitional period, the fan changes
the rotation direction and starts cleaning to blow away the accumulated dirt from the radiator. After
approximately 5s, the fan automatically restores forward rotation.
5.3.13 Rear mirrors
Once the seat has been adjusted to the specific operators needs the mirrors must be adjusted. It is important to do
this after adjusting the seat so that the operator has the proper angles of visibility.
WARNING! Rearview mirrors adjustment!

− Adjust all rearview mirrors as per the regulations of the Operation and maintenance manual, otherwise a poor
visibility will probably result in personal injuries or deaths.
 Adjustment of exterior rearview mirror

— The rearview mirrors can provide an additional visual field around the machine. Keep the rearview mirrors
clean and under good working status. Adjust all rearview mirrors at the start of every work shift or at the
change of operator.
− In addition, it‘s recommended to clean up the working site to minimize the danger arising from the visual
field problem. Before the operations, adjust the left and right exterior rearview mirrors of the cab as necessary,
in order to ensure that at least 1m areas on both sides of the machine can be observed from the operator's
position. In addition, a backward visual field of as large as possible shall be provided.
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Figure 5-37 Exterior mirror
5.3.14 HVAC Controls
WARNING!
− Do not perform any lubrication, maintenance, or repair work for the A/C, unless you have mastered
skillfully the operation, lubrication, maintenance, and repair information.
− It‘s dangerous to perform improper lubrication, maintenance, or repair work for the A/C, otherwise it will
probably lead to injury or death.
 The control panel is located on the front dashboard of cab.
Figure 5-38 A/C control panel
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Figure 5-39 A/C and heater air vent
Figure 5-40 Front windscreen defroster vent
 Functions of control switches:

1) Fan speed switch (power switch): It‘s functioned to control the airflow output of fan and the turn-on of
A/C system.
2) Temperature control knob: It‘s functioned to adjust the cab temperature during the air conditioning or
heating.
3) Air conditioning indicator lamp: Its turn-on indicates that the compressor is started and the air
conditioning system is working. Its turn-off indicates that the compressor is stopped.
 Operation instructions:
1) Air conditioning:
 Start the engine

− turn on the power switch (―COOL‖),
− rotate the fan speed knob to high speed position (―H‖) and run for approximately 5min
− Rotate the temperature control switch to maximum position (COOL) (The indicator lamp turns on.). In such
case, the air conditioning system starts working and the temperature within the cab starts to drop. When the
required temperature is reached,
− rotate the temperature control knob counter-clockwise slowly, till the indicator lamp turns off and the
compressor.
2) Stops working
In such case, the temperature within the cab is the set temperature. When the temperature within the cab is
126
higher than this temperature, the indicator lamp turns on and the air conditioning system restarts working. When
the temperature within the cab is below this temperature, the indicator lamp turns off and the system stops
working. Adjust the fan speed knob to achieve three airflow rates (high speed, medium speed, and low speed).
Adjust the angle of air vent to change the angle and direction of the cool airflow.
 Air conditioning and heating system
1) A/C mode:
NOTICE! Air conditioning and heating system!
− While using the A/C, do not rotate the temperature control knob to position ―COOL‖ and rotate the fan speed
knob to low speed position, in order to prevent impairing the cooling effect due to frosting of evaporator.
− For the air conditioning and heating system, if the air conditioning system is working in summer, do not open
the heater valve. Turn off the A/C temperature control switch during heating in winter.
2) Heating mode:
Figure 5-41 Add heater valve photo

− In the winter, firstly turn off the temperature control switch. After the start of engine, open the heater valve
and turn on the fan speed switch. When the temperature within the cab starts to rise and the required
temperature is reached, turn off the fan speed switch. When the temperature is below the required
temperature, turn on the fan speed knob again.
Adjust the fan speed knob to achieve three airflow rates (high speed, medium speed, and low speed). Adjust the
angle of air vent to change the angle and direction of the cool airflow.
127
NOTICE! Heating System!

− As the heat source for the heating system is the engine coolant and is connected with the engine water
tank. If the environment temperature is below 0ºC and the engine is not running, fully drain the engine water
tank or add antifreeze into the water tank, in order to prevent the frosting cracking of the heating system
heater core.
− This machine has already been checked and adjusted completely prior to purchase. However, if initial work is
under extreme environmental conditions, the service life of the machine may be shortened. It is then
necessary to carry out a warm up period with the machine for the first 50 operating hours.
5.3.15 Brake and Accelerator Pedals
 Brake Pedal and accelerator pedals
Figure 5-42 Brake Pedal & accelerator pedals
Table 5-14
Floor Pedals
Key Component
1 Brake Pedal
2 Accelerator Pedal
128
 Parking/Service Brake Control
Figure 5-43 Parking brake
− Turn the rocker switch to position ―B‖ to lock the parking brake.
− Turn the rocker switch to position ―A‖ to release the parking brake.
5.3.16 Fire Extinguisher
 A regularly serviced fire extinguisher is required on the machine.

The fire extinguisher on the machine is located on the cab pillar behind the operator seat to ease the quick use.
CAUTION
Always have an easily

accessible fire extinguisher
on the machine.
Figure 5-44 Warning label
129
Figure 5-45 Extinguisher location
NOTICE!
− Make sure that you are familiar with the operation of the fire extinguisher.
− Inspect the fire extinguisher and service the fire extinguisher on a regular basis.
− Obey the directions on the instruction plate.
− The operator must be trained on the proper use of the fire extinguisher.
Usage of the fire extinguisher:

a. Pull the pin.
b. Aim the nozzle of the fire extinguisher at the base of the fire.
c. Squeeze the handle to release the extinguishing agent.
d. Sweep the extinguisher from side to side across the base of the fire until the fire is out.
CAUTION! Use of fire extinguischer!

− Only use the fire extinguisher in situations that can be controlled by this form of fire suppression.
− Personal safety is the most import.
− If a fire becomes out of control, exit the machine by the safety exit.
− Depending on the location of the fire, use the main point of entry or the egress exit.
Do not operate or service a machine if a potential fire hazard is present. Remove any fire hazards from the
workspace.
130
5.3.17 Main battery insulation switch
NOTICE! Use of battery insulator switch!

− Connect the battery isolator switch before staring the machine.
− Turn the switch to the ―ON‖position to operate the machine.
− Disconnect battery isolator switch when parking the machine.
 Battery Isolator Switch
Figure 5-46 Bettery isolator switch

a. The switch has two positions: OFF/―O‖and ON/―I‖.
b. To deactivate the electrical system, turn the switch to the OFF position.
c. When the battery isolator switch is in the OFF position, the entire electrical system is disconnected.
d. To activate the electrical system, turn the switch to the ON position.
NOTICE! Battery isolator switch while the engine!
− Turning off the battery isolator switch while the engine is operating could result in serious damage to the
electrical system.
NOTICE! Battery isolator switch while the engine!
− Turning off the battery isolator switch while the engine is operating could result in serious damage to the
electrical system.
131
WARNING! Hazards from a battery!

− To reduce the risk of electric shock, turn the battery isolator switch to the OFF position before servicing the
electrical system or any other machine components.
 Emergency Stop Switch

a. The engine emergency stop switch beneath the left stand is shown.
b. Rotate or press the switch to stop the engine，pull out the switch for reset to start the engine normally.
Figure 5-47 Emergency Stop Switch

This diagram shows the engine emergency stop switch within the cab. Pull out the switch for reset to start the
engine normally.
132
5.4 ROPS & FOPS Cab
DANGER! Hazards if ROPS/FOPS not installed!

− Danger of crushing.
− Never operate the machine if ROPS/FOPS is not provided.
− It is prohibited to operate machines equipped with ROPS/FOPS without being secured by retention
system(e.g. seat belt)
5.5 Illumination
 Lights – Standard Arrangement

Lights on the front and the rear frame are included in standard machines standard content.
Figure 5-48 Front and Rear lamps view
CAUTION! Headlamp!
− Always keep the driving lights on while driving on the job site under insufficient light.
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5.5.1 Rear Combination Lamp
 The rear combination lamp is installed behind the frame. (Refer to Figure 5-34.)
Figure 5-49 Rear Combination Lamp
5.5.2 Light switches
5.5.2.1 High / Low beam
Figure 5-50 Control lever (light)

This lever is located on the right side of the steering column. The light switch only operates when the ignition
switch is in the ON position.
— Turn the knob on the end of the lever to change your lights between OFF and one of the two ON positions
( ):
- First Position. Position lights, instrument panel illumination, tail lights.
- Second Position. Headlights, instrument panel illumination, tail lights.
— To change from low beam to high beam, push the turn signal lever forward(see direction ② in the
above figure). When the headlights are on high beam, the high beam indicator light on the instrument panel
134
will be illuminated.
— To switch back to low beam, pull the lever back to the default position(see direction ③ in the above figure).
NOTICE! Battery status!

− To prevent battery‘s over consumption, switch all lights off while starting engine whenever possible.
5.5.2.2 Turn lights
Figure 5-51 Steering indication operation

— Push the control handle away from you to flash the right turn signal lamp and indicate a right turn of machine.
At completion of the turn, turn off the turn signal lamp. This function is operational only when the starter
switch is at position I.
— Push the control handle away from you to flash the left turn signal lamp and indicate a left turn of machine.
At completion of the turn, turn off the turn signal lamp. This function is operational only when the starter
switch is at position I.
5.5.2.3 Warning flasher
 In case of potential hazardous situations activate immediately the warning flashers by pressing button.
135
Figure 5-52 flash light
NOTICE! Warning flashers and rotating beacon operation!

− Operating the warning flashers and rotating beacon light while engine is not running will discharge the
battery.
− Secure control panel if machine is parked to avoid misuse
− Warning flashers do not operate if main battery insulation switch is switched off.
− Ensure the machine is not accessible to unauthorized persons.
136
5.6 Operator's Seat
DANGER! Prevent hazards in operation!

− Keep seat-belt fastened while operating the machine.
5.6.1 Seat adjustment
Figure 5-53 Operator‘s seat

1. Longitudinal adjustment 2. Weight adjustment 3. Weight adjustment indicator
4. Backrest angle adjustment 5. File pocket
 Weight adjustment
Use the knob to increase or decrease the weight resistance.
Adjust the seat as operator preference and comfort.
Figure 5-54 Weight adjustment
 Seat fore/aft adjustment

Pull the slide adjustment lever up and adjust the seat forward or
backward as required.
Release the lever to lock the seat in position.
Always make adjustments from the front center of the adjustment bar.
Figure 5-55 Fore/aft adjustment
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 Backrest adjustment
Lift up the handle and move the backrest to the desired position.
Release the handle to lock position.
Figure 5-56 Backrest adjustment
 Height adjustment
Hold two sides of the seat cushion by two hands and lift upward, till a
click locking sound is heard, which indicates that the seat height is
adjusted successfully and the seat cushion is clamped in position.
This seat totally has three adjustment positions. The first position is
the lowest position. Lift up from the first position to shift to second
position. Lift up from second position to shift to third position
(Highest position). Lift up from the third position and then release
both hands to automatically return the seat to first position.
Figure 5-57 Headrest
5.6.2 Seat Belt
CAUTION! Hazards if not fastened by seat belt!
− Seat belts must always be fastened and adjusted properly when operating the machine.
− Not doing so can result in serious injury or death.
NOTICE! Seat Belt!
− Check the status of seat belt and mounting fasteners.

− Consult with XCMG‘s dealer for relevant replacement parts of seat belt.
5.6.2.1 Adjustment of non-retractable seat belt
Adjust two ends of seat belt. The seat belt must make the operator feel close fitting and
comfortable.
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 Stretching of seat belt

a. Release the seat belt
b. Rotate the buckle (2) to tension the outer belt (1). In such case,
the lock rod can be loosened.
Move out the seat belt from the buckle.
c. Pull the buckle to tension the outer belt of the seat belt.
d. Release the other half of the seat belt by same method. If the
seat belt can‘t be fastened by buckle in the middle, please
readjust the seat belt.
 Retracting of seat belt

a. Fasten the seat belt: Pull outward the outer belt of the seat belt
to tension it.
b. Adjust the other half of the seat belt by same method.
c. If the seat belt can‘t be fastened by buckle in the middle,
please readjust the seat belt.
 Fastening of seat belt

a. Fasten the tab (3) of seat belt to the buckle (2). Ensure that the
seat belt is wrapped around the lower waist portion of the
operator.
 Release of seat belt

a. Pull up the release bar. This will release the seat belt.
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5.6.2.2 Adjustment of retractable seat belt
 Fastening of seat belt

Pull out the seat belt (4) from the retractor continuously.
Fasten the tab (3) of seat belt to the buckle (2). Ensure that
the seat belt is wrapped around the lower waist portion of the
operator. The retractor can adjust the length of the seat belt
and lock in place. The comfortable seat cover allows the
operator to have a certain movement space.
 Release of seat belt

Push down the release button on the buckle to release the seat
belt. The seat belt will automatically retract into the retractor.
5.7 Engine start and shutdown

5.7.1 Starting engine
 Before starting engine, refer to Sections 4.8.4 - 4.8.6:
WARNING! Be aware of hazards when starting engine!

− Become familiar with the engine operation and maintenance manual before operating the machine
 The machine is equipped with ROPS/FOPS, thus prior engine start and during the entire operation,
the operator must sit on operator’s seat and keep seat-belt fastened.
 Follow the following guidelines for engine start:
− Battery insulation switch is connected.
− For all engine specific operations refer to the engine supplier‘s documentation.
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Figure 5-58 Battery insulation switch
5.7.1.1 Starting engine
− Adjust the seat to the ideal position after buckling up

− Move the steering column to the ideal position.
− Place the shift level to the position of neutral position.
− Join with the parking brake.
− Move all operating lever to the central position.
− Inspect whether no people or obstacle appear in the circulating area before starting the engine, then honk the
horn and start the engine.
− The exhausted gas is poisonous; and pay the special attention to ensure the nice ventilation when starting
the engine in the closed space.
− Start the engine by turning the start key switch of the engine to the position START; and release the start
switch key immediately when the engine is started.
− Check if all dashboards warning indicators are off.
Figure 5-59 Ignition key-lock
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WARNING! Hazards on hot surfaces!

− Risk of burns or injury due to unexpected moving parts.
− Do not use any aerosol or chemical fluids as a startup aid
NOTICE! Attention on engine start!!
− The engine shall be started again after 2min if it is not started within 5-10s and cannot started again if it is
not started in consecutive three times, and the reason shall be found out.
− The turbocharger may be damaged if the engine fails to run at low speed before the oil pressure gauge
indicates that the oil pressure is enough.
5.7.1.2 Engine intake preheating start auxiliary device (If Equipped)
− Engine intake preheating start auxiliary device is the preheating unit under automatic control of engine ECU.
After energization of whole vehicle, engine ECU will automatically control the opening and closing of intake
preheating start auxiliary device according to temperature. In case of opening of preheating unit, preheating
indicator lamp will be on.
− When intake preheating start device is working, do not turn on engine.
− The corresponding relation between temperature and preheating time is set out in the table below:
Table 5-15
Temperature(℃) Preheating time (s)
-40 30
-29 30
-18 30
-15 30
-12 30
-9 20
0 10
10 10
10 10
20 10
5.7.1.3 Cold Weather Conditions Operating
− Warm-up your telescopic handler completely before working. If the telescopic handler has not been
warmed-up completely, it will react slowly and may result in an accident.
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− Operate every operating lever to circulate hydraulic oil throughout the hydraulic system and get warmed, this
process ensures the telescopic handler can function fully.
− If the electrolyte in the battery has frozen, do not charge electricity to battery. Do not use another
electrical source to start the engine; doing so can cause a battery fire.
− When charging electricity or using other electrical sources to start the engine, make sure that the electrolyte
has thawed out and check for leakage before starting.
− After working, clear ice, snow, water or sludge away from wires, sockets, switches, and sensors or their
surfaces. Failure to do so can cause damage to your machine.
5.7.2 Engine and Warm up Period
5.7.2.1 The following steps must be performed during the warm up period:
− The engine can be started after 3s when the whole machine is powered on or upon self inspection of
the instrument (the process of powering on or self inspection, which takes longer time, shall prevail).
− After starting the telescopic handler, idle the machine for 5 minutes to get it warmed up.
− Do not accelerate the engine suddenly during the warm up process.
− Observe the indicator lamp and the instrument frequently during operations; stop the machine for inspection
if the abnormal information displayed cannot be removed.
− Avoid sudden startups, accelerating, steering, and braking, except in the case of an emergency.
− During warm up period, every gear should be engaged equally in time.
− During warm up period, it is best practice to load the bucket with loose materials and avoid overloading
during initial operation. The loading capacity should not exceed 70% of its rated capacity and the driving
speed should not exceed 70% of the rated maximum speed.
− Check the lubrication state of the machine, and replace or add any lubricants needed according to the
maintenance schedule.
− The machine can be warmed up by the hydraulic oil if the operating lever of the bucket is remained at the
closed position in short run (10s and below); in this way the hydraulic oil can achieve the safety pressure and
the engine can be warmed up by the hydraulic oil more quickly.
− Operate all operating levers in the circulating way so that the hydraulic oil can flow through all hydraulic oil
cylinders and all hydraulic oil pipes in the circulating way.
− Observe and comply with the following suggestions when rotating the engine at low speed to warm up.
− The engine shall be warmed up for about 15min when the temperature is higher than 0℃.
− The engine shall be warmed up for about 30min when the temperature is less than 0℃.
− The warm-up time may be longer if the temperature is at below -20℃. Moreover, the more warm-up time
may be needed if the hydraulic action is slow.
− The whole machine should not run at low revolving speed in presence of low load for a long time; or the
machine may be easily trapped in phenomena, such as oil expelling.
− The machine shall be allowed to run at full load only when the temperature of the outlet water is higher than
60℃ and the temperature of the engine oil is higher than 50℃. Moreover, the load and the revolving peed
shall be increased gradually, and the sudden increase and sudden unloading of the load shall be avoided as far
as possible.
− Check and repair the machine according to regulations.
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NOTICE! Attention and care on engine start!

− The engine shall run at low speed until the alarm indicator lamp of the engine oil pressure is turned off.
− The engine shall be stopped if the alarm indicator lamp cannot be turned off within 10s and can be started
again after finding out the reason; or the engine may be damaged.
5.7.2.2 After 10 hours of running in period, the following operations should be carried out:
− Clean the rough engine oil filter, fine engine oil filter, and fuel filter.
− Check bolt tension on fan bolt, generator bolts, and air-conditioner compressor bolts.
− Check the battery charge level and tighten the connections on the battery.
− Check the transmission oil level.
− Check for leaks in the hydraulic system and braking system.
− Check the temperature and connection of all components in the electrical system.
− Check the generator performance, check all working lights.
5.7.3 Jump-starting engine
DANGER! Danger while jump-starting!
− Make sure that red/black cables‘ ends do not contact each other.
− First the ignition is switched off.

− To start the engine there are two ways – from the additional battery or charging device or from another
vehicle.
− In case the supply system is another vehicle, check the battery voltage of supporting vehicle.
− Switch ignition off on supporting vehicle as well.
5.7.3.1 Connection principle for jump-starting engine
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Figure 5-60 Connection between donating and receiving batteries

In case battery of the machine is empty, connect it with an external power supply (according to Figure5-61) :
− Ensure the GND pole (-) is connected to the machine‘s frame.
− Ensure battery insulation switch is ON, and all loads on the receiving machine are off (e.g. lights)
− Connecting cables for provide jump-start support to the machine should have a cross-section above 50mm²
(complying with ISO 6722).
 Connect the cables in the following order to minimize hazards:

− Connect 1st the red cable with the (+)-pole of the ―empty‖ battery.
− Then connect the other end of the red calbe with the (+) pole of the ―full‖ battery.
− Connect the black cable with a GND pole close to the battery on the receiving machine.
− Then connect the other end of the black cable to the (–) pole of the ―full‖ battery.
− Charge battery for at least 5 minutes before any starting attempt.
− If engine start was successful, keep the cables connected for another 3 minutes before disconnecting them.
− In case the supply system is another vehicle, keep its engine running during the entire charging process.
 Disconnecting the auxiliary battery

− Switch on lights on the donating machine prior removing connection to avoid overload.
− Disconnect the cables in exactly the opposite order as described above when connecting.
− After disconnection, switch electrical loads off.
− Let engine run to charge battery.
NOTICE! The battery at low temperatures!
− Batteries can freeze if kept discharged at temperatures below freezing point (0°C / 32°F).
− Ensure battery is defrosted prior charging of jump-starting.
− Avoid unnecessary engine operation as often as possible to support environmental protection
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5.8 Operate the machine

5.8.1 Before operation
 Safety checks: refer to Section 4: Safe operation guidelines
Figure 5-61 Personal Protective Equipment

− Operator must wear proper Personal Protective Equipment (PPE) including and not limited to safety hat,
safety clothing, safety shoes, safety glasses, gloves, and respirator if needed.
 Procedures for operation to follow for driver

− Only operate the machine while you are sitting in the operator seat. The seat belt must be fastened during
operation. Only operate the controls while the engine is running.
− Begin operation of the machine slowly, in an open area. Check controls and all protective devices for
proper operation.
− Before you move the machine, make sure your path is clear of all personnel.
− Note any needed repairs during machine operation. Report any needed repairs.
− Carry work tools at approximately 40 cm above ground level.
− Do not operate close to the edge of a cliff, an excavation, or an overhang.
− Avoid operating the machine across a slope. When possible, operate the machine up the slopes and down the
slopes. If the machine begins to side slip on a downgrade, immediately remove the load and turn the
machine downhill.
− Avoid any conditions that can lead to tipping the machine. The machine can tip when working on hills, on
banks, and on slopes. Also, the machine can tip when crossing ditches, ridges, or other unexpected
obstructions.
− Maintain control of the machine. Do not overload the machine beyond the rated machine capacity.
WARNING! Hazards by overloading of the machine!

− The failure to abide by the regulation of rated loading capacity will probably result in personal injuries and
property losses.
− Before any operation, refer to the rated load of specific attachment once again. The adjustment of rated load is
required for non-standard structure product.
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 Keep away from electric wires and cables. Keep other personnel away from electric wires and cables.
− Know the maximum dimensions of your machine.
− Adjust mirrors to suit the needs of the operator‘s visual range.
− Check for loose tools or parts around the operator‘s seat. Machine movement can cause these tools or parts
fall down and damage operating levers or switches.
− Adjust the angle of the seat for optimum operation, and ensure the safety belt is securely fastened.
− Ensure the fire extinguisher is in place and operational.
− Clear grease and debris away from handrails, ladders, and shoes to avoid of sliding.
− Abnormal sounds or vibrations while the engine is running indicate a problem with the telescopic handler.
Resolve the problem, and report to managing personnel.
− While in neutral gear, check the accelerator pedal for proper working condition.
− Test all meters, apparatus, and alarm lamps, ensure that they work normally and remain within the regulated
range.
− Test all operating levers and ensure they are functional.
− Test the gear-shifting lever to ensure proper operation.
− Under low speed, inspect the braking pedal, accelerator pedal, and inspect that the steering is responsive.
− Test that the reverse alarm working.
− Ensure that the hand braking has been disengaged.
5.8.2 Getting on Telescopic Handler
Figure 5-62 Get-on Diagram
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WARNING! Hazards of falling of the machine!

− Adhere to the following list of precautions to prevent a fall from the machine that could result in serious
injury or even death.
− Inspect the ladder and handrail before and after getting on and off the telescopic handler. Wipe away oil,
lubricant, and debris that are on the ladder or handrail. Further, any parts damaged shall be repaired in time
and any bolts loosened shall be fastened.
− When climbing the ladder make sure to keep three points of contact at all times to prevent a fall.
 Follow the safety rules presented hereafter to minimize these hazards

− Use hand rails to insure the three points of contact will be maintained while climbing ladders.
− Do not jump on or off of the telescopic handler. Never get on or off the telescopic handler when the telescopic
handler is moving.
− Do not jump onto the machine and try to stop the machine if the machine starts to move without driver.
− Always face the machine when getting on or off the telescopic handler.
− Do not enter or exit the telescopic handler from the frame or tires.
− People can step on/down the machine from the place having the ladder and/or handle only.
− Do not grasp the operating lever or the lock lever when stepping on/down the machine.
− Do not climb onto the engine protective shield or cover without anti-skid pad.
− Do not leave from the steps behind the machine or the place from the steps on the side of the driving room to
the frame on the top of the tire.
− Do not step on/down the machine with tools or objects in hands.
 No person shall be allowed to ride on the working device!
WARNING! Hazards when driving machine!

− Become familiar with the engine operation and maintenance manual before operating the machine.
− No person shall be allowed to ride on the working device or other auxiliary devices, or people may drop
and be suffered from serious injury or loss of life
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Figure 5-63 Person in danger
 Notes when leaving the driver seat

− Always place the working device on the floor before standing up from the driver seat if the driver seat is
required to adjust. Place the stop/brake pressure switch at the position ON and stop the engine.
− The machine may move suddenly and people may be suffered from serious injury or loss of life if the
operating lever is touched unexpectedly.
Figure 5-64 Working device placement
 Notes when leaving the machine

The machine may move suddenly and automatically and people may be suffered from serious injury or loss of life
if the correct steps are not taken when stopping the machine. Moreover, the following steps shall be always
implemented:
− The working device must be placed on the floor completely before leaving the machine; the engine shall be
stopped after placing the stop/brake pressure switch at the position ON.
− Ensure to use footplates and handrails to get off from the machine. Face towards the machine and hold the
handrails by both hands. Before get-off, ensure that there is no foreign material on the footplates.
− Check the inside of engine compartment for presence of fragments. Remove all fragments and papers to
prevent fire.
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− Remove all inflammable fragments to reduce the potential danger of the fire. Properly dispose the fragments.
− If the machine is to be unused for at least one month, make sure to shift the battery disconnect switch to OFF
position.
− Furthermore, all devices shall be locked; and people shall take out the key usually and store it at the place
specified.
 Machine access
− The machine access system shall meet the technical requirements of Earth-Moving Machinery--Access
systems ISO 2867.
− The access shall be available for the operator in the access system in order to facilitate going in/out the control
console and repairing of the machine.
 Emergency exit of the Cab
Figure 5-65 Emergency exit

− The machine shall be equipped with one Cab, the left side thereof shall be equipped with one door, and the
right side thereof shall be equipped with one door for emergent escape.
− People can leave from the emergent escape door on the right side if the door on the left side cannot be opened.
5.8.3 Start of Telescopic Handler
NOTICE! Before getting on telescopic handler!

− Before getting on the telescopic handler, ensure that no one is standing in or around the telescopic handler.
Ask personnel to keep a safe distance away from the telescopic handler.
− Do not start the engine if the control lever has any notifications stating ―No operation‖.
− Adjust seat and steering wheel for comfort and optimal view angles.
− Ajust the rear view mirrors for the best vision of the area the machine.
− Always wear your safety belt while seated in the operator compartment.
− Identify all alarm devices, meters, and operating devices.
− Ensure that the parking brake has been released and all operating levers have been set to their Neutral
positions.
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− Ensure that the horn, the backup alarm, and all other warning devices are working properly.
− Sound the horn to alert surrounding people.
5.8.4 Traveling of Machine
5.8.4.1 Forward/backward starting drive
− Place the battery isolator switch into the ON position (see 5.8.1).
− Sit in the operator‗s seat with the seat belt correctly fastened. Make sure you can push the foot pedals
completely down with your back against the seat cushion.
− Ensure no miscellaneous personnel appears on the machine or around the machine before driving.
− Sound the horn to warn those around the work area of your intentions.
− Make sure to sufficiently retract two outriggers.
− Fully retract the boom. Lower the boom sufficiently and then lift it slowly. Tilt backward the forks (or
attachment) to maximum backward tilting status and lift the boom to the traveling position in such manner
that the root of the forks (or attachment) is approximately 300mm above the ground.
Figure 5-66 Retraction of Forks

− 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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Figure 5-67 Installation of Tooth Protective Plate
CAUTION! It’s really dangerous to drive under loaded condition!
− Do not drive the machine under loaded condition on public roads.
− Adjust four wheels to linear alignment and select two-wheel steering mode. Do not select crabwalk steering
mode or four-wheel steering mode while driving the machine on public roads.
− 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.
Figure 5-68 FNR Joystick
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Figure 5-70 Traction Force

Figure 5-69 Gearshift Switch Figure 5-71 Parking Brake Switch
Selector Switch
− Depress the brake pedal and shift the FNR joystick to forward gear or reverse gear.
− Press the gear switch to select gear I or II (Refer to Figure 5-69).
− Press the traction force selector switch to select appropriate traction mode (Refer to Figure 5-70).
− Push the rocker switch to ―A‖ to release the parking brake (Refer to Figure 5-71).
− Release the brake pedal and slowly depress the accelerator pedal to drive forward or backward the machine.
5.8.4.2 Traction Force Mode Switchover
− To switch over from low traction force mode (Rabbit) to high traction force mode (Turtle) during traveling,
release the accelerator pedal to slow down the machine appropriately and then switch over to high traction
force mode.
− To switch over from high traction force mode (Turtle) to low traction force mode (Rabbit) during traveling,
release the accelerator pedal and meanwhile switch over to low traction force mode and then depress the
accelerator pedal to continue the driving.
5.8.4.3 Selection of Gear
Under each speed mode, two gears are provided at choice, namely gear I and gear II, which correspond to
different speed ranges. Please use the gear rocker switch to select specific gear based on the actual operating need.
CAUTION! Make sure to operate the gearshifts after the stop of

machine!
− Select the gear only after the machine is stopped completely.
− Start the machine only after your desired gear number is displayed on the instrument display.
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5.8.4.4 Steer the machine
The telescopic handler can be steered by rotating the steering wheel toward the direction to be changed during
driving.
NOTICE! Driving the Machine!

− Do not change the direction suddenly or on the steep slope when driving at high speed.
− The vehicle shall not be allowed to change the direction when the engine is stopped.
− Be sure to close the cab door in the process of machine turning to avoid damage to the cab door or objects
flying out of the cab.
− Be careful of opening the cab door after the vehicle is stoped when machine stops at the maximum turning
angle, so as to prevent the cab door from collision with the frame.
5.8.4.5 Machine operation shut down
− Park the machine on a level surface. If it is necessary to park on a grade（slope）, block the wheels.
− Apply the service brakes in order to stop the machine.
− Move the transmission to the NEUTRAL position.
− Engage the parking brake.
− Lower the work tool to the ground and apply slight downward pressure.
− Allow the engine to run for 3～5 minutes before shutting down.
− Turn the engine start switch to the OFF position and remove the key.
− If the machine will not be operated for a month or more, remove the battery isolator switch key.
Figure 5-72 Battery disconnect switch
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5.8.4.6 Engine stopping
− Do not stop the engine immediately after the machine has been operated under load. This can cause
overheating and accelerated wear of engine components.
− The engine shall run 3～5min at low and idle speed when the machine is stopped; in this way, the part
which is too hot in the engine can be cooled gradually.
− The start switch key of the engine shall be switched over to the position OFF and shall be drawn out.
NOTICE! Stopping the Engine!

− Stopping the engine immediately after it has been working under load, can result in overheating and
accelerated wear of the engine components.
5.8.4.7 Leave the machine
− The ladder and the handrail must be used when taking off the vehicle; and people shall hold the ladder and
handrail with two hands when facing the machine. Moreover, ensure that no impurity is left on the ladder
before leaving the vehicle.
− Inspect whether no fragment is left in the engine room; and clean the fragments and all kinds of papers in
order to prevent fire.
− Clear up all combustible fragments to reduce the potential risk of fire and discard the fragments properly.
− Inspect the oil surface and cleanness condition of the bottom housing of the engine oil; find out the reason if
the oil level is too high and the oil is being thinning gradually and eliminate the problem.
− Inspect whether the oil pipe, the water pipe, the gas pipe and all kinds of accessories are subjected to
penetration and leakage.
− Inspect the fixation and sealing condition of the gearbox, the torque converter, the hydraulic oil pump and
the front and rear axles, and check whether excessive heating occurs.
− Inspect whether the bolts of the rim, the bolts of the transmission shaft and all pin shafts are loosened.
− Discharge the cooling water (except the moment when the antifreezing solution is added) when the
temperature is less than 0℃.
− Close all covers, lock all parts having locks, draw out the keys and keep them carefully.
5.8.5 Operation Instructions of Machine
5.8.5.1 Introduction
This section describes the methods and techniques for safe and effective operations of the machine.
Your machine can be used under diversified conditions. Therefore, in all cases, the driver must determine the
operation and maintenance manual and the working conditions depending on the actual situation, in order to meet
the relevant laws and regulations.
We provide the most useful information with deep sincerity. XCMG accepts in a responsible way the suggestions,
opinions, statements, viewpoints, clear conclusions, and baseless views, which will be equally valued.
Ensure that you have passed sufficient training and are sure that you are competent for operations of machine
155
before driving the machine safely.

The carefulness, well-training, and rich experiences are your magic keys for safe and effective operations of
machine. Lacking of experiences or carelessness will make your driving dangerous. Do not threaten your life or
others due to your irresponsible driving.
DANGER! The unexperienced operations are really dangerous!

The influencing factors on the stability of machine include driving mode, load type, elevation angle and
extended length of boom, ground condition, and wind speed and direction.
− It‘s the operator‘s responsibility to evaluate the wind direction and speed and load scale before the operations.
− It‘s also operator‘s responsibility to evaluate the terrain, ground roughness (Bear in mind that the roughness is
different on wet and dry grounds), and ground hardness before the operations.
− Before starting the operations, read and understand the load chart of this manual and the boom manual.
Ensure that you can accurately control the machine before the actual operations.
− Use a load of standard weight for testing. Do not use any unknown load, unless you can handle a load of
standard weight safely and confidently.
Read and understand this section. Use the load chart and boom indicator before operating this machine. Practice
repeatedly, till the operations are correctly understood. Firstly practice the operations of flat loads. After the flat
loads can be operated safely and skillfully, operate the complicated loads. The machines covered by this section
are equipped with standard fork attachment. Please operate other attachments with reference to the section
Optional Attachments.
Before using any attachment, take the possible safety influence of attachment into consideration. After the
installation of attachment, the gravity center or the overall dimensions of the machine will probably vary, which
will probably influence the stability of the machine. Therefore, pay attention to the safety of ground operations
and the safety distance from the power cables.
Pay attention to the maximum wading depth of this machine. If the water is too deep, the water will breach 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 section Operating Safety in the preface and the following information:
5.8.5.2 Safety Rules
1. Clothing and safety appliances

Near the control or motion device of the machine, do not wear loose clothing or jewelry. Wear the protective
clothing and labor protection appliances as per the working conditions or local laws and regulations or the owner‘s
requirements.
2. Forklifting of load
a. Ensure that the place for the placement of load can carry the load safely.
b. Make clear the direction and keep calm during driving. If the load is too large to block your visual field,
appoint a person to assist the guidance.
c. Pay special attention to the level condition of the ground during driving. Refer to the section Operations
of Machine on Slopes (Operation Instructions).
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d. The stacking height of the loads shall not be higher than the forks.
e. The driving speed shall depend on the driving conditions. Drive at low speed on moist, slip, or loose
ground.
f. Drive with care on rugged roads, as it will probably shake off the load.
5.8.5.3 Risk Evaluation
In consideration of specific operating environment and working conditions, it‘s the operator‘s responsibility to
prepare appropriate operation regulation for the safe operations of the machine.
It‘s of great importance to perform correct risk evaluation and ensure effective safety protection measures for
fulfillment of operations.
If you don‘t know how to handle specific works, please contact a XCMG dealer, who will serve you with
pleasure.
During the risk evaluation, some factors below should be taken into consideration as suggestions. Sometimes,
other factors should also be taken into consideration.
NOTICE!
− The correct risk evaluation is originated from the well training and rich experiences. Never neglect your life
or others.
1. General knowledge
a. In the loading/unlocking area, the working area should be enough to accommodate the machine body
and outriggers (if equipped). It‘s unnecessary to operate the machine in a narrow space.
b. The working area shall be hard enough to carry the machine and load without clear deformation. The
ideal condition is that the working area can accommodate two machines and its gradient is no higher
than 2.5%(1:40).
c. When the machine is working in a loading/unloading environment probably not handled specially, the
operator can handle with well training and rich experiences. If equipped, the lateral regulator can
enhance the working capacity of your machine.
d. The traveling path shall be solid and reliable and its gradient shall be no higher than:
Maximum upslope gradient: 15%
Maximum downslope gradient: 15%
Maximum lateral gradient: 15%
These data can be used only for normal driving mode of the machine, namely the boom is retracted, the root of the
forks is >300mm above the ground, and the machine is not speeding. It‘s necessary to restrain the loads of specific
shapes, especially on lateral slopes.
2. Personnel
a. Among the personnel for this operation, who is better trained? Who is better experienced? Who is better
competent for this operation? Are they well rested? The driving under ill or fatigue state is really
dangerous.
b. Is the supervision necessary? Is the supervisor well trained and experienced?
c. Is an assistant or other assistance needed for the driver?
3. Machine
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a. Is the working state good?

b. Is the malfunction report corrected?
c. Is the routine checking fulfilled?
d. Do the tires for fulfillment of operation have sufficient pressure? Are they under good state? Is the fuel
sufficient?
4. Load
a. How heavy is it? Is it within the load capacity of the machine?
b. How large is it? A large surface area will be influenced by wind speed.
c. Is it a shape load? Where is its gravity center? An unbalanced load is difficult to handle.
d. Is it smooth and easily sliding? If yes, can it be handled by forks?
5. Loading/unloading area
a. Is it horizontal? The careful consideration shall be taken if its gradient exceeds 2.5%(1:40).
b. Is there more than one direction to access the load? If possible, avoid crossing over any slope.
c. Is the ground solid? Can the ground carry the weight of machine under full load?
d. Is the ground really rough? Is it harmful to the machine, especially to the tires in event of any
emergency?
e. Is there any obstacle or dangerous article nearby? Such as fragments, large pits, and electric wires.
f. Is the operating space enough? Is there the accessing of other vehicle or personnel during the working
of the machine?
6. Crossing path
a. Is the ground solid? Can it provide sufficient traction force and braking force?
b. How about the steepness of the slope (upslope/downslope/lateral slope)? It‘s really dangerous to cross a
slope. Is it possible to make a detour?
7. Weather
a. 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.
b. Is it raining or is there a possibility of raining? The influences on traction, steering, and braking of the
machine are different between dry and wet roads.
5.8.5.4 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, logs, and steel blocks).
DANGER!
− Without permission, it‘s prohibited to lift any person to the high air or stand on the non-protected forks. The
violation of such rule will probably cause serious injury or even death.
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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 rugged roads.
− Do not operate the boom/attachment during the traveling of the machine.
WARNING!
− The high slopes and soil ditches will probably collapse. It‘s probably dangerous to park or drive the machine
too close to a high slope or soil ditch.
WARNING!
− It‘s probably dangerous to leave the machine unattended in a public place. In a public place, if the
environmental visibility is impaired, set up safety railings in the working area to keep away the people.
− Maintain 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 defects will probably lead to pressure loss of the tires.
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 several 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 chart (Refer to the load chart 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 horizontal status of the ground. Whenever possible, do not carry the
load on a non-solid ground.
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DANGER!
− It will probably cause electric shock if your machine or attachment is too close to the power cables. Observe
the working area for presence of power cables before starting the working. If yes, contact your local power
supplier and inquire which safety measures shall be taken. Meanwhile, understand the requirements of local
laws and regulations on the operations near power cables.
− After you understand the safety measures to be taken in the working site and understand the laws and
regulations, make sure to abide by these requirements.
NOTICE!
− The load will probably fall off if the spacing between forks is not incorrect. With respect to the load, always
correctly place the forks. Before the lifting, ensure that the forks are completely beneath the load.
NOTICE!
− The load on single fork will fall off. It‘s prohibited to lift the load by single fork.
NOTICE!
− It‘s prohibited to unload the load from the forks by suddenly stopping the machine. Follow the unloading
procedure specified by the Operation Manual.
WARNING!
− Do not exceed the load grade of the forks. The forks will probably break to lose the load and cause possible
damages.
WARNING!
− Maintain 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 defects will probably lead to pressure loss of the tires.
5.8.5.5 Load grades of forks
WARNING!
− Do not exceed the load grade of the forks. The forks will probably break to lose the load and cause possible
damages.
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The forks must be used by pair.

The maximum carrying capacity is described in the section Performance of Machine (Technical Specification).
The carrying capacity of the forks for this machine must be equal to or higher than the maximum carrying
capacity of the machine.
If the carrying capacity of the machine differs from that of the forks, the smaller value shall be taken as the
carrying capacity of the machine.
WARNING!
− 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 countries 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.
5.8.5.6 Regular Loads
NOTICE!
− Load and unload on a solid and level ground. Take cautions against possible dangers, especially during
steering and reversing.
WARNING! Operate as per the load chart!

Before lifting or handling a load, make sure to know the weight of load.
− Never exceed the safe working load of your machine. Do not exceed the lifting angle and the extended length
limit indicated by the load diagram within the cab. Observe and use the load chart and boom indicator (in
section Operations).
WARNING!
− Take cautions to separate or stack the fork bodies, as the forks are really heavy.
5.8.5.7 Selection of Attachment
− Use the XCMG approved attachment only on the machine.

− Ensure that the attachment is suitable for the operation to be completed.
− Ensure that the attachment is correctly installed and locked on the machine carriage.
− Ensure that the machine attachment works normally.
− Abide by the limitations of the handler load chart with installed attachment.
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− Do not exceed the rated load of the attachment.

− Do not lift the load without the lifting attachment, otherwise there is a sling slip risk.
− Do not handle a belt-hung load directly on the forks (Such as large bag), as the sharp edges have a shear risk.
− Use an attachment designed for this purpose.
5.8.5.7.1 Installation and Disassembling of Attachment
 Installation of attachment
− Ensure that the attachment is in a position easy for connection to quick change bracket. If the attachment
orientation is incorrect, please adjust the attachment to correct direction and then start operation.
− Take out the locking pin from the quick change bracket and preserve it in a safe position.
− Adjust the posture of machine till the quick change bracket is paralleling with the attachment in the front and
then tilt forward the quick change bracket.
− Drive forward the machine slowly. After the quick change bracket coincides with the mounting point above
the attachment, tilt backward the quick change bracket and slightly lift the boom to lift the attachment off the
ground.
− Insert the locking pin to lock the attachment to the lower portion of quick change bracket. Bear in mind to
lock the fastener on the other side of the pin.
− If the attachment is equipped with hydraulic or electric accessories, connect and lock the hydraulic or electric
pipelines and circuits to the reserved connectors on the front end of the boom.
 Disassembling of attachment
− Operate in reverse sequence of the installation procedure of the attachment. Please ensure that the attachment
already stops operation and place the attachment levelly onto the ground before disassembling the attachment.
 Non-authorized attachment:
Do not use any non-authorized attachment. The reason is as below:
− The scope and the capacity limitations of the ―appropriate‖, self-made, refitted, or other non-authorized
attachment can‘t be determined.
− The excessive extending or the overload of the telescopic handler will probably result in tip-over of machine
with few warning or without warning and cause serous harms or deaths to the operator and/or surrounding
personnel.
CAUTION! It can’t be guaranteed that the non-authorized attachment is

competent to fulfill its expected function safely.
5.8.5.7.2 General Requirements for Use of Attachment
− Some attachments have specific load capacity chart. The type, weight, and dimensions of the attachment must
be equal to or smaller than the data indicated on the load curve chart of the cab. If the specific load capacity
chart is unavailable, please use the applicable load curve chart attached in the telescopic handler.
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− The telescopic handler attachments are only applicable for the telescopic handler with standard quick change
bracket.
− All attachments installed on the telescopic handler must be securely connected to the pins on the quick change
bracket. Do not directly fix the attachment to the forks, quick change bracket, or boom by chain, belt, or
fixture.
− For any applied load, the forks of the fork carriage must support 2/3 of the load length.
− The weights of attachment, rigging, and related load installed on the telescopic handler shall be included in
the total lifting load. Please refer to the load curve chart in use.
− The load curve chart applicable for the fork attachment is established based on the 600mm load center. The
load center must be equal to 600mm for the attachment and load, in order to utilize the available load curve
chart capacity.
− If the load center of combination attachment or load exceeds 600mm, make sure to calculate the equivalent
load, in order to ease the use along with the machine load curve chart.
CAUTION! Ensure that the gravity center of the load to be lifted is centered
between the forks before the lifting of the load.
Calculation of equivalent load

Determine the equivalent load by following calculation. The equivalent load is the value applied to respective load
capacity chart, in order to determine the applicable working area.
(Attachment weight × Connected distance) + (Attachment load weight × Load distance)/600mm = Equivalent load
The attachment gravity center distance and the attachment load weight distance are measured horizontally from
the front surfaces of forks.
 Example
Based on attachment weight = 200kg, attachment gravity center = 800mm, attachment weight = 1,000kg, and load
gravity center = 740mm, the equivalent load for this example is:
200×800 = 160,000
1000×740 = 740,000
（160,000+740,000）/ 600 = 1500kg
Perform the cross checking for this value and the load capacity of forks, in order to ensure that the rated value of
forks can uniformly carry this load. Then, utilize the load curve chart to determine the safe movement position of
1,500kg and place it within the operating limit scope of the machine.
CAUTION! This calculation is not applicable for the personnel work platform.
5.8.5.7.3 Use of Load Curve Chart
To correctly use the load curve chart, the operator must firstly determine/or have the following information:
1. Authorized attachment.
2. Appropriate load curve chart.
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3. Weight of lifted load.

4. Placement information of load:
a. Placement height of load.
b. Placement distance of load to the front tires of telescopic handler.
5. Find out the height line on the load curve chart and then move along it to the distance line.
6. In the zones within the load curve chart, the intersection point between any horizontal and vertical position
lines denotes the maximum load of the machine. If the horizontal and vertical positions of the load intersect
between the zones, make sure to use the zone of smaller value to restrain the load.
The weight of the load to be lifted must be equal to or smaller than the weight limit of corresponding zone within
the load curve chart. Determine the limitation of load zone on the load curve chart and operate the machine by
keeping within the limitation scope.
 Location of load indicator

Boom extending position sign Angle indicator
Quick change bracket
Fork carriage
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 Example of load curve chart
Boom extending
position sign
Lifting height
Lifting angle
Forward extending length
Attachment type
Outrigger status
Load zone: Indicate

maximum carrying capacity
of corresponding attachment
within this zone
Note: This is only one example of the load curve chart. Please use the chart within the cab, instead of this chart.
WARNING!
— Tip-over hazard. All loads indicated on the load curve chart are based on the condition that the machine
is on a solid ground, the frame is horizontal, the forks are placed uniformly on the fork carriage, the load
is concentrated on the forks, the tires of appropriate specification are inflated appropriately, and the
telescopic handler is under good working status.
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5.8.5.8 Load Weight and Gravity Center
- Make sure to understand the mass and gravity center of the load
before handling.
- The longitudinal position (Figure B1) of gravity center with respect to
the root of the machine is defined on the load chart of the machine.
- To achieve higher gravity center, please consult with your dealer.
- For irregular load, determine the lateral gravity center (Figure B2)
before handling and then place it to the longitudinal axis of the
machine.
WARNING! Pay attention to the change of load gravity center!

− It‘s prohibited to move any load in weight of exceeding the effective load specified by the load chart of the
machine.
− For any load with moving gravity center (Such as liquid), take into consideration the change of gravity center,
in order to determine the load to be handled.
− Take special caution and attention to restrain such change whenever possible.
5.8.5.9 Moment Limiter Warning Device
This device indicates the longitudinal stability of the machine and

restrains the hydraulic motion to guarantee this stability at least under
following operating conditions:
− The machine is under stationary status;
− The machine is on a solid and stable ground;
− The machine is used for handling and placement operation.
− Move the boom carefully while approaching the permissible load
limit.
− Please always observe this equipment during operations. −
− If the hydraulic motion of the machine is cut off, operate the
hydraulic deceleration motion (Figure C) as per following
sequence: If necessary, lift the boom (1), retract the boom (2)
whenever possible, and then lower the boom (3) to put down the
load.
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WARNING!
− The reading of the instrument will probably be error when the steering is under fully locked status or the rear
axle is swung to maximum degree.
− Before lifting the load, ensure that the machine is not under either of above two conditions.
5.8.5.10 Lateral Attitude of Machine
The lateral attitude is the lateral gradient of chassis with respect to horizontal plane. Lifting the boom will impair
the lateral stability of handler. Make sure to set up the lateral attitude of machine with the boom lowered, as
shown below:
1. Machine without frame leveling device

− Position the machine to ensure that the level air bubble is in the
center.
2. Machine with frame leveling device

− Correct the inclination by hydraulic control device and check the
levelness by level gauge. The air bubble in the level gauge must be in
the center.
3. Machine with stabilizers

− Place two stabilizers onto the ground and lift two front wheels of
machine (Figure D1).
− Correct the inclination by stabilizers (Figure D2) and check the
levelness by level gauge. The level air bubble must be in the center.
− In this position, two front wheels must be off the ground.
5.8.5.11 Picking of Load from Ground
Approach the handler to the load in the direction perpendicular to the

load, retract the boom, and keep horizontal the handler (Figure E1).
− Adjust the fork spacing and the self-centering with respect to the
load, in order to guarantee the stability (Figure E2) (The optional
solutions are available. Please consult with your dealer.).
− Do not lift the load by single fork.
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WARNING!
− During the manual adjustment of forks, take cautions to guard arms and legs against pinch and crushing risks.
Slowly move forward the machine (1) and move the machine to the stop
position in front of the load (Figure E3). If necessary, slightly lift the boom
(2) while picking the load.
− Place the load to transport position.
− Tilt backward the load far enough to guarantee the stability (prevent
load loss during braking or downslope traveling).
− For non-stacked load
Tilt forward the carriage (1), slowly move forward the handler (2) to insert
the handler beneath the load (Figure E4) (If necessary, block the load by
wedges.).
Continue to move forward the machine (2) and tilt backward the carriage
(3) (Figure E4) to place the load onto the machine and guarantee the
longitudinal and lateral stability of the load.
5.8.5.12 Picking and Stacking of High-Position Load
WARNING!Do not lift the boom in any case without checking the
lateral attitude of the machine.
NOTICE! Ensure that the following operations can be made under good
visibility condition.
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1. Picking of high-position load
Ensure that the forks can pass easily beneath the load. Lift and extend the boom
(1) (2), till the forks are level with the load. If necessary, move forward the
machine (3) (Figure F1) slowly and carefully. Bear in mind to maintain the
distance required to insert the machine beneath the load between the load and
the machine (Figure 1) and use boom length as short as possible.
− Extend and lower the boom (1) alternately. If necessary, move forward the
machine (2) (Figure F2) to stop the machine to the front of the load. Apply
the parking brake and shift the forward/reverse gear selector to neutral gear.
− Slightly lift the load (1) and tilt backward the carriage (2) to stabilize the
load (Figure F3).
− Tilt backward the load sufficiently to guarantee its stability.
− Monitor the moment limiter warning device.
If overloaded, place the load to original position. If possible, lower the load
without moving the machine. Lift the boom (1) to relieve the load, retract (2)
and lower the boom (3) to place the load to transport position (Figure F4). If
impossible, reverse the machine (1) carefully and gently to release the load.
Retract (2) and lower the boom (3) to place the load to transport position (Figure
F5).
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2. Stacking of high-position load
Approach the load in the front transport position to the stacking position (Figure
F6).
− Apply the parking brake and shift the forward/reverse gear selector to
neutral gear.
− Lift and extend the boom (1) (2), till the loader is higher than the stacked
pile, and meanwhile monitor the moment limiter warning device.
− If necessary, move forward the machine (3) (Figure F7) slowly and
carefully.
− Place the load to horizontal position and lower and retract the boom (1) (2)
to place the load onto the pile, in order to ease the correct positioning of
load (Figure F8).
− If possible, retract and lift the boom (1) alternately to release the forks
(Figure F9). Then place the forks to transport position.
− If impossible, please reverse the machine (1) really slowly and carefully to
release the machine (Figure F10). Then place it to transport position.
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5.8.5.13 Picking and Stacking of High-Position Load with Stabilizers
WARNING!
− Do not lift the boom in any case without checking the lateral attitude of the machine.
NOTICE! Ensure that the following operations can be made under good
visibility condition.
The stabilizers are used to optimize the lifting performance of machine. Position
the stabilizers when the forks are in transport position (Unloaded and fully
loaded).
- Place the forks to the transport position in front of the elevator.
- Maintain a sufficient spacing to allow the lifting of boom.
- Apply the parking brake and shift the forward/reverse gear selector to
neutral gear.
- Place two stabilizers onto the ground to elevate two front wheels of handler
(Figure G1) and ensure the appropriate lateral attitude of the machine.
Elevate the stabilizers (unloading and unlocking) when the forks are in transport
position and fully elevate two stabilizers simultaneously. Lower the stabilizers
(unloaded and fully-loaded) under lifted condition of boom.
WARNING! This operation must be one special operation to be

made with extreme caution.
Lift and fully retract the boom.

- Position the machine in front of the elevation (Figure G2) and move it
slowly can carefully.
- Apply the parking brake and shift the forward/reverse gear selector to
neutral gear.
- Once the stabilizers approach to or touch the ground, move the stabilizers
slowly.
- Lower two stabilizers and elevate two front wheels of machine (Figure G3).
- During this operation, make sure to permanently maintain the lateral attitude
and keep the air bubble within the level gauge in the center.
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WARNING!
− This operation must be one special operation to be made with extreme caution.
 Keep the boom lifted and fully retract it (Figure G3).
− Once the stabilizers touch the ground and leave the ground, please move the
stabilizers slowly.
− During this operation, make sure to permanently maintain the lateral attitude
and keep the air bubble within the level gauge in the center.
− Fully elevate two stabilizers.
− Release the parking brake and reverse the machine really slowly and carefully
(1) to release and lower the machine (2) to transport position (Figure G4).
 Use stabilizers to pick the high-position load and ensure that the forks can
pass easily beneath the load.
− Check the machine position with respect to the load and if necessary perform
the test run under unloaded condition.
− Lift and extend the boom (1) (2), till the forks are level with the load (Figure
G5).
− Extend and lower the boom alternately (1) and stop the forks in front of the
load (Figure G6).
− Slightly lift the load (1) and tilt backward the carriage (2) to stabilize the load
(Figure G7).
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− Monitor the moment limiter warning device.
− If overloaded, place the load to original position.
− If possible, lower the load without moving the machine. Lift the boom (1) to
relieve the load, retract (2) and lower the boom (3) to place the load to transport
position (Figure G8).
 Stacking of high-position load with stabilizers
Lift and extend the boom (1) (2), till the load is above the elevation (Figure
G9), and meanwhile monitor the moment limiter warning device.
− Horizontally position the load and lower and retract the boom (1) (2) to release
the load, in order to position the load correctly (Figure G10).
− Retract and lift the boom alternately (3) to release the forks (Figure G11).
If possible, place the boom to transport position without moving the machine.
5.8.5.14 Picking up and Putting down of Hung Load
WARNING!
− The failure to abide by following instructions will probably result in instability and tip-over of machine.
− Make sure to use together with the handler installed with operable hydraulic motion cutoff device.
 Working Conditions
− The length of sling or chain shall be as short as possible to restrain the swing of load.
− Lift vertically along the axis and do not pull laterally or longitudinally. Do not move machine during
handling.
− No matter the stabilizers or the tires, the lateral attitude shall not exceed 1%, the longitudinal attitude shall not
exceed 5%, and the level air bubble shall be kept in the center.
− Ensure that the wind speed is no higher than 10m/s.
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− Ensure there is no person between load and machine.

− Transport with hung load
− Before movement, check the terrain, in order to avoid falloff due to excessive gradient or crossing and avoid
the rugged, pitted, or soft ground.
− Ensure that the wind speed is no higher than 36km/h.
− The machine speed shall not exceed 0.4m/s (Namely 1.5km/h, 1/4 of walking speed).
− Drive and stop the machine handily and stably, in order to minimize the swing of load.
− Handle the load several centimeters (30cm at most) off the ground with minimized boom length. Do not
exceed the offset indicated on the load chart.
 If the load starts to swing excessively, stop and lower the boom to put down the load and
do not hesitate.
− Before movement, check the moment limiter warning device. Only the green lamp should turn on and the
yellow lamp can probably turn on.
− During transport, the machine operator must be assisted by one ground person (in the place at least 3m away
from the load), who will use a rod or rope to restrain the swing of the load. Ensure that this person is always
clearly within your vision field.
− The lateral attitude shall not exceed 5% and the air bubble in the level gauge must be kept in the center.
− The longitudinal attitude shall not exceed 15% during loaded upslope traveling and shall not exceed 10%
during loaded downslope traveling.
− The boom angle shall not exceed 45°.
− If the first red lamp of the moment limiter warning device turns on during traveling, stabilize the load lightly.
Retract the telescopic boom to reduce the offset of load.
NOTICE!
− Never lift the boom by >300mm off the ground or luff the boom for >45°.
5.8.5.15 Use of Bucket
 Shoveling
WARNING!
− Do not lift the boom in any case without checking the lateral attitude of the machine.
NOTICE!
− Ensure that the following operations can be made under good visibility condition.
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 Filling of bucket
− Place horizontally the bottom of bucket exactly in contact with the

ground (Figure A1).
− Move forward (2) gradually and meanwhile lift the boom and tilt
backward the bucket (3), in order to improve the filling and material
leaking (Figure A1).
− Reverse the machine (1) really carefully and gently to release the bucket.
Lower the boom (2) to transport position (Figure A2).
NOTICE!
− Tilt backward the bucket sufficiently to prevent the material leaking and guarantee its stability.
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 Loading to truck
− Approach to the side face of truck in transport position (Figure A3).
− Lift and extend the boom (1) (2), till the bucket is above the truck, and
meanwhile monitor the longitudinal stability limiter and warning device
(Load handling description: C - Longitudinal stability limiter and
warning device) (Figure A4).
− Drive forward the handler (3) carefully and gently to empty the center
load of truck by bucket (Figure A4).
− Apply the parking brake and shift the FNR joystick to neutral gear.
− Slowly dump the material (4) (Figure A4).
− Tilt backward the bucket (1) and reverse the handler really carefully and
lightly (2) (Figure A5).
− Retract (3) and lower the boom (4) to transport position (Figure A5).
 Backfilling
Place horizontally the bottom of bucket exactly in touch with the ground (1)
(Figure B1). Drive forward gradually (2). Once fully filled, the bucket will
function as one leveling blade (Figure B1).
NOTICE!
− Watch for the ditches and recently dug and/or backfilled ground during driving.
5.9 Braking and Stop of Telescopic Handler
WARNING! Rated loading capacity!

− The failure to abide by the regulation of rated loading capacity will probably result in personal injuries and
property losses.
− Before any operation, refer to the rated load capacity of specific attachment once again. The adjustment of
rated load capacity is required for non-standard structure product.
5.9.1 Braking and Stop
1. There is no danger or threat to park the machine on a dry level ground.
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WARNING! Stop!
− The incorrectly parked machine will probably move without the operator. Please abide by the relevant
instructions for correct parking of the machine in this manual.
2. 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 (Steps 3 and 4).
CAUTION! Parking Brake!
− The parking brake can‘t be used to slow down the traveling speed, unless in event of an emergency.
Otherwise the braking efficiency of the parking brake will be impaired.
3. Push down the parking rocker switch. Ensure that the parking brake indicator lamp turns on. Release the
brake pedal.
WARNING! Do not get off machine!

− Do not get off the machine during movement of machine.
4. Shift the forward/reverse gear knob in neutral gear. Ensure that the brake indicator lamp turns off when the
knob is in this position.
5.9.2 Brake System
− The brake system is used to control the speed to park the machine on a flat ground or slope.
− The telescopic handler is equipped with two sets of brake systems:
− Service brake system
− Emergency parking brake system
Figure 5-74 Emergency Stop Figure 5-75 Parking Brake

Figure 5-73 Service Brake
Switch Switch
 Service brake system

− This brake system is used to control the normal traveling speed.
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− This brake system is stable and safe.

− This brake system adopts full-hydraulic brake.
− This brake system can automatically compensate the wear of friction discs, featuring high radial performance
efficiency, long life, and no noise.
− This system features simple structure, high reliability and safety, and easy maintenances.
 Engine emergency stop and parking brake system

− This system is used for emergency stop or parking of telescopic handler on flat ground/slope.
5.9.3 Parking and Shutting down the engine
5.9.3.1 Parking the Machine
WARNING! Park the Machine!

− Park the machine on supervised areas to prevent possible accidents or the access by unauthorized persons.
− Remove the ignition key and cover the machine with a hood for extra security against misuse.
− Park the machine on stable, flat ground to prevent hazards or damages to it.
NOTICE! Operating the machine

− Follow local traffic regulations while parking the machine on public areas.
 Safe parking
− Choose a place as flat as possible to park the telescopic handler.
− Do not park the telescopic handler on a slope. If parking the telescopic handler on a slope is unavoidable, the
gradient of the slope should not exceed 1/5.Use wedges to fix wheels, and drop the working apparatus down
onto the ground.
− If the telescopic handler is in parked dangerously or has to be parked in a heavily trafficked area, set a fence,
signal flags, or warning poles around the telescopic handler. Take methods to make other vehicles see the
telescopic handler clearly.
− Dump all loads out before stopping the telescopic handler.
− Drop the working equipment to the ground and lock all operating levers.
− Twist and push down on the parking brake to engage braking position.
− Lock all devices and take out the keys.
− When exiting the telescopic handler, face the machine and keep your body stable by keeping three points of
contact with the machine.
− Do not enter or exit the telescopic handler while it is running.
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5.9.3.2 Shutting down engine
Figure 5-76 Shutdown operation

− Release the accelerator pedal(see Figure5-76 ②) and press the brake pedal(see Figure5-76 ①).
− Return the shift lever to neutral position(see Figure5-76N) and rotate the lever to 1(see Figure5-76I).
Figure 5-77 Default position

− Place the attachment in the ground and push the controller in the default position(see Figure5-77)
− Turn off the engine ignition key switch(see Figure5-78) and remove the key from the switch.
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Figure 5-79 Push down the Figure 5-80 Emergency stop

Figure 5-78 Ignition key
parking brake switch. switch
− Push down the parking brake switch.
− The parking brake indicator lamp (Refer to 5.3.2 Warning Lamps) on the instrument should turn on.
− Fully push down the emergency stop OFF switch.
NOTICE! Engine operation!

− Ensure all devices are switched off and switch the engine to low idle.
− Ensure any additional equipment installed on the machine are secured.
− Shuting down engine while at high speed may reduce engines service life.
− Turn off the battery main isolator switch to prevent rapid discharge.
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6 Maintenance
 Improper or wrong maintenance may lead to violation of laws and regulations!
 Improper or wrong maintenance will void/invalidate the warranty
WARNING! Maintenance Work!

− During maintenance, if someone starts the engine, touches or operates the working joysticks, it may cause
serious personal injury or damage to the machine
 "No Operation" warning label must be hung on the working joysticks in the cab to warn
that someone is maintaining the machine.
CAUTION! Suitable tools!
− The use of damaged, defective, temporary or unsuitable tools may cause serious personal injury!
NOTICE! Maintenance!
− Maintenance shall be carried out by trained and instructed persons.

− If maintenance needs to be done with the running engine, a qualified driver in the cab must be involved in the
process!
− Excessive or insufficient lubrication cause severe damage to the machine.
− Use lubricants and other consumables that meet at least the quality recommended in this operation and
maintenance manual.
− Read this instruciton manual with care prior carrying out maintenance.
− Regular maintenance of the machine is required!

− Tasks included into the regular maintenance scope are described in this operation and maintenance manual.
− For tasks extending the content of this operation and maintenance manual contact your XCMG representative.
− Maintenance period is given for the case of usual operation.
− Maintenance intervals may become shorter depending on the way the machine is used.
− The time related to maintenance intervals is referred to machine‘s hour meter.
− Additional engine specific instructions can be found in engine‘s operation and maintenance operation and
maintenance manual.
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NOTICE! Impact of modifications!
− For any task not described within provided manuals contact your XCMG partner.
− All refitting not approved by XCMG will void the warranty of the machine.
6.1 Safety during maintenance
 Avoid any accident

− Be sure to remember the maintenance regulations before you start working.
− Keep your workplace clean and dry.
− Don‘t spray water or steam inside the cab.
− Don‘t lubricate or maintain the machine while moving.
− Avoid body limbs contact, or clothes getting sucked in rotaing parts.
Figure 6-1 Illustration of accident
 Tasks before starting maintenance

− Park the machine on flat ground.
− Lower the forks or attachment onto the ground.
− Run the engine for 3～5 minutes at low speed and empty load.
− Stop the engine, turn off electric power and remove the key from the switch.
− Set the safety lever to the ―lock‖ position.
− Let the engine cool down.
Figure 6-2 Illustration of status

− Check the parts at regular intervals and repair or replace them according to the needs.
− Keep all the parts in good working state and install them correctly.
− Replace the worn or damaged parts in time, and remove any accumulated grease, oil or scrap.
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− Adopt non-flammable cleaning oil and do not use fuel, gasoline or other highly flammable substances to clean
the parts or surface.
− If spilled on any machine parts, or surfaces, clean them instantly.
− Disconnect the grounding cable (- pole) of the battery before regulating the electric system or performing any
welding on the machine.
WARNING! Lighting at the workplace!

− Ensure adequate lighting at the workplace.
− If working below or inside the machine, always use guarded work lights. Otherwise the bulb may ignite
any of the flammable liquids (fuel, engine oil, anti-freezing or washing fluid) it contact or in case it
breaks.
 Protection against flying debris or parts

− Use the safety goggles or safety glasses to avoid injuries due to flying particles, fragments or debris of any
material.
− Prevent others from entering the working place in case of hazard of flying objects.
Figure 6-3 Illustration of protection

− If the fragments are filled into the eye or bounced to any other part of body, they will cause the severe
injuries.
 Safety during the maintenance process

− Warn the others that any unexpected machine movement may cause severe injuries and hang up the warning
plate ―No Operation‖ on the control joystick before maintaining the machine.
 Handling machine parts in a safe manner

− Always secure the affected machine parts safely before starting maintenance or repairs on them.
− Always lower the equipment to the ground before maintaining and repairing the machine.
− Do not use such as slag bricks, cord tires, racks to support the machine. Special equipment is necessary.
 Keep away from rotating parts

− The entrapment of limbs within rotating parts causes severe injuries.
− In case of working next to rotating parts, do not let your limbs, clothes or hair get sucked-in by the rotation.
− Do not remove any of the grease coupler or valve body.
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− Keep your body and face far away from valve body since it may fly out suddenly at any time.
Figure 6-4 Illustration of danger
 Safe storage of fittings

− The machine parts assembled with bearings (e.g.bucket, grapple, wood tongs) may loosen up and fall, causing
serious injuries to unawared people nearby.
− Disassemble and store the interchangeable equipment if it is not used for a longer period of time, and
personnel should be far away from the storage area.
Figure 6-5 Crushing of body
 Hot fluids
− Avoid burns caused by sprayed high-temperature fluid. After the operation, the engine‘s cooling water is hot
and pressurised.There is hot water or steam inside the engine or the radiator, too. If the skin contacts the
spilled hot water or steam, the severe skin burns will be caused.
Figure 6-6 Burns of hot fluids

− Prevent burns from hot water. Do not open the cover of radiator before the engine has cooled down. When
opening the cover, turn the cover to bottom slowly, and remove the cover after the pressure is completely
released.
− Pressure exists in the hydraulic oil tank. Ensure that the pressure is released before removing the cover.
− High-temperature fluid and surface. During the operation, engine oil, gear oil and hydraulic oil may become
hot; engine, hose, pipe and other parts will also become hot.
− Start to check or maintain them after the oil and parts cooled.
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 High-pressure fluids
− If the fuel, hydraulic oil or other fluids injected under high pressure can penetrate the skin or rip into the eyes,
it will cause severe injury, blindness or death.
− Release the pressure before removing the hydraulic or other pipes to avoid the risk of high-pressure fluids
− Fasten all connections before repressurizing.
− Use cardboard to find leaks, and protect your hands and body from high-pressure liquids. Wear the face mask
or safety goggles to protect your eyes.
Figure 6-7 Injuries of high-pressure fluid

− In case of any accident, let the doctor who‘s familiar with this type of wound cure immediately.
− Any fluid injected into skin must be removed through surgery within several hours, otherwise the dermal
gangrene will be caused.
 Treatment of accumulator
− In case of treating the accumulator, wear the safety goggles and protective gloves. The high-pressure liquid
will stab the skin and cause the injury.The pilot control system is equipped with an accumulator filled with
high-pressure nitrogen, so the pressure of machine must be relieved during the maintenance of pilot control
system. It‘s very dangerous in case of incorrect operation.
Figure 6-8 Illustration of danger Figure 6-9 Personal protection
− Do not drill on the accumulator, or do not make it contact the flame, fire or heat source.
− Do not weld the accumulator, or do not attach any article on it.
− In case of removing, maintaining or treating the accumulator, the filled gas must be discharged.
− Contact with our company or supplier.
 Safety maintaining air-conditioning system

− The splash of refrigerant on skin will cause the frost injury.
− During the maintenance of air-conditioning system, use refrigerant correctly as per the instructions for
refrigerant container.
− Adopt the recovery or recirculation machine to prevent refrigerant from discharging into the atmosphere.
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− Do not make coolant fluid into the skin.
Figure 6-10 Frost injury
 Correct treatment of discards

− Any improper treatment of discards will harm the environment and ecology. The potential harmful discards
include hydraulic oil, fuel, engine oil, coolant, filter and battery, etc.
Figure 6-11 Environmental requirement
− In case of discharging the fluid, use the leak-proof container.

− Do not use the food or drink vessel, because it may cause the wrong drinking.
− Do not pour the waste liquid on the ground, into sewerage or any water source.
− The air-conditioning refrigerant is leaked into the air, which will damage the atmospheric layer of the earth.
According to the government regulations, an air-conditioning service center with desired certificates may be
required to recover and regenerate the air-conditioning refrigerant.
− Inquire the correct recovering or treatment methods of discards from local environmental protection or
recovery center or your assigned dealer.
6.2 Inspection checks before starting maintenance
 Check the area and keep the work area clean and tidy
− Keep the work area clean and tidy, so as to secure the working process.
− Do not scatter the hammer or other tools in the work area. Wipe off all slippery grease, oil or other
substances.
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 If the work area is not kept clean and tidy, persons may stumble, slip or drop, and cause injury.
Figure 6-12 Slip danger
 Appoint one conductor when working with others!

− When repairing the machine or when disassembling or installing working devices, a conductor should be
appointed and follow his command during the operation.
− When working together, persons that not familiar will cause serious accidents.
Figure 6-13 Aconductor
 Shut off the engine before maintenance.

− The machine should be stopped on solid and flat ground.
Figure 6-14 Parking sequence

− The place with unfallen stones, collapses or is of no danger of being submerged should be chosen.
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− Lower the working device completely to the ground and shut off the engine.
− Put stopper blocks under the machine tyres in order to prevent it moving.
 Maintenance with running engine

 Advice: to prevent injury, do not carry out the maintenance when the engine is running.
 If the maintenance must be carried out when the engine is running, operate it with at least two
people, and follow the rules below:
− One must sit in the operator‘s seat and be ready to shut off the engine. All people must keep communication
with each other.
− Press the emergency parking switch(button) to lock position.
− When operating near the fan, the fan belt or other rotating parts, the operator must pay special attention to
prevent being coiled.
− Prohibit touching any operating lever. If necessary, the operator needs to send signals to other people to warn
them to move to a safe place.
− It is forbidden to drop or insert tools or other objects into the fan or fan belt, otherwise the parts may break or
fly out.
 Energy container (accumulator)
Figure6-15 Notice of container
 The energy container is filled with high pressure nitrogen!

− When operating the energy container, the careless operation will cause explosion, and cause serious injury or
damage. Therefore, the following matters must be observed:
− Do not decompose the energy container.
− Do not approach the energy container to the fire.
− Do not punch and weld on the energy container, or use the welding torch on the energy container.
− Do not collide or roll the energy container, and do not make the energy container suffer any impact.
− When disposing of the energy container, gas must be discharged. Please contact with XCMG dealer to deal
with this task.
 When disposing the energy container, gas must be discharged! Please contact with XCMG dealer to
deal with this task.
 Personnel:
− Only trained personnel is allowed to maintain or to repair the machine, untrained personnel is not allowed to
enter this area. If necessary, an observer can be arranged.
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 Installing accessories
− Before removing or installing the accessories, a conductor will be appointed.
− The accessories which are removed from the machine should be put in a stable place. Measures should be
taken to prevent unauthorized persons from entering storage area.
If you need to carry out maintenance under the machine or working equipment, firmly support the working
equipment and machine with pads and brackets strong enough to support the weight of the working equipment
and machine.
If the control levers or hydraulic pipes are accidentally touched, the equipment or the machine may suddenly fall.
If the pads or the frames are not used to support the machines, working under the machine is prohibited.
Figure 6-17 Hearing protection
 Noise protection
− If the noise of the machine is too loud, temporary or permanent hearing problems can be caused.
− When persons maintain the engine and suffer the noise for a long time, ear covers or earplugs should be worn.
 Using the hammer

− When using the hammer, fragments may fly out, metal particles may scatter, the serious damage can be
caused, and then, the following steps need to be followed:
Figure 6-18 Eyes protection

− If the hammer is used to strike hard metal parts, such as pins, bucket teeth, blade or bearings, fragments may
scatter and cause harm, and therefore, goggles and gloves should be worn during operating.
− When striking the pins or the bucket teeth, the fragments may fly out, ensure there are no people around to
avoid personnel injury.
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− If struck strongly, the pins may fly out and cause injury to surrounding people.
 Welding operation
− Only the proper device can be used, and the operation shall be performed by qualified welders.
 Removing the battery terminals

− When repairing electrical systems or welding, the terminals of the battery negative electrode (-) will be
dismantled, which prevents the current from flowing.
Figure 6-19 Detail record
 Checking the machine

− To avoid injury, carry out a patrol inspection around the machine before starting it per day or per shift.
 Relevant safety rules of high-pressure oil
The internal part of the hydraulic system always has pressure; when checking or replacing pipes or hoses, the
pressure in the hydraulic oil pipe must be checked whether it has been released or not. If oil pipe still has the
pressure, serious injury or damage can be caused, so the following rules need to be obeyed:
Figure 6-20 Illustration of pressure
− When the hydraulic system has the pressure, before releasing the pressure, do not carry out check or replace.
− If the surrounding area of the pipes or the hoses is wet, the pipes or the hoses should be checked for break,
and the hoses for inflation.
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− When checking, goggles and leather gloves should be worn.

− The high-pressure oil which leaks from small orifices can penetrate skin and may cause blindness if contact
eyes directly. If skin or eyes contacted with the high-pressure oil were injured, skin or eyes should be flushed
by clean water and go to hospital for treatment immediately.
− If the hose leaks, it may cause fire or faulty operation, resulting in serious injury or damage.
− If the bolt looseness is found, stop operations and fasten the bolts to the specified tightening torque.
− If there is any damage to the hose, stop the operation immediately, and contact with the dealer of XCMG.
− If there is any of the following problems, replace the hose:
− Damage or leakage of hydraulic pipe connection.
− Cladding frayed or disconnected, and or strengthening layer wire exposed.
− Cladding expands in some places.
− Movable parts distorted or crushed.
− Impurities inside cladding.
 Waste treatment
To prevent pollution, attention should be paid to the treatment of waste:

− Discharge the oil from the machine into the container; do not discharge it directly to the ground, or into the
sewers, rivers, oceans or lakes.
− When dealing with hazardous materials, such as engine oil, fuel oil, cooling fluid, solvents, filter and batteries,
it is necessary to comply with the laws and regulations.
Figure 6-21 Treatment of waste

− According to the requirements of laws and regulations, the whole machine, parts and accessories that need to
be disposed and must be properly handled in accordance with laws and regulations.
 Air conditioner maintenance

− If the air conditioner refrigerant gets into the eyes, it may cause blindness; if the refrigerant comes into
contact with skin, it can cause frostbite.
 Using compressed air

− When cleaning with compressed air, it may be caused by flying particles causing personal injury or machine
damage.
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− When using compressed air to clean the filter element or radiator, wear goggles, dust masks, gloves and other
protective equipment.
 Periodic replacement of critica safety-related parts

− For long-term safety of in operation of the machine, there is need for regular lubrication and maintenance.
− To further enhance security, the safety-related parts such as hoses, seat belts should be periodically replaced.
− When exceeds the allotted time, the material of parts will naturally change. Reuse will cause deterioration,
wear and damage. Finally, these parts may break down and cause serious injury or damage. During the
operation, it is difficult to judge how long these parts can keep working according to an external inspection or
touch, so replace it regularly.
− If there are any defects in safety-critical parts, replace or repair it even it has not reached the allotted time.
6.3 Lubrication and Repair
WARNING! Hazards during lubrication and Repair!

− Only those trained and qualified can repair and maintain this machine.
− Before any maintenance, read carefully the related content in this manual.
− If diesel engines are running indoors, ensure good ventilation condition.
− For the details of diesel engine, see ―OPERATION MANUAL OF DIESEL ENGINE‖, which is included in
the documents along with the machine.
− While carrying out maintenance or repair for this machine, the related record should be made and saved.
− It is important to maintain and ensure its normal function. So the machine should be kept clean so that any
failure such as leakage, looseness of screw or connection will be spotted.
− Pay attention to environmental protection! Don‘t let oil and other harmful things to pollute our environment.
The waste liquor should be disposed of according to the local laws and regulations and it is not permitted to
discharge waste liquor casually.
− The content of this chapter includes items related to regular check, maintenance and repair.
− The operator of machine should carry out according to the regulations.
6.3.1 Correct procedures of maintenance and check
 In order to maintain and repair the machine correctly, follow the correct maintenance and
check procedures described in this manual.
− Check the machine before starting it every day.
− Check the controller and instruments.
− Check the levels of coolant, fuel and hydraulic oil.
− Check the hoses and pipes for leaks, twists, wears or damages.
− Make a patrol inspection of common conditions, noises or heat around the machine.
− Check the part for looseness or missing.
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− If anything is wrong with the machine, repair it before the operation, or contact with your assigned dealer.
NOTICE! Use correct oil products!

− Use correct oil products, grease and anti-freeze fluid.
− Refer to the List of recommended Lubricants (see Section 6.3.2)
− Any use of incorrect oil, grease or not original OEM (sterling) part will lead to the loss of product warranty.
− Don‘t adjust the engine speed limiter!
− Don‘t adjust the hydraulic system safety valve.
− Avoid any contact of electric component with water and steam.
− Don‘t disassemble the main controller, any sensor or other electric components.
− Check the hour meter frequently.

− Determine the time of machine check and maintenance according to the operating hours shown by the engine
working hour meter.
− The intervals shown in List of Maintenance Periods are determined as per the normal operation and maintain
the machine in shorter interval in case of running the machine under the bad conditions.
− Make a periodic check and adjustment of lubrication or maintenance as per the readings of periodic
maintenance meter.
− When the hours of hourmeter reach the replacement time of recommended lubricant and filter element, or
during the periodic check every day or every month, replace the lubricant and filter element.
− Use correct oil products, lubricant and anti-freeze fluid.
6.3.2 Fluid Chart
Table 6-1 Fluid chart
Oil Specification Quantity

Description
Summer Winter L
No. 0 or 10 light diesel No. -10 or -35 light diesel 125

Diesel oil
(<15ppm sulfur content) (<15ppm sulfur content)
Diesel engine oil API CH-4 SAE 15W-40 API CH-4 SAE 5W-40 9
Transmission oil API GL-5 80W-90 Gear oil API GL-5 80W-90 Gear oil 3.7
Axle oil API GL-5 80W-90 Gear oil API GL-5 80W-90 Gear oil 26.2
L-VG46 wide temperature range L-VG46 wide temperature range 125

Hydraulic oil
anti-wear hydrualic oil anti-wear hydrualic oil
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Antifreeze agent -45# -45# 15
Lubricating grease NLGI Grade 2 NLGI Grade 1 2.5kg
Refrigerant R-134a R-134a 1.8kg
In event of brake noise during emergency braking, please add 120ml/120ml Afton H397
top-treat additive into the main reducers of front and rear axles respectively.
6.4 Maintenance and lubrication

6.4.1 Lubrication period
 Lubrication and Maintenance

− Proper maintenance helps increasing service life of the machine.
− Respecting the maintenance schedules and procedures accurately and thoroughly will help to prevent costy
repairs by early trouble identification.
− Maintaining proper lubrication levels will also keep the machine in optimum operational condition and
lighten the stress influence on the mechanical system.
− The checklists of maintenances tasks scheduled for longer periods include all tasks that have a shorter period,
aswell. (e.g. regular weeky maintenance include the content of daily maintenance, just as ).
194
Figure 6-23 Lubrication diagram
195
6.4.2 Periodical maintenance
− Each user is equally responsible for the common compliance with the maintenance rules and schedules,
including all adjustments, correct use of lubricants, oils, filters and replacement of parts that wore out
normally.
− Failure to comply with the proper rules and regular maintenance periods will reduce the performance of the
product and/or accelerate the abrasion of the machine parts.
− Refer to both the maintenance schedules chart and the operation hour meter to determine the maintaining
period listed in this manual.
− Also take the following into account, whichever has more impact:
− The local work time
− The oprating conditions
− The various maintaining periods are 10h, 50h, 100h, 250h, 500h, 600h, 1000h and 2000h.
− Perform the tasks listed in the requirements for each period each time the respective period revolves,
including the tasks for shorter periods interlaced within the longer ones.
− For example, the maintaining programs listed shall be implemented every 100h (two weeks), every 50h
(weekly period) and every 10h (daily period) while implementing the maintaining programs every 250h
(monthly period).
− The corresponding hours of use which is not implemented within the corresponding calendar period shall be
in line with the following provisions in case the machine is used under irregular frequency:
a. Implement the program which shall last for 10-100h once every 3 months.
b. Implement the program which shall last for 250-500h once every 6 months.
c. Implement the program which shall last for 1000-2000h once every year.
 Maintenance every 10h/every day

− Inspect the level of the coolant of the radiator sets, and complement the coolant if necessary.
− Inspect the levels of the fuel oil and the engine oil and complement the oil if necessary.
− Inspect level of the hydraulic oil and complement the hydraulic oil if necessary.
− Inspect operability of parking brake and driving brake, wherein the parking brake and the driving brake shall
be in the normal state.
− Inspect the action states of the steering cylinder and the steering wheel.
− Inspect the reliability and flexibility during controls of the accelerator and speed change.
− Inspect whether the circuit of the electric system and the electric element are normal.
− Add lubricant to all lubricating points of the working device and the swing frame pins in accordance with the
directions of the identifiers of the lubrication sketch map.
− Inspect whether the pipelines of the hydraulic system and the brake system are trapped in leakage.
− Inspect whether all systems are normal and trapped in leakage with eyes in the way of surrounding the
machine.
− Water drainage of fuel-water separator.
 Maintenance every 50h/every week
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− Maintain the machine every 10h at the same time.

− Discharge the sediments and water by releasing the discharging plug at the bottom of the fuel oil tank.
− Inspect the levels of the front and rear axles and complement the oil if necessary.
− Inspect and fasten the coupling bolts of the front and rear transmission shafts.
− Inspect the levels of the gearbox oil and complement the oil of the gearbox if necessary.
− Add lubricant to all lubricating points of the transmission shaft, the center pin, the driving room and other
places in accordance with the directions of the identifiers of the lubrication sketch map.
− Clean the fuel oil tank and the filter element of the breathing apparatus.
− Clean the filter of the air conditioner.
 Maintenance every 100h/every two weeks

− Maintain the machine every 10h and every 50h at the same time.
− Inspect the levels of the front and rear axles and complement the oil if necessary.
− Clean the filter element of the air intake filter.
− Clean the fuel filter of the fuel oil tank.
− Inspect and fasten the fixation bolts of the rim and the brake disc.
− Inspect the pressures of the tires (the pressures of the tires in cold state: front /rear wheel: 0.525±0.02MPa)
and complement the gas if necessary.
 The following steps shall also be required as for the first 100h:
− Replace the gearbox oil and the oil filter.
− Replace the engine oil and the filter element of the engine oil.
 Maintenance every 250h/every month

− Maintain the machine every 10h, every 50h and every 100h at the same time.
− Replace the engine oil.
− Adjust the degree of tension of the fan belt.
− Press one point at the middle of the belt pulley of the generator and the fan belt with finger (with force of
about 10kg), wherein the tension deflection of the normal belt shall be about 10-12mm.
− The bolts and the nuts shall be screwed up tightly after adjustment.
− Fasten the coupling bolts of the front and rear axles, the engine, the gearbox and the frame.
− Clean the return air screen of the air conditioner.
− Further, the following steps shall also be required as for the first 250h:
− Replace the oil of the gearwheels of the front and rear axles.
 Maintenance every 500h/every two months

− Maintain the machine every 10h, every 50h, every 100h and every 250h at the same time
− Replace the engine oil.
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− Replace the filter element of the engine oil.

− Replace the filter element of the fuel oil filter.
− Replace the thick filter element of the fuel oil.
− Replace the fine filter element of the fuel oil.
− Replace the induced draught filter cotton of the air conditioner.
− Inspect the wearing state and the fastening condition of the parking brake.
− Inspect and fasten the coupling bolts of the front and rear axles, the engine, the gearbox and the frame.
 Maintenance every 1000h/every six months

− Maintain the machine every 10h, every 50h, every 100h, every 250h and every 500h at the same time
− Replace the engine diesel filter element.
− Replace the engine fuel-water separator element.
− Replace the gearbox oil, the filter element of the gearbox and clean the oil bottom housing.
− Replace the filling strainer of the fuel oil tank.
− Replace the suction filter element of the fuel oil tank.
− Replace the gearwheel oil of the front and rear axles.
− Clean the fuel oil tank.
− Inspect the gaps between all hinging points and the wearing condition.
− Replace the return oil filter of the hydraulic oi
 Maintenance every 2000h/every year

− Maintain the machine every 10h, every 50h, every 100h, every 250h, every 500h and every 1000h at the same
time
− Replace the hydraulic oil and wash the oil tank and the return oil filter.
− Replace the coolant of the radiator set.
− Inspect the performances of the engine, the gearbox and the front and rear axles.
− Dismantle and inspect the steering machine, the steering valve and the other parts and correct the steering
angle.
− Inspect the sealing performance of multi-way valves and the working cylinder and measure the working
pressure of the system by testing the natural decrease of the working cylinder.
− Dismantle and inspect the cylinder and the distribution valve if the decrease exceed one time of the value
specified.
− Inspect whether the welds of all parts of the working device and the frame have cracks and inspect the
fixation conditions of the bolts and the nuts.
− Inspect the welds of the rim and all parts subjected to stress and correct deformation thereof.
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NOTICE! Third part instructions!

− The instruction and maintenance manuals of the purchased equipment (as diesel engine, optional attachments,
etc.) shall be delivered with the machine and are to be followed first in the manintenanace.
6.4.3 Inspection and adding of oil
NOTICE! Oil change!
− If not otherwise specified, drive the machine on the flat floor in order to inspect the oil level or/and replacing
the oil. Place the bucket flat on the floor
− Stop the engine. The oil will be hot!
− Wear the protective equipment when discharging the sundries and replacing the oil
− Operate carefully in order to protect the operators from injuries.
6.4.3.1 Filling capactity of oil
Table 6-2 Fluid capacity
Oil Liquid Volume

Parts or system
L
Fuel (diesel) 125
Lubricating oil of engine 9
Transmission oil 3.7
Hydraulic oil tank 125
Single Axle 13.1
6.4.3.2 Notes about the oils
− Highly flammable materials like fuel oil, lubricant, hydraulic oil or antifreeze present fire hazards.
− Do not smoke and keep open fire handling oils or other flammable fluids.
− Ventilate the work place well whenever handling or storing flammable fluids (e.g.: fuel oil, lubricant,
hydraulic oil or antifreeze).
− Seal tight the covers of the containers for packing all fuel oil, lubricant, hydraulic oil and antifreeze.
− The fuel oil, gear and hydraulic oils and all kinds of lubricants must conform to the quality requirements
specified. Refer to the list of recommended lubricant specification, Sections 6.3 and 6.4.
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− Wipe up and dry the tools for filling the oil, the containers and the filling holes to prevent the transport of
water contaminants and debris traces into the oil.
− Stop the engine when filling the fuel oil or other lubricants.
− Wipe up immediately the overflowing fuel oil, the lubricant, the hydraulic oil and the antifreeze.
− Use oils of different viscosities in different ambient temperatures! Use oils in accordance with the XCMG or
oil manufacturer recommendations.
− Use appropriate containers or barrels when replacing the the coolant, the engine oil, the gearbox oil or filters.
− The wastewater disposal is according the local environment laws and regulations!
− Check for oil leakage after refueling and oil exchange!
6.4.3.3 Fuel oil
 Inspect the oil level
Method 1: Digital level indication

− Turn on the power key switch
If the fuel gauge is installed on the LCD screen of instrument panel, the reading of fuel gauge must be higher
than the warning level.
Figure 6-24 Fuel gauge
 Full drainage of fuel

− Clean up the water and impurities accumulated within the fuel tank through the upper cleaning port and drain
through the bottom drainage port.
Figure 6-26 Fuel Tank Drainage Port
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 Cleaning of fuel tank cap filter element

− Unscrew the filler cap of diesel tank and take out and thoroughly clean the filter element.
Figure 6-27 Filler Filter Screen of Fuel Tank
 Bleed the water out of fuel system

− Place an appropriate container beneath the fuel-water separator to collect the fuel.
− Ensure that the outside of the filter subassembly is clean, without dirt or contamination.
− Install an appropriate pipeline to the drainage port. Open the drainage valve.
− Visually check the outflow of fuel. Drain the fuel into the container.
− When the fuel flowing out from fuel strainer is free of water, tighten the drainage valve clockwise by hand
only. Disassemble the pipeline and take away the container.
Figure 6-29 Drainage of Water and Air from Fuel System
6.4.3.4 Hydraulic oil
 Requirements to oil quality

− Pollution grade of particles in hydraulic oil: --/18/15. Replacement period of the hydraulic oil shall be 2000h
and below.
 Refilling the oil

− Check the oil level indicator of the oil tank!
201
− Keep the oil level at the point close to the middle scale of the oil level indicator
− Refill the oil if the oil level is below the low-level indication.
− Add hydraulic oil through the oil refilling port of the air filter.
Figure 6-30 Hydraulic oil tank filling inlet and the oil level indicator
6.4.4 Precautions for Fuel, Oils, and Fluids
− Guard the fuel, lubricating oil, hydraulic oil, antifreeze, and brake fluid against fire, as they can be ignited by
open fire.
− Smoking and fire shall be prohibited in the area having oil.
− Keep the place for filling or storage of fuel, lubricating oil, hydraulic oil, antifreeze, and brake fluid well
ventilated.
− The caps of all containers for fuel, lubricating oil, hydraulic oil, antifreeze, and brake fluid shall be securely
tightened.
− The fuel, torque converter oil, hydraulic working oil, brake fluid, and all lubricating points must be clean and
meet the specified quality requirements.
− The tools for filling the oil, the containers and the filling holes shall be wiped up in order to prevent the water
contaminants from entering into the oil.
− The engine shall be stopped when filling the fuel oil or the lubricant.
− Any overflown fuel, oil, hydraulic oil, antifreeze, and brake fluid must be wiped clean immediately.
− The oils of different viscosities shall be taken in different ambient temperature; please use the oils in strict
accordance with the oil trademark mentioned.
− The liquid shall be packaged by the appropriate containers when replacing the parts, such as the cooling liquid,
the engine oil, the gearbox oil and the filter.
− The treatment of the wastewater shall be in line with the local laws and regulations for environment
protection.
− Inspect whether oil leakage appears after refueling and replacement of the oil.
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 Replace the oil
NOTICE! Short hazard description!
− When replacing the oil follow the relevant basic safety guidelines!
− The hydraulic oil cannot be filled if the breathing apparatus is removed.
− Unscrew the nut on the top end of the breathing apparatus when dismantling the hydraulic pipeline or
connector connecting with the oil tank .
− Release the overpressure in the oil tank by pressing the exhaust valve.
− The hydraulic pipeline or connector can be dismantled.
Figure 6-31 Hydraulic oil drain valve

− Elevate the swing arm to the maximum height and
− incline the bucket maximally; and shut down the engine.
− Remove the oil drain-plug at the bottom of the oil tank and discharge the sump oil.
− Disassemble the air filter and add hydraulic oil.
− Fill new oil through the oil filler port, till the oil level reaches the specified middle position of the oil level
gauge.
− Start the engine and run it at idle speed;
− Operate the swing arm gradually to elevate
− Lifting/lowering of the bucket shall be implemented for 2-3 times respectively!
− Discharge then the air in the system by keeping the engine run at idle speed for abt. 5 minutes.
− Place the bucket on the floor flatwise!
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− Shut down the engine!

− Check the level of the hydraulic oil and refill the oil to the position specified again.
 Removal of the accumulated water

− Every 1000h check and discharge the water and settlements accumulated at the lower part of the oil tank!
− Stop the machine for 2h and empty the accumulated water and settlements at the oil drainage plug at the
bottom of the oil tank. (Figure6-31)
6.4.4.1 Gearbox oil
 Inspect the gearbox oil-level

− Place the machine on the level ground, put the stop dogs at the front and
rear tires, put the gear shift lever in the neutral position and pull up the
parking brake;
− Start engine, make it in idle running for several minutes.
− Disassemble the screw plug from the transmission observation port. The
oil should flow out. If there is no outflow of oil from the observation port,
add the transmission oil.
Figure 6- 32
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 Replace the oil

− Place the machine on the level ground, put the stop dogs at the front and
rear tires, put the gear shift lever in the neutral position and pull up the
parking brake;
− Start engine, make it in idle running for several minutes and then shut
down it.
− Open the drain plug on the bottom of the side of gearbox, and use a vessel Figure 6- 33
to hold it. (Figure 6- 33)
− After the oil is exhausted, clean up the greasy dirt around the oil outlet of
gearbox, clean out the sundries attached on the drain plug, and re-twine
the appropriate raw material on the plug screw according to the screwing
direction of thread and then install it in the original place.
− Unscrew the transmission observation port, fill the drive oil of specified
trademark and volume, and install the oil leveler.
− Start the engine, make it in idle running for 5 minutes and then re-examine
the oil level of gearbox. (Figure 6- 34)
Figure 6- 34
6.4.4.2 Drive axle oil

− Place the machine on the level ground, put the stop dogs at the front and rear tires, put the gear shift lever in
the neutral position and pull up the parking brake;
− Start engine, make it in idle running for several minutes.
− Disassemble the screw plug from the transmission observation port. The oil should flow out. If there is no
outflow of oil from the observation port, add the transmission oil.
Figure 6-35
 Replace the oil
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− Drive the machine slowly on a flat site, till the oil drainage plug on the end face of front drive axle wheel
reducer is in the lowest position. (Figure 6- 36)
− Stop the engine, shift the gearshift joystick to neutral gear, and pull up the parking brake button.
− Unscrew the drain plugs on the center bottom of axle housing of the front drive axle and on the end faces of
sides of the two wheels to discharge the oil, and use a vessel to hold it.
− After the oil is exhausted, screw on the drain plug on the center bottom of axle housing of the front drive axle.
− Start the engine, push down the parking brake button, and drive the machine slowly, till the indicating arrow
of the oil filler port is horizontal. Then, stop the engine, shift the gearshift joystick to neutral gear, and pull up
the parking brake button.
− Unscrew the main driving (examination) oil filler plug on the axle housing of the front drive axle and the plug
of view hole on the end of arrow of wheel side of both end faces.
− Inject the new oil from the place of oil filler plug of wheel side (examination) and oil filler plug of main drive
(examination) until the moment that the oil overflows from the oil filler of main drive in the axle housing and
the oil overflows from the view hole wheel side.
− Screw the five spout plugs mentioned above. Change the gear oil of rear drive axle according to the above
process.
Figure 6-36
6.4.4.3 Engine oil
NOTICE! Check and change the engine oil!
− Check the oil level before operation or 30 minutes after the engine is shut down.
− The used engine oil is carcinogenic and it can cause other reproduction diseases!
− Avoid to inhalte the oil vapours
− Avoid swollowing and longer skin contact with the oil.
− Used oil to be treated according to the local environmental protection regulations
− Avoid swollowing and longer skin contact with the oil.
− Used oil to be treated according to the local environmental protection regulations
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Figure 6-37 Oil dipstick position
Figure 6-38 Oil dipstick

− Drive the machine on the level ground!
− Shut down the engine,
− Put the gear shift lever in the neutral position and
− Press the parking brake.
− Pull out the dipstick on the side of engine body, infix its head and then infix its whole body, and last pull out
it for examination. (Figure6-37)
− The engine oil level shall be between the lines of ―L‖ and ―M‖ on the dipstick. If the oil level is too high, the
cause shall be found out and be solved; if the oil level is too low, more oil shall be added. (Figure6-38)
− Inspect whether the oil is polluted and whether there are some sundries in the oil. If the oil is polluted
excessively, the oil shall be changed.
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 Exchange the engine-oil
Figure 6-39 Drain plug of engine oil

− Place the machine on the level ground,
− Put the stop dogs at the front and rear tires,
− P ut the gear shift lever in the neutral position and
− Pull up the parking brake.
− Start the engine
− If the engine is not warmed up, idle the engine.
− After the oil temperature reaches 20℃~40℃, stop the engine.
− Open the drain plug of engine oil at the right front of fuel tank of the engine, discharge the oil and use a
vessel to hold it. (Figure 6-39).
− Change the oil filter.
− After the oil is exhausted, screw the drain plug.
− Inject the new stipulated oil from the oil filler on the left posterior of engine.
− Start the engine and keep the slow drainage.
− Check whether the oil filter and drain plug leak.
− After about 15 minutes when shutting down the engine, make the oil to flow circularly and sufficiently, and
re-check the oil level of engine.
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6.4.4.4 Engine cooling liquid
WARNING! Hot cooling fluid and cooler surfaces!

− Wear all required PPE (gloves, googles, cloth, shoes, helmet)!
− Do not open the radiator cap if the engine is running or immediatelly after the engine stops
− Severe injuries to the operator checking or maintaining the system!
The cooling system under pressure can make overheated cooling liquid spewing out and this can cause severe
injuries!
− Cover the radiator cap with a large piece of cloth and open it very slowly and carefully to the first limiter in
order to release the system overpressure!
 Inspect the liquid level
Figure 6-40 View hole Figure6-41 Water level
− When the water temperature of engine is too high,

− First, check the cooling liquid level.
− Add more cooling liquid if nacessary.
− Check whether the radiator core is blocked and
− Check whether the tube is damaged.
− Put the gear shift lever in the neutral position,
− Press the parking brake and
− Shut down the engine. when the water temperature to drop to below 50℃.
− Observe the liquid level of expansion tank, which shall be near the midline.
− Add more water.
− Open the radiator cap from the view hole at the rear top of the engine cover, and the cooling liquid level shall
reach to the bottom of filling neck of water tank of the radiator; and complement the cooling liquid if it is not
enough. (Figure6-40, Figure6-41).
− After checking, fasten down the radiator cap to prevent the cooling liquid from evaporating.
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6.4.4.5 Change of antifreezing solution
 Clean of Radiator
Figure 6-42 Drain valve Figure 6-43 Water temperature

− Operate the engine for 1-1.5 hours under normal water temperature (at least 85°
C).
− Put the gear shift lever in the neutral position,
− Pull on the parking brake,
− Shut down the engine, wait the water temperature to drop to below 50℃.
− First, open the radiator cap,
− Switch on the water drain valve on the bottom,
− Discharge the antfreeze fluid
− Switch off the water drain valve after all antifreezing solution is discharged. (Figure6-42)
− Fill the clean water into the cooling system to the normal water level.
− Start the engine,
− Speed up the engine gradually,
− Run the engine on idle speed for 5 minutes (if water temperature is over 85°
C).
− Shut down the engine,
− Discharge the cooling water after the water temperature is below 50°C. If the discharged water is still dirty, it
shall be continued to wash until the clean water is discharged.
− Switch off the water drain valve after all water is discharged. (Figure6-43).
− Fill antifreezing solution until the cooling liquid level reaches to the bottom of filling neck of water tank (or
expansion tank) of the radiator.
− Start the engine, make the liquid level drops slightly,
− Shut down the engine and
− Re-Fill the antifreeze solution.
WARNING! Cooling liquid – hot and poisonus

− Use only recommended antifreeze liquid and appropriate mix with industrial water
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− Wrong antifreese can damage the cooling system or the aluminium parts.
− The cooling liquid is poisonous, avoid possible contact with children and pets.
− Disposal of cooling liquid shall be according to the local environmental protection regulations.
NOTICE!
− Use only the recommended antifreezing solutions required for the cooling system of the machine.
− When the machine leaves from the factory, the antifreezing solution has been filled into the radiator.
− Also when the machine is operated under normal conditions, the antifreezing solution is required.
− Do not use rainwater, tap water or river water to replace it.
− The diesel engine or radiator might be damaged.
− When the temperature is under 0℃, the antifreezing solution may not be discharged. If under the urgent
situation, the antifreezing solution must be replaced with the ordinary water temporarily, all water drain
valves must be switched on to discharge all cooling water and to prevent the machine from being frosted
cracking.
− When the temperature is over 30℃, the engine shall be placed in the shady and cool place because it is easy
to overheat.
− After operation, to prolong the service life of engine, the engine must be operated at low speed for 5 minutes
and shall be stopped after the water temperature drops.
6.4.5 Checking and maintaining components
6.4.5.1 Engine
The detailed checking method and maintenance to this engine are listed in the manual along with the engine.
 Engine air filter main element - Cleaning/replacement

− The air filter is located on the right side of machine and between the engine and lower hood.
− Loosen the circlip 1.
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Figure 6-45 Air filter

− Remove the filter cartridge cover 2 and take out the filter element 3.
− Clean the filter element and replace it at least once a year.
− Clean the filter element 3.
- Blow by compressed air from inside to outside (Notice not to apply excessive pressure).
- Knock it lightly and take cautions not to damage the filter element (Only when it‘s necessary).
- Clean the filter element as per manufacturer's manual.
- Check the filtration paper of filter element. Upon detection of damage (Transparency), replace
timely.
- Check the sealing performance of seal rings. Any damaged seal ring must be replaced timely.
− Close the engine hood.
Figure 6-46 Disassembling of Air Filter Main Element
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 Fine filter element of engine air filter – replacement
NOTICE! Replace air filter safety element!

Never clean the filter element by gasoline or hot water!
− Ensure to replace the safety filter element 4 (Non-cleanable) after 5 cleaning cycles or up to 2 years.
− The air filter is located on the right side of machine. Turn backward the engine hood.
− Unscrew the screw 5 and take out filter element 4.
− Install new filter element and then tighten.
− Install filter element 3, reinstall the cover 2, and clamp the circlip 1.
 Air filter dust drainage port
− As shown by arrow, push the dust drainage nozzle to drain the dusts.
− Periodically clean the dust drainage nozzle.
− Push together the upper portion of dust drainage port to remove caked dusts.
Figure 6-47 Air Filter Outer Cover

 Coolant level check
− Check the level of coolant every day.
− The coolant level must be in the middle of the water tank observation port.
− If the coolant level is below the middle of observation port, add coolant into the water tank.
− After adding the coolant into the radiator,
− Check the level,
− Add the coolant-mix into the coolant expansion tank.
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Figure 6-49 Coolant Observation Port
 Cleaning and coolant exchange
Figure 6-50 Drainage Plug

 Engine oil filter-replacement
− Open the engine oil drainage valve to drain the oil into an appropriate container. After full drainage, close the
valve.
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Figure 6-51 Drainage Port
● Disassemble the filter ● Wipe clean the sealing ● Tighten the engine oil filter
cartridge by an appropriate surface of filter seat. element by half turn, till it's
tool. ● Apply some engine oil onto aligned with the fixing
● Disassemble the filter the rubber sealing gasket of retainer ring and the thread is
element. new engine oil filter element. tightened.
● Catch the engine oil by a ● Screw the new filter ● Check oil level.
container. element by hand, till it comes ● Check oil pressure.
Guard yourself against into contact with the washer. ● Check filter cartridge for
scalding by hot oil. leakage.
 Fuel system strainer (Fuel-water separator) element - Cleaning and replacement

Open the engine hood.
NOTICE! Collect the liquid in a container!
− Take cautions to ensure the collection of liquid in a container during the inspection, maintenance, testing,
adjustment, and repair of product.
− Prepare an appropriate container to collect the liquid before opening any chamber or disassembling any
liquid-contained part.
− Dispose all used liquids as per local laws and regulations.
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− Clamp the diesel pipeline.

− Place an oil tray under the strainer.
− Unscrew the drainage plug 4 to drain the diesel.
− Unscrew the fastening bolt 1 and take out the filter housing 5 and filter element 3.
− Clean the sealing surface of filter seat 7 and filter housing 5.
− Install new sealing gasket 6 and filter element 3 (Replace as necessary).
− Install the filter element into the filter housing, till the filter element is higher than the filter housing by 3cm.
− Push the filter housing 5, filter element 3, and seal ring 6 into the filter seat 7 and fix by bolt 1 (Tightening
torque: 25N.m).
Notice: Ensure to orient properly the sealing gasket 2!
− Tighten the drainage plug 4.
− Relieve the fuel pipeline.
− Start the engine and then check for leakage.
Figure 6-54 Fuel filter
NOTICE! Fuel-water separator!
− The fuel-water separator is under negative pressure during normal engine operation.
− Securely tighten the drainage valve to prevent the air ingress into the fuel system
− The fuel leaking or splashing to any hot surface or electric component will result in fire. To prevent possible
harms, turn off the starter switch while replacing the fuel filter or fuel-water separator element. Immediately
wipe away any splashed or leaked fuel.
− Make sure to stop the engine before starting any repair or maintenance work.
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 Fuel system strainer(fuel-water separator)element – replacement

Open the engine hood.
NOTICE! Fuel system strainer!

− Do not refill fuel before replacement of fuel filter. otherwise, the fuel will not be filtered and may cause
system contamination.
− The contaminated fuel will accelerate the wear of fuel system parts.
− Use a container-pot to collect of liquids during the inspection, maintenance, testing, adjustment, and repair of
machine.
− Add fuel into the fuel system before starting the engine.
− Before opening any plug or disassemble any liquid-contained part prepare an appropriate container-pot to
collect the liquid
− Dispose all liquids as per local environment laws and regulations.
NOTICE! Fuel-water separator cup!

− The fuel-water separator cup is reusable.
− Do not discard the fuel-water separator cup.
− Water drainage:
- Place an oil tray under the strainer.
- Loosen the drainage plug 4 and observe the flowing liquid. When the flowing liquid turns to diesel,
tighten the drainage plug 4.
- Start the engine and then check for leakage.
− Air bleeding:
- Relieve the fuel pipeline.
- Start the engine and run for approximately 2min.
- Place an oil tray under the strainer.
- Loosen the air bleeding screw 8 to bleed the air, till the air bubbles disappear and the diesel flows
out.
- Tighten the air bleeding screw 8 (Tightening torque: 15N.m).
- Start the engine and then check for leakage.
 Installation of new air filter element

− Figure 6-55 Fuel filter
− Clamp the diesel filter.
− Take out the filter element by an appropriate tool.
− Collect the flowing diesel by a container. Caution: The smoking and fire are prohibited!
− Clean the sealing surface.
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− Apply some engine oil or diesel to the rubber sealing surface of new filter element.
− Screw the filter element by hand, till it comes into contact with the washer. When replacing with new diesel
filter element, notice not to add the unfiltered diesel to the new diesel filter element, in order to prevent the
dirt contained in the diesel from blocking the diesel injector nozzle.)
− Finally, tighten by half turn.
− Relieve the fuel pipeline.
− Check for leakage. (The air bleeding is not required for diesel system.)
 Fuel tank cap and filter screen-cleaning

The fuel filler port of fuel tank is located beneath the cab of telescopic handler.
Figure 6-55 Filter screen

− Disassemble fuel tank cap and filter screen from the fuel tank.
− Check seal ring for presence of damage. If the seal ring is damaged, replace the fuel tank cap.
− Clean the filter screen in a clean non-flammable solvent.
− Install filter screen to the filler port.
− Install the fuel tank cap.
 Water and sediments in fuel tank-drainage

− The fuel tank drainage valve is located on the bottom of fuel tank:
− Open the fuel tank drainage plug.
− Drain the water and sediments into an appropriate container.
− Dispose all liquids according to the local environment laws and regulations.
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Figure 6-56 Drainage valve of fuel tank
 Repairs and Maintenances of Drive Belt - Checking of Poly V-Belt

− Check whole belt for presence of damage.
− Replace damaged belt.
− After replacement with new belt, run the engine for 15min and then check the belt tension.
- Install the indicator arm 1 into the gauge.
- Place the gauge onto the belt 2 in the middle position between pulleys and cling the bottom flange 3
of the gauge to the belt.
- Slowly push down the black boss 4 as per correct angle, till the spring is locked.
- Carefully move away the gauge and do not change the position of indicator arm.
- Read out the correct reading of black indicator arm 1.
- If necessary, tension the belt and re-measure.
− Notice: Ensure to stop the engine during the checking, tension, and replacement of belt.
Figure 6-57 Engine belt

 Repairs and Maintenances of Drive Belt - Tensioning of Belts for Cooling Water Pump and
Fuel Delivery Pump
− Tensioning:
- Loosen the fastening bolts.
- Insert an appropriate square bore wrench into the square bore on the connecting plate of fuel
delivery pump and push the fuel delivery pump to correct tensioning position along the arrow
direction.
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- Tighten the fastening bolts.

− Replacement:
- Loosen the fastening bolts.
- Push the fuel delivery pump in reverse direction of the arrow to loosen the belt.
- Replace and tension the belt (Refer to above procedure).
− Tighten the fastening bolts.
6.4.5.2 Electrical system
 Battery
− Keep the batteries clean.
− Cleaned frequently the tops or terminals of batteries. Polluted or corroded that will be the main reason for
possible supply failure.
− Grind terminals first and then clamp them firmly
− Disconnect first the negative terminal (-) of the batteries before inspecting the electrical system
− The batteries will release explosive hydrogen gas. Do not keep open flame close to battery compartment.
− The used battery need to be returned to the following departments:
− Battery supplier
− Designated battery recycling point
− Recycling point
 Wires and fuses

− Always pay attention to the connections and fraying of wires and the clamping of the fuses.
− Fuses are located in the back corner of the cab.
− Check the fuse first if one line is not working properly
− For the fuse to be replaced,
− determine the cause, and then
− check the lamp bulbs and disconnection.
NOTICE! Fuse replacement!

− The fuses protect the electric system against the overloaded circuits.
− Any failed or burnt fuse shall be replaced.
− Replace the fuse only by new one of same type and specification.
otherwise, the circuit system will be damaged.
− If already replaced fuse burns again, check the electric circuit.
Find the failure and if necessary, repair the electric circuit.
− The capacity (ampere) on the lamp and clamp must be checked.
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 Fuses
Figure 6-59 Fuses function diagram

Table 6-3 Function list
PN Type/Specification Qty PN Type/Specification Qty

803682282 ATS-20A 5 803694612 ATN-15A 17
803682280 ATS-10A 1 803611478 ATN-20A 5
803682281 ATS-15A 1 803670807 HFV6/024Z-TR 19
803682283 ATS-25A 3 803668839 ATN-5A 1
803682284 ATS-30A 1 803701695 SG252 1
803691447 ATN-10A 11 803682286 HFV4/024-1Z1GR 5
 Lamps and instruments

− Check the function of each lamp switch.
− Dirt on lamps must be cleaned away.
− Press the horn button to check the sound.
− If the meters needle stays in green area, it is normal.
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6.4.5.3 Steering device
This type of telescopic handler provide fully hydraulic steering unit. By slight turning the steering wheel the
driving direction of the telescopic handler will be changed if the telescopic handler steering works correctly. Do
not try to apply more force to turn the steering wheel if it becomes hard to turn!
 Stop the telescopic handler!

− Check the steering function. Operation can be resumed after the failure has been eliminated.
− Do not turn the steering wheel before starting the machine.
− After 2000 working hours, dismantle the steering valve for inspection.
− Correct the steering angle.
− Check the steering cylinders for leackage!
− Replaced the seals if any leackage is found.
6.4.5.4 Transmisson system
− Pay attention to abnormal noises from the transmission system during operation.
− After 2000 working hours dismantle for inspection:
− the gearbox,
− torque converter,
− main drive and
− hub reducers of the driving axles.
− Replacing the filter element,
− first release the dirt and debris out, and then
− take off the cover to change the filter element with a new one.
− Afterwards, replace the cover.
NOTICE! Collection of liquid in a container!

− Use a container-pot to collect and dispose liquids during the inspection, maintenance, testing, adjustment, and
repair of machine.
− Before opening any plug or disassemble any part prepare an appropriate container-pot to collect the waste
liquid
− Dispose all liquids according to local environment laws and regulations
 Wheels
− Inspection of tires to be done on cold machine.
− Check the tires surface for wear appereance.
− Look for any metal partials embedded in tires.
− Check the mounting nuts on the wheel rims.
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− Check the tire inflation pressure.

− Normally the tire inflation pressure should be a little bit lower when machine operating in a sandy area than
when machine operating on hard-ground.
CAUTION! Tires under pressure!
− Check to see if the locking ring is disengaged.

− This must be confirmed when inflating the tires.
− After 2000 hours, check the welding seams on wheel rims and also check the parts which are loaded.
− Correct any deformation or exchange the broken part.
− The machine from the plant is delivered with tire pressure suitable for transportation only.
− Charged the tires to appropriate pressure before put into operation!
− Moving the machine from a warm workshop of 18º C~21º C (65ºF~70º F) to a place low temperatures, the
tire pressure will change remarkably. If the tires are charged to correct pressure in a warm workshop, the tire
pressure will become insufficient under low temperature conditions.
− Insufficient charge pressure will shorten the useful life of tires.
6.4.5.5 Checking, Cleaning, and Maintenance of Chain
Check, clean, and lubricate every chain once every 250 running hours. If the chains are working under severe cold
condition or in an environment with corrosive substance, the checking, cleaning, and lubrication interval shall be
shortened to <150h. The chain life can‘t be predicted under different load cycles and environmental conditions.
Therefore, make sure to check frequently, till the prediction of replacement life is required.
6.4.5.6 Checking and Maintenances:
 Checking and adjustment of chain tension (It’s recommended to check at least once every 250h.)
1. Park the telescopic handler on horizontal ground, put down the outriggers, and keep horizontal the boom with
respect to the ground.
2. Fully extend the boom and then retract it by 200mm.
3. At the middle point of the extended section of telescopic boom, measure the vertical distance (L1) between
the lower end of chain (The side near the boom surface) and the boom plane by a ruler or tape measure.
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4. The measurement shall be within the following range:

Chain above second section of boom (L1): The measurement is between 107mm and 117mm.
5. Adjustment of chain tension
If the measurement is out of the above range, it indicates the inconsistent tension for the extending chain and
retracting chain of one same boom section and the adjustment of chains is required, as shown in diagram below:
The adjustment end for every chain has two nuts. The one far away from the end is the adjustment nut and the one
near the end is the lock nut. During adjustment, take the following methods comprehensively based on the actual
situation:
a. Tightening adjustment nut (1) can move outward the third boom section.
b. Tightening adjustment nut (2) can move inward the third boom section.
6. After completing the adjustment of chain tension, tighten both adjustment nut and lock nut to 120Nm and
ensure that there is at least one complete thread outside of the lock nut.
7. Star the machine, repeat the first three steps, and check the dimension L1.
8. Start the machine, telescope the boom for at least three cycles, and verify the dimension L1.
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 Checking of chain wear status (It’s recommended to check at least once every 1,000h or two years.)
The chain wear occurs in following positions:

− At the chain link joint, leading to elongation of chain;
− Link plate edge in contact with sprocket;
− Contact with sprocket flange edge, leading to wear of chain pin end face;
− Relative rotation between link plate and pin;
− Cracking of link plate.
1. Elongation of chain
− Park the telescopic handler on horizontal ground, put down the outriggers, and keep horizontal the boom with
− Fully extend the boom and repeat the telescoping for several minutes to appropriately tension the chains.
− As the chain probably wears non-uniformly in length, divide the exposed chain to 4 equal parts and check at
the center of every part by a ruler.
− For 25.4mm pitch chain, measure the distance (9 pitches) from the pin center of one link plate to the 10th pin
center. If the measurement exceeds the maximum size (228.6mm+228.6mm×2%=233.2mm), please contact
your dealer to replace the chain.
2. Wear of link plate edge

Check the chain for wear of link plate edge due to repeated running on sprockets and measure in the middle of
every equal section by a vernier caliper.
The maximum material reduction shall not exceed 5%. Measure the chain part rolling on the sprockets and
compare it with normal link plate height. If the measured link plate (1) is less by 5% than normal plate height (2),
please contact your dealer to replace the chain.
In addition to the wear, the high pressure between link plate edge and sprockets can probably squeeze out material
to block the link plate. In such case, replace the chain as well.
3. Wear of chain pin end face:
Measure in the middle of every equal section by a vernier caliper:
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The maximum material reduction shall not exceed 2%. Measure the chain part rolling on the sprockets and
compare it with normal pin length. If the measured pin length is less by 2% than normal pin length, please contact
your dealer to replace the chain.
4. The abnormal friction force between link plate and pin due to insufficient lubrication results in rotation of pin
within the link plate to bring about the falloff risk from link plate.
If the plane is not aligned with the longitudinal direction of chain, please contact your dealer to replace the chain.
5. Cracking of link plate

Check the front, rear, and two sides of the chain for link plate breakage trace. Upon detection of any cracking,
replace the whole chain.
It‘s really important to determine the cracking cause before installing new chain, in order to prevent the
reoccurrence.
Types of cracking:
a. Fatigue cracking (As shown in Figure 1) - Due to repeated cyclic load in

excess of durability limit of chain.
b. External stress corrosion cracking (As shown in Figure 2) - The link plates
are vulnerable to stress corrosion cracking.
c. The corrosion fatigue cracking is highly similar to the fatigue cracking. The
corrosion fatigue is caused by the joint action of corrosive environment and
cyclic stress.
In event of any of above conditions or clear elongation or breakage of chain due to overload, immediately replace
the chain. It‘s recommended to replace all chains or replace the chain pair of same function during the
replacement.
6.4.5.7 Cleaning
− Park the telescopic handler on horizontal ground, put down the outriggers, and keep horizontal the boom with
− Fully extend the boom.
− Wipe the extended chain by a clean lint-free cloth and then carefully check the chain for wear symptom.
− Scrub the chain by a hard nylon brush and clean diesel to remove the impurities from the chain.
− Scrub the chain by a paint brush dipped with clean diesel and blow it dry by compressed air.
− Lubricate the chain by gear oil and operate the telescoping motions for multiple times, in order to ensure the
sufficient lubrication for every working surface of chain. Meanwhile, check the chain for stable and smooth
motion.
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The special consideration shall be taken for the lubrication of the

NOTICE! chains on the machine working continuously under extremely high or
low temperature condition. Please contact your dealer for guidance.
6.4.5.8 Boom Sliders
The boom sliders are planarly rectangular nylon blocks with metal inserts.
6.4.5.9 Checking and Lubrication of Sliders
− Park the telescopic handler on horizontal ground and adjust the boom to keep it horizontal with respect to the
ground.
− Fully retract the boom and then extend it for 100mm.
− Check all sliders for wear. If the angular indicators (1) on two ends of any slider are invisible or worn
non-uniformly, replace the slider. During replacement, make sure to replace the whole set of sliders. Readjust
the adjustment shims between sliders and boom.
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− Measure the gaps of all side and top sliders. The total gap of side/top slider and next boom section shall be
0.5mm~1.5mm.
− If the gap is too large, please carefully check the wear status of this slider and the opposite slider (slider in
same height or width direction). In event of non-serious wear, restore the gap by adding adjustment shims.
− The boom is already lubricated in the plant before the delivery. Generally, the further lubrication is required
after a period of use, in order to mitigate the wear of sliders. After replacement of any slider or long-time
non-use, the appropriate lubrication is required before the next operation. The multi-purpose lubricating
grease can be used for lubrication.
− Lubricate every 10 hours for the first 50 hours and every 250 hours thereafter. Lubrication time can be
shortened according to working conditions.
CAUTION! Precautions for replacement of sliders

− Before the replacement of any slider, determine the wear cause. It‘s recommended to replace whole set of
sliders.
− The use of other assisting equipment is required for the replacement of some sliders. Please replace under the
condition of guaranteed safety.
6.4.5.10 Braking system
In case of insufficient braking oil pressure (4Mpa), alarm display shows braking oil pressure. Check the system.
The machine will reset and continue to work only after troubleshooting.
Figure 6-63 Alarm display
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In case of power off, the whole machine will be in braking mode automatically. Therefore, the machine has the
functions of gear protection and low oil pressure protection.
In case of need of dragging, the parking brake should be released. If parking brake is in braking mode due to
engine out of work, whole vehicle no power and solenoid valve seizure, the parking brake must be released. The
release method is as follows:
Turn the rocker switch to position ―A‖to release the parking brake, and teh indicator light of the parking meter
goes out. (See Table 5-5)
Figure 6-64 Release the parking brake
Note:In case of dragging, be doubly careful of safety.
6.4.5.11 Miscellaneous (others)
− After 2000 hours operation, the whole telescopic handler must be visually checked. Check for damages,
deformations, cracking, welding peelings, and other shortcomings which can hinder normal operation,
especially the working apparatus and wheels.
− After 2000 hours, check the fastening of each screw and nut on the telescopic handler. Fasten it if necessary.
− Special attentions should be paid to the rim nuts and screws on the suspending parts. Check the sealing of
each hose connection, engine, and radiator and transmission system for oil or water leakage.
− If the leak is hard to find, stop the engine, and clean the part that is to be checked, then restart the engine.
6.4.6 Structural principle and maintenance precautions
− This telescopic handler is composed of:

− engine,
− transmission system,
− steering system,
− braking system,
− frame,
− working device,
− hydraulic operation system,
− cab, and
− electrical equipment.
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6.4.6.1 Engine
− The engine is composed of:

− diesel,
− air filter, and
− exhaust system,
− cooling system and
− pipes.
 Service and maintain the engine according to the ―Engine Manual‖ that is included with the engine and
delivered techical documentation of the machine.
NOTICE! Hazard during transport!
 For a long distance transport or a long time parking/storage in cold weather and its cooling liquid has
not been filled with antifreeze agent, open the drain-plug of the:
− diesel engine,
− water pump,
− engine oil cooler,
− lower chamber of water tank and
− oil cooler of torque converter
− to discharge all water.to prevent freezing of the cooling water.
− Check for oil-debris traces in cooling water or water-debris traces in engine oil ,
− Check if the filters for both water tank and engine oil are leaking or are cracked.
− Check the fastening bolts on the engine fan.
− Rain water, tap water and clear river water can be used as cooling water. It is not recommended to use well
water! Use well-water it only after it is softened. All minerals in well-water may cause poor cooling
performance for the engine.
− In the circumstance of machine application under extremely cold area or in winter, fill antifreeze agent into
the cooling water to prevent cooling water from freezing.
6.4.6.2 Transmission system
The drivetrain system includes: Gearbox, drive shaft, front and rear steering and drive axles, and wheels.
 Maintenance for Gearbox

− Proper running of the gearbox is critical to the machine performance, therefore, correct and regular
maintenance to the torque converter and gearbox must be performed according to what is stated in this
manual.
230
 Maintaining, driving preparation work, and maintenance before machine driving

− Before having the gearbox running, the oil level must be checked inside the gearbox. If the oil level is not
enough, replenish with fresh gear oil of the correct type and spec.
− Checking oil level in gearbox should be done only when the neutral gear is engaged and gear oil inside the
gearbox being at ambient temperature.
− Check the gearbox oil level on the left side of the gearbox.
Figure 6-68 Lubricating Points
 Machine driving and gear shifting
CAUTION! Hazards from control joystics!
− Put all the control handles at their neutral position before starting the engine.
− Before starting the engine, place the controller in the neutral position.
− For safety, the parking brake should be engaged before starting the engine, preventing the machine from
moving when the engine is started. After the engine is started and before driving the machine, disengage the
parking brake and move the controller to the desired gear and drive the machine forward slowly.
− Every time you stop the machine, engage the parking brake, otherwise the machine can move under a certain
conditions such as traction force generated by engine before the engine itself totally stops.
− While the machine driving, you also need to disengage the parking brake, otherwise oil temperature inside
the gearbox will rise very high and parking brake will also get very high temperature very soon, as the
machine torque converter produces a large amount of power output while driving the machine with gear
shifting lever being engaged.
 Temporary parking and stop

− In case of stopping the machine, you need to place the controller in the Neutral position, then immediately
press the parking brake to get the machine braked. There isn‘t a rigid link between the machine engine and
the output shaft of torque converter. When parking the machine on a slope (both upward or downward)
and the operator needs to leave the machine unattended, then it is highly recommended to block the
machine wheels with wedges or wood blocks in addition to already having the parking brake engaged, as an
added precaution to keep the machine from slipping on the slope.
− When parking a machine for a long term on a flat area, then it is also required to block the machine wheels
with wedges, just for the sake of accident prevention and machine safety.
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− After the machine stops, do not let the engine and torque converter run for a prolonged time at idle speed.
NOTICE! Lube oil checks!
− After the initial 100 working hours do the first-time oil exchange for the machine!
− From the first oil exchange check every 1000 working hours and exchange if necessary.
− Drain oil from the gearbox, torque converter, axles, steering system and engine.
− Keep on regularly scheduled maintenance and service to the machine!
− For any signs of deterioration of oil quality or mixing with other substances, check, clean and replace the
filling quantities with the recommended fresh oil.
− Always refer to the list of recommended fluids, lube oils and greases (See Section 6.4 for reliable
information)
 Oil Replacement
a. The oil fluid used on this machine must be periodically replaced at certain intervals according to what is
stated in this manual.
b. When performing an oil change.
c. Park the machine onto a flat surface.
d. Start the engine until the oil temperature inside the gearbox rise up to 60°C (140°F).
e. Unscrew the oil-drainage plugs on the gearbox and radiator.
f. Empty the used oil out the gearbox and then the radiator respectively.
g. After the oil has been drained, clean the plugs and area around the plugs.
h. Re-mount the plugs onto their original location with a new sealing-ring.
i. Replace the oil filter and fill the gearbox and radiator with fresh gear oil up to required level.
 Driving Axle
− The driving axles has both a front and rear driving axle. The main difference is the rotation speed of their
gear. Gears inside the front axle rotate left, while gears inside the rear axle rotate right.
− For the purpose of increasing traction power, the machine adopts a 4-wheel drive system.
− The driving axle is composed of an axle casing, main reducer (including its differential), and axle shaft and
hub reducer.
− The axle casing is fixed to the frame, which bears the load of the machine frame and transfers it to wheels. It
also is the casing for the main reducer, axle shaft and hub reducer.
− The main driver is a one stage spiral bevel gear reducer, it is mainly used to increase the torque of the
transmission system, lower the transmission, and change the driving direction.
− The differential is a planetary gear couple consisting of two beveled axle shaft gears, spider gears, four
bevel pinion gears and a left and right differential cage. This differentiates the speed for the left and right
wheel and transfers the torque of the main transmission and movement to the hub reducer.
− The left and right side shaft are a full floating type, which can transfer the torque from main transmission
to rim decelerator.
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− Semi-shafts on both left and right are of fully floating type, which function to transfer power and movement
generated from the driving axle and differential to the hub reducer.
− Hub reducer is a planetary gear transmission mechanism. With its inner gear ring fixed on a hub bearing,
planetary gear and hub rotating together. The function of the hub reducer is to increase the torque of driving
system and reduce the speed of transmission.
− Tires and rims are the main driving device are low-pressure wide-base cross-country tires (20.5-25), the
telescopic handler performs effectively off-road.
 Tire System
WARNING! Hazards from tires under pressure!
− The force of a tire explosion and the flying debris can cause personal injury, or death or property damage,
− The following information pertains to proper tire safety and servicing:
 If there is a tire explosion, it can throw the wheel hub, tires, driving axle and other components 500m.
or more from the machine.
− Correct tire pressure must be maintained. Never inflate a tire beyond the rated pressure range.
− Operating at high speeds for a prolonged amount of time can cause tire pressure to rise and create heat,
which can result in an explosion. To avoid damage, do not reduce tire pressure, simply slow down the
operation speed of the machine or stop until tires have cooled.
− Inflating the tires with combustible gas is prohibited. It is recommended to use dry nitrogen gas because it
does not aid in combustion. Nitrogen mixes well with air so it can be used even if air was initially used to fill
the tires. When adding pressure to the tire, it is recommended to use nitrogen.
− Inflating tires with nitrogen can possibly reduce the risk of tires explosion, since nitrogen helps prevent
rubber oxidation and corrosion of the wheel hub components.
− Proper tools must be used by specifically trained personnel to inflate tires with nitrogen.
− Do not operate the telescopic handler when the tire pressure is low.
− Check tires for cracks or deformation.
− Check the mounting screws and bolts on the wheels to see if they are securely fastened as required.
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− When performing any welding near or around tires, avoid contact or damage to the tire from the welding.
Tire explosion could result from excessive heat or burning of the tire.
− Repairing the tires and wheel hubs is a potentially dangerous procedure. Only trained personnel using the
proper tools and correct procedures are to perform inspection and maintenance to tires and wheel hubs.
 Braking System
− Braking system is used for speed controlling or parking on the flatland or slope.
− This telescopic handler has two braking systems, a foot and button controlled brake.
 Service braking system (foot brake)

− This braking system is used to control speed in normal traveling, this type of braking is smooth and safe.
− The system adopts full hydraulic braking system, which is reliable, safe, easy to maintenance and has a
simplified structure.
− The system can automatically offset wear for friction disks, with efficient radial performance and long service
life and lack of noise.
Figure 6-73 Foot brake
 Emergency and parking brake system
− This system should be used after the telescopic handler stops on a slope or a flat ground.
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Figure 6-74 Parking brake button
 Check the braking performance

− Check that the brake system is functioning correctly! Braking performance is directly related to your safety
and working efficiency.
− If it an issue is found repair immediately!
− The telescopic handler must brake quickly without delay after light step on pedal when the telescopic
handler driving at speed of 32km/h
− Once repaired, the brake distance at telescopic handler speed of 32km/h on a straight and dry road must be
less than 14 meters.
 Maintain the braking system:

− CLEAN: The braking system must always be kept clean to avoid malfunctions.
− CHECK:
a. The braking system for any possible leaks.
b. All connection points must be secure.
c. The oil level must be normal range.
d. Oil pipes need to be straight free of dents.
e. Rubber parts must be free of damage and wear.
f. Hoses and wiring must be free of fraying and other signs of damage.
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6.4.6.3 Hydraulic system
NOTICE! Hazard from the hydraulic system!
− The hydraulic system of this telescopic handler includes working hydraulic system and steering hydraulic
system
− Don‘t run the engine without oil in hydraulic oil tank.
− Drain the dirt of hydraulic oil tank every 250 hours!
(1) Level gauge (2) Oil suction/return filter (3) Air filter
Figure 6-75 Main components
 Working Hydraulic System (Common type)

− The working hydraulic system of telescopic handler is used to control the lifting and lowering of boom, the
telescoping of boom, outriggers, levelling of frame, and dumping/retracting of forks. It‘s mainly composed of
hydraulic pump, multi-way reversing valve, luffing cylinder, telescoping cylinder, outrigger cylinder,
levelling cylinder, fork cylinder, oil tank, and pipelines.
− If the boom lifting/lowering, boom telescoping, outrigger, frame levelling, or fork dumping/retracting control
valve stem on the multi-way reversing valve is in neutral position, the front and rear chambers are completely
cut off for the luffing cylinder, telescoping cylinder, outrigger cylinder, levelling cylinder, or fork cylinder. In
such case, as there is no input of feedback signal to hydraulic pump, the hydraulic pump has no output and the
boom, outriggers, and forks remain in original position.
− The boom circuit reversing valve stem and the boom cylinder are functioned to control the lifting and
lowering of boom, the telescoping circuit reversing valve stem and the telescoping cylinder are functioned to
control the extending and retracting of boom, the outrigger circuit reversing valve stem and the outrigger
cylinder are functioned to control the erection and retraction of outriggers, the levelling circuit reversing valve
stem and the levelling cylinder are functioned to control the lateral swing of frame, and the fork circuit
reversing valve stem and the fork cylinder are functioned to control the retracting and dumping of forks.
 Working Hydraulic System (Lead operation)

− The working hydraulic system is used to control the lifting and lowering of boom, the telescoping of boom,
outriggers, levelling of frame, and dumping/retracting of forks. It‘s mainly composed of pump, multi-way
reversing valve, electronic control joystick, balance valve, priority valve, cylinders, oil tank, and oil pipes.
− The electronic control joystick is used to control the boom circuit valve stem, telescoping circuit reversing
valve stem, outrigger circuit reversing valve stem, frame levelling circuit reversing valve stem, and fork
circuit valve stem. Every valve stem is designed with forward tilting, neutral, and backward tilting positions
(Refer to 5.3.7).
− When the electronic control joystick is in neutral position, all circuit valve stems of multi- way reversing
valve are at original positions and all working oil ports are closed. In such case, the control oil port of the
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multi-way reversing valve is connected with return oil and the multi-way reversing valve is in neutral
position.
− When the electronic control joystick is pushed forward, the electronic control joystick outputs the
corresponding current to control the motion of boom circuit valve stem of multi-way reversing valve and
lower the boom.
− When the electronic control joystick is held at certain position, its output current keeps constant and the
corresponding chambers of cylinder also keep constant pressure.
− When the electronic control joystick is pulled upward to neutral position, the boom circuit valve stem of
multi-way reversing valve turns to neutral position.
 Check and adjust the hydraulic system

− For on-spot checking, the hydraulic system of working mechanism can be checked by means of raising or
lowering lifting arms, tilting the bucket, releasing pressure from distribution valve and safety valve and
descending the lifting arms.
 Check the highest pressure of the system

− Under the oil pipe plug of pressure measurement connector, install a 40MPa pressure gauge, lift the boom to
the horizontal position, maintain the engine and hydraulic oil at working temperatures, and run the engine at
rated speed. Operate the bucket joystick to tilt backward the bucket to pressure holding status, till the 27MPa
maximum pressure is reached.
 Steering hydraulic System

− The steering system is functioned to control the traveling direction of telescopic handler to maintain the linear
traveling and change the traveling direction of telescopic handler.
− This system is featured in the following points:
− Regardless of the load of the machine or the rotating speed of steering wheels, the pressure oil is preferentially
distributed to the steering system to guarantee more stable and reliable operations and performances of
steering system.
− Oil pumped out from the pump, on the one hand, is distributed to the steering system; while, on the other
hand, part of it will flow into other working system. Such way of oil distribution serves to efficiently prevent
oil power loss that possibly happens due to too much oil distribution to the steering system, therefore, the
machine production efficiency can be greatly improved.
− The steering hydraulic system incorporates three steering modes, namely two-wheel steering, four-wheel
steering, and crabwalk steering modes.
Figure 5-13 Steering Mode

Changeover Diagram
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The steering mode joystick is located on the right side of cab and has three modes, namely A, B, and C. A denotes
four-wheel steering mode, B denotes two-wheel steering mode, and C denotes crabwalk steering mode. Shift the
joystick to position B by default under normal traveling status. To change the steering mode, push the joystick
switch to A or C to complete the changeover of steering mode.
 Working principle
− The steering system is functioned to control the traveling direction of telescopic handler to realize the linear
traveling and change the traveling direction of telescopic handler. The telescopic handler adopts full-hydraulic
steering system, which is composed of hydraulic pump, steering gear, priority valve, steering cylinder,
steering mode changeover valve, and hydraulic oil tank. The oil outputted from the steering pump is inputted
into the steering gear. When the steering gear is rotating, the pressure oil flows from steering gear to the
steering cylinder to control the steering of telescopic handler.
 Maintenance to hydraulic system
Working hydraulic system
238
Figure 6-76 Brake hydraulic system
 Check the level of hydraulic oil every day!

− Park the machine on the flat ground.
− Stop the engine as per the shutdown steps of engine.
− Retract all working cylinders.
− Check the liquid-level meter on hydraulic oil tank.
− The oil level must be between the marks on the level meter, otherwise add the hydraulic oil.
− If required, add the hydraulic oil and check the level meter again.
− Keep the hydraulic oil clean in the system!
− Checked hydraulic oil at regular intervals!
− For oil cleaning degree under 10 stages (ISO4406-19/16) according to NAS1638 chart, the oil must be
filtrated or renewed.
− After 1200 hours of the telescopic handler operation, the oil must be changed and new oil should be filled
according to the following procedures:
− Lift the arms to their utmost height, and then
− stop the engine.
− Retract all working device cylinders.
− Unscrew the drarin plug at the bottom of the tank to discharge out the debris from still hot oil.
− Unscrew the plug of the oil tank and cylinder hose to discharge out the dirty oil.
− Clean the tank and filter by kerosene (or diesel).
− After oil exchange, run the engine on low speed and operate the working apparatus to vent air from the
system.
239
− Keep working place tidy and clean, prevent dust, dirt, debris dropping into/onto the removed dismanteled
hydraulic components.
− Check rubber, oil-seal, and O-rings on components that need to be re-installed. Replace the weared elements.
− Do not strike or hammer for installation of the elements.
6.4.6.4 Electrical system
The function of electrical system is to start the engine and provide power supply (as negative(-) pole ground
DC24V voltage system ) to:
− illumination lamps,
− gauges,
− electrical controls;
− other auxiliary apparatus;
− support safe driving and;
− support safe operation of the machine.
The electrical system is consisted of those parts such as:
− battery recharer,
− engine starter,
− illumination,
− monitor lamps,
− auxiliary elements.
 Battery recharging
− Consisting of battery, alternator and adjuster.
− Pay attention to following points:
 Battery
Position of battery
Figure 6-77 Battery (1 level meter 2 Porthole)
 Battery Check:
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− Park the machine on flat ground and stop the engine as per the shutdown steps of engine, then check the
capacity of battery through observing the densimeter from the upper part of battery.
− The following circles are seen from round porthole:
o Green circle──indicates the normality of battery;
o Black circle──indicates the low capacity of battery that needs to be charged;
o White circle──indicates the discarding of battery that needs to be replaced.
− There are two batteries in series, with negative pole (―-―) of the first battery being linked with the positive
pole (―+‖) of the second battery, while the negative pole (―-―) of the second one being grounded. The
positive pole (―+―) of the first battery is connected with the main power switch, so as long as the main power
switch is turned on, then the battery provides power to the machine.
Figure 6-78 Two batteries linking

− If the battery can work soundly, you don‘t need to remove the battery for charging or discharging the battery,
as it can recharged by itself during its working procedure. Only in the case of none-working for long term,
the battery should be removed off from the machine and get it charged once time every month at least.
− It is necessary to check the battery electrolyte level once time at least at interval of every 10—15 days in
winter season and every 5—6 days in summer, and it needs to check the battery appearance condition and
keep it clean.
− Never put any metal parts onto the battery! Danger of shorting the battery.
− Secured the battery in its compartment to prevent damage due to mechanical impact during the machine
driving or operation.
− Fasten firmly the battery terminal connectors and wirings.
 Alternator
The alternator is driven by the engine. The battery will be charged by the alternator during the engine operation.
For detail,km,k.s of the generator, see Engine Manual.
241
Figure 6-79 Motor on engine
 Adjuster
− It is used for adjusting the output voltage and current volume from the generator, by which to achieve the
stable output voltage from the generator.
 Starter
− The starter assembly is consisted of ignition button, main power switch and starting motor. When starting
the machine, put the ignition button at ―ON‖ position, then the main power switch is turned on; afterwards,
move the ignition button to ―START‖ position to engage the starting motor for starting the engine. Bear it in
mind that time for starting the engine should not be over 10 seconds. If you fails to start the engine in one
time, then you have to wait at least 3 minutes before you try to another attempt to re-start it again.
− It is strictly prohibited to start the engine while it has not completely stopped yet.
− It is recommended, to make the following checks for safe start:
− Check the electrical wiring of the engine to see if they get loose or tear off.
− Check the battery status to see if it can work properly.
− Check the oil input to the engine system.
 Illumination and signal lamps

− Operation monitoring gauges
242
Figure 6-80 Monitor panel

− Function of operation monitoring gauges: to display and feed the operator the critical data of a working
telescopic handler, so that the operator could know and keep in-time monitoring to the machine performance,
and take necessary measure timely in case of any unintentional accident happening, so as to avoid any human
injury or machine damages and to maintain the machine be in good order.
− The monitoring instruments on the machine are: engine thermometer, torque converter oil thermometer, fuel
gauge, engine tachometer, voltmeter, engine oil pressure gauge.
− All of these gauges (meters) have ―red‘ settings and ―green‖ settings, with the ―green‖ settings area meaning
the sound working setting data.
− If the meter (gauge) points at ―red‖ area, it shows there is something wrong with the machine or there is
potential trouble, so stop the machine and eliminate possible problems.
− Only after all the monitoring gauges point at ―green‖ area cans you drive and operate the machine again,
otherwise, it will cause severe human casualty or machine damage.
Note: see 5.3.2 & 5.3.3 for details.
6.4.6.5 Air-conditioning system
− The air conditioner system fitted on the machine can be used for heating and cooling performance.
NOTICE! Air-conditioning!
− Run the engine for a while until the water temperature reaches to 70°C, then start the heaterof the heating
system.
− For low ambient temperature below to 0°C, discharge water out from the pipes and radiator to avoid water
being frozen.
If the water has been injected with anti- freezer, there is no need to discharge water.
 Precautions:
243
− Only the professional technician can repair the air-conditioner.

− In case of needing to check and repair any part on the machine, you need to park the machine onto a flat
ground, and keep the transmission lever at Neutral position, have the braking system engaged, and keep
unconcerned people away from the repair site or working area.
− Contacting with freezer can cause injury, so wear eyes protector and other safety guards to protect the eyes
and skin from being hurt by exposed cooling liquid. Take special care when touching any machine parts,
especially the parts with high temperature or any moving parts.
− No matter if or not the engine is running, the air conditioner system is always with pressure, so never try to
heat the cooling-agent system. In case of needing to empty the air conditioner system, it is a must to wear
eye-protector, even if the pressure gauge reads at zero. It is kindly required to dismount the air conditioner
parts with much care, even with protective measures being taken.
− Smoking, flame and fire are extremely not allowed at the repair site for air conditioner, as the
cooling-agent inside the air conditioner will produce a kind of poisonous air when it is getting near the
heating source, so sucking in such poisonous air will cause severe human casualty or even death.
− The air conditioner can be started only after the machine engine being started. After the engine totally stops,
switch off the air conditioner power, so as to save the machine power.
− For soundly operating the air conditioner system, it is highly recommended to use ―High‖-gear for cooling
performance.
− In case of none use of air-conditioner for a long period of time in spring, autumn or in winter, it is a must to
have the air conditioner run for 5 minutes every two week at least, so as to prevent the air conditioner parts
from getting rusty due to long-term none-running.
− In case of needing to replenish cooling agent to the air conditioner, select and use the proper cooling agent
as stated in the Air Conditioner Manual. Never try to mix two different kinds of cooling agent together
on the air conditioner.
 Maintenance to the air conditioner

Sufficient and scheduled maintenance to the air conditioner is critically important for maintaining sound and
reliable, prolonged service-life of the air conditioner. So scheduled maintenance to air conditioner is very
necessary and needed.
Table 6-4 A/C maintenance chart
Maintenance period
System part Maintenance description
Monthly Half-yearly Yearly
A/C pipes Check wear and intactness of pipeline. ※

Check for leakage (generally, leaks have
Connectors ※
oil stains).
Condenser Check radiator fins. ※
Dryer reservoir Check working status or replace. ※

A/C system
Observe the refrigerant status by
Refrigerant ※
sightglass.
Check fixing and installation status of
A/C unit A/C unit (The A/C unit shall be free of ※
looseness)
Airtightness of Check airtightness of vehicle body and
※
system A/C.
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Electromagnetic
Check actuation status of clutch. ※
clutch
Belt Check intactness and tension of belt. ※
Compressor
Fixing bracket Check fastening and installation status. ※
Running of
Check for abnormal running sound. ※
compressor
Wires Check wear and intactness of circuits. ※
Electric
Connector Check contact and intact status ※
circuit system
Control switches Check contact and intact status ※
Maintenance period
Item Method
Daily Weekly Monthly Quarterly Yearly
Condenser core Check cleanliness and check for △
damage.
Conde Front of Check for presence of foreign △
nser condenser materials.
Condenser Check for presence of looseness and △
bracket damage.
Evaporator Check for reliability and damage. △
bracket
Circulating air Check for non-obstructed airflow. △
inlet
Evapor Fan motor Check for intactness and good △
ator contact.
Fresh air filter Clean or replace. △
element
Air return filter Clean or replace. △
element
Connector Check for intactness. △
Electric Electromagnetic Check for normal actuation. △
access clutch
ory Control Check for normal working. △
switches
Note: Under especially severe working condition, notice to increase the replacement frequency of A/C filter
element
245
6.5 Fluids and grease qualities & quantities

Table 6-5 Fuides and grease overview
Symbol Consumable Specification Volume Instructions
For hydraulic pump and

Summer NLGI Grade motor spline shaft,
2.5kg
Lubricating grease 2// vibratory drum eccentric
As required
Winter NLGI Grade 1 shaft and transmission
shaft spline
depending on ambient
L-VG46
125L (hydraulic temperature. Ex works
Hydraulic oil wide-temperature
tank volume) machine is filled with
anti-wear hydraulic oil
L-VG46.
Summer:
Use engine l ubrication oil
API CH-4 SAE
suitable for heavy duty
Engine oil 15W-40 9L
water- cooled diesel
Winter:
engines
API CH-4 SAE 5W-40
For ambient temperature＞

Coolant antifreeze
-45# 15 L (cooler ) – 35°C; increase
protection concentration for lower
temperatures.
Summer
No. 0 or 10 light diesel
(<15ppm sulfur Use winter or arctic diesel
Diesel fuel content) 83 L as recomended in your
Winter region.
No. -10 or -35 light
diesel (<15ppm sulfur
content)
246
6.6 Special Maintenance Conditions

Table 6-8 Common working conditions
Operating conditions Maintenance cautions
− Pre-operation: check if the screw plug and all the drain plugs are tightened.
Mud field, rainy or
snowy − After-operation: clean the machine, and check if there are broken, damaged, loose
or missing nut and bolt, and lubricate all the required parts immediately.
− Pre-operation: check if the screw plug and all the drain plugs are tightened.
Seaside − After-operation: clean the machine thoroughly with clean water to remove the salt
content, and maintain the electric appliances frequently to avoid their corrosion.
− Air filter: clean the filter elements at regular service intervals.

− Radiator: clean the mesh enclosure of oil cooler to avoid the blockage of radiator
core.
Dusty air
− Fuel system: clean the filter elements and sieve at regular short service intervals.
− Electric appliances: clean them at regular intervals, especially the terminals of AC
generator and starting motor.
− Fuel: adopt the appropriate low-temperature high-quality fuel.

− Lubricant: adopt the high-quality low-viscosity hydraulic oil and engine oil.
− Engine coolant: be sure to adopt the anti-freezing agent.
Frosty/cold weather
− Battery: charge the battery up at short regular intervals. In case of not charging the
battery up, the electrolyte may be frozen.
− Track: keep the track clean, and park the machine on the hard ground to avoid
freezing the track on the ground.
− Track: careful operation. Check if there are broken, damaged or missing bolts and
nuts frequently, and loosen the track a little looser than usual.
Stony ground
− Equipment: in case of digging the stony ground, the standard accessories may be
damaged, adopt the front reinforced bucket or heavy-duty bucket.
− Cab: if necessary, install the cab roof support to avoid the damages of falling rocks
Falling rocks
to the machine.
247
7 Faults and Troubleshouting
7.1 Power System

7.1.1 Engine system
Engine system
Reason For Breakdown Reasons Of Breakdown Remedies
Gear has not been engaged. Engage the gear.
There is not enough transmission oil. Replenish oil to regulated amount.
Engine is running but Transmitting oil pump is damaged Replace or repair the oil pump.
machine cannot drive.
Check if the torque converter has
Damage to the torque converter.
leakage or is damaged.
Parking brake non-released Check and release parking brake.
7.1.2 Transmission System
Transmission System
Reason For Breakdown Reasons Of Breakdown Remedies
Valve pressure is adjusted improperly. Adjust it to regulated value.
Clutch has serious oil leakage Replace the oil seal and its bracket.
Gear-shifting valve restores to its original Check the valve return spring and check
Oil pressure for position for debris in the cavity.
gear-shifting is too low
Leakage from oil circuit Tighten the tubes.
Oil pump fails to work. Replace the oil pump.
Oil filter is blocked. Clean the oil filter.
Oil pressure for gear-shifting is low See the above text.
Gear shifting could not be
Transmission pipeline is clogged. Dismantle and dredge it.
engaged.
Clutch has serious oil leakage. See above text.
Oil in the transmission system is
Replenish the oil.
insufficient.
Oil pressure for gear-shifting is
See above text.
The driving power is too low.
insufficient. Braking system is adjusted improperly;
Check and adjust it.
the brake clamp couldn‘t be disengaged.
The temperature in the torque converter is When the oil temperature is over 115°
C,
too high. stop the machine and check it.
248
7.2 Steering System
Steering System
Malfunction Malfunction cause Troubleshooting
Low oil temperature Start working after temperature rise.
Low regulated pressure of relief valve Adjust pressure of relief valve.

Heavy steering
Tight fit of steering gear parts Check and repair or replace.
Replace with oil of recommended

Excessive viscosity of hydraulic oil.
viscosity.
Damage of steering cylinder Replace.

Further rotation of steering
wheel after reaching end
Damage of steering gear Replace.
Slow steering in both left and Internal leakage of steering pump Check and repair or replace.
right directions
Damage of steering cylinder Check and repair or replace.
Leakage of relief valve Check and repair or replace.
Damage of priority valve Replace.

No steering
Damage of two-way overload valve Check and repair or replace.
Breakage of steering gear shifting pin Check and repair or replace.
Normal steering under low Leakage of main oil circuit relief

Check and repair or replace.
steering resistance and slow valve
steering under high steering
resistance Low pressure of steering system Adjust.
Remove impurities from inside of

Blockage of steering gear valve sleeve
Spontaneous rotation of valve.
steering wheel
Breakage of steering gear spring Replace.
Air content in steering oil pipeline Enhance airtightness of pump

suction connector.
High noise of steering pump
and slow motion of steering Insufficient hydraulic oil Add oil till the specified level is
cylinder piston reached.
Internal leakage of steering cylinder Replace seals.
Blockage of steering changeover

solenoid valve
Impossible switchover to
Damage of steering changeover
four-wheel or crabwalk Replace.
solenoid valve coil
steering mode
Damage of changeover switch or
circuit
249
7.3 Electrical System
Electrical System
Problem symptom Reasons of breakdown Remedies
The battery is damaged or not fully

Replace the battery or charge it fully.
charged.
It is hard to start the engine
or the engine can‘t be Switch is damaged. Repair or replace the switch
started at all. Poor wire connections. Check and repair the starting wires.
Fuel oil way or the air way is damaged. Check the fuel oil way or air way.
The starting key can‘t restore to its
Repair or replace the starting key.
original position.
Starting motor is burnt out The electrical adapter for starting motor
frequently. could not be fully disengaged due to Repair or clean the adapter.
corrosion.
Starting circuit has shortcut. Check and repair the starting circuit.
Wire is loose or disconnected. Replace or repair the wire.
Meter indication is Sensor is damaged. Replace the sensor.
abnormal
Replace the damaged meter with the
Meter is damaged.
same type one.
Wire is loose or disconnected. Replace or repair the wire.
Braking pressure is too low. Check the oil-way.
Buzzer sounds ceaselessly.
Buzzer is damaged. Repair or replace the buzzer.
Pressure sensor is damaged. Replace the pressure sensor.
The fuse is broken. Replace the fuse.
Lamp cannot be turned
Bulb filament is burnt down. Replace the bulb.
―ON‖.
Connecting wire gets loose or shed off. Repair the connecting wire.
Some wires get broken or loose. Connect wire properly.
Fuse is broken. Replace the fuse.
Diode is burnt out. Replace the diode.
Generator can‘t be
re-charged Electrical brush is blocked or the slip Repair the electrical brush and the
ring is poorly connected. slip ring.
Circuit of stator and rotor is broken or
Replace the generator.
shortcut.
250
7.4 Braking System
Braking system
Problem symptom Reasons of breakdown Remedies

There is still air inside the braking
Discharge the air.
hydraulic pipelines.
Incorrect regulated pressure of brake

Adjust it to 4Mpa.
valve.
The nitrogen pressure of accumulator is Fill the nitrogen until the pressure
too low. reach to 4Mpa.
Foot-braking pressure is
The lead pump is damaged. Repair or replace the pump.
insufficient.
The braking discs have been worn out
.Replace the braking disc or oil seal.
or braking oil chamber leaks oil.
Malfunction of prefill valve core. Check and repair or replace prefill

valve core.
Damage of foot brake valve. Check and repair or replace.
The position of braking valve rod is

wrong, the piston rod is jammed or the Repair or replace the bake valve.
Release failure of parking returning spring breaks down.
brake
The returning spring of rim brake fail to
Replace the returning spring.
work.
Malfunction of drive axle parking brake

Readjust or replace
Insufficient parking braking spring
force Incomplete relief of braking pressure oil
Readjust or replace
due to leakage of brake valve
251
7.5 Hydraulic system

Hydraulic system
Problem symptom Malfunction cause Troubleshooting
Damage of cylinder oil seal Replace.
Internal leakage of multi-way reversing Check and repair or replace.
valve
Oil leakage of hydraulic oil circuit Find out the oil leakage source and
eliminate the oil leakage problem.
Weakness or even failure
of various motions Serious internal oil leakage of oil pump Check and repair or replace.
Low system pressure due to incorrect Reset the system pressure to correct
safety valve adjustment value.
Blockage of oil suction pipe and oil filter Clean oil filer and replace oil.
Damage of pilot oil source block Replace.
Low hydraulic oil level Add oil till the specified level is
reached.
Noise
Filter blockage Clean or replace.
Air ingress of oil pump or its suction pipe Find out and bleed air.
Spontaneous drop of Damage of corresponding balance valve Replace.
boom, telescopic boom, or
forks
Low hydraulic oil level Add oil till the specified level is
reached.
Internal leakage of working pump Check and repair or replace.
Jitter during working Air ingress of oil pump or its suction pipe Find out and bleed air.
Looseness of cylinder piston Check and repair.
Unstable opening pressure of safety valve Check and repair or replace.
Damage of corresponding balance valve Replace.
Under-low oil level Add oil till the specified level is
reached.
Dirty or deteriorated oil Replace.
Over-high oil temperature Failure of oil radiator Clean or replace.
Long continuous working time or Stop for cooling or prevent overload.
overloaded working
Internal leakage of oil pump Check and repair or replace.
Damage of control knob Replace.

Slow tilting or no motion of
forks and normal function
of other motions Damage of circuit Replace.
252
7.6 A/C system
A/C system
Malfunction Symptom Malfunction cause Troubleshooting
1. Water content in system, leading to Replace dryer reservoir,

freezing blockage of expansion valve re-vacuumize, fill
Intermittent Abnormal turn-on 2. Mis-adjustment of thermostat refrigerant, and adjust.
cooling of or turn-off of A/C Check and repair.
3. Poor grounding wire
A/C system system
4. Poor contact of control switch Check and repair.
5. Poor contact of relay Check and repair.
1. Loose belt Adjust or replace.

2. Loose compressor bracket Adjust.
Increased Abnormal system
3. Loose evaporator fan impellor Adjust.
noise sound
4. Clutch skid Repair or replace.
5. Internal wear of compressor Repair or replace.
Open valve.
1. Non-opened valve
Repair
Insufficient 2. Blockage in pipeline
Cool hot air Turn on after temperature
heating output 3. Low heating medium temperature
rises.
4. Leakage in pipeline
Repair or replace.
1. Compressor clutch
Replace.
a) Open-circuit or short-circuit of coil
Repair or replace.
b) Clutch skid
Check and reconnect.
Normal functioning 2. Falloff of wires
Replace.
of evaporator fan 3. Breakage of belt
and working failure Find out leaks and add
4. Activation of pressure switch
of compressor refrigerant.
a) Excessive leakage of refrigerant
Drain as appropriate.
b) Excessively filled refrigerant
Replace damaged parts.
c) Damage of switch
Replace damaged parts.
5. Damage of thermostat
No cooling
Find out leaks and add
Normal functioning 1. Excessive leakage of refrigerant
refrigerant.
of evaporator fan 2. Excessively filled refrigerant
Drain as appropriate.
and compressor 3. Damage of compressor
Repair or replace.
No rotation of Malfunction of input power supply

evaporator fan and a) Poor contact of grounding wire Check and repair.
working failure of b) Burnout of fuse Check and replace.
compressor c) Damage of power switch Check and replace.
No rotation of 1. Damage of fan Replace.
253
evaporator fan and 2. Burnout of fuse Replace.

normal working of 3. Damage of fan speed switch Replace.
compressor 4. Damage of speed regulation resistor Replace.
1. Loose belt
2. Insufficient refrigerant due to leakage
3. High pressure on both high and low Adjust.
pressure ends Find out leaks and add
a) Dirty and blocked condenser radiator refrigerant.
fins
b) Stop of condenser fan Clean.
c) Excessively filled refrigerant Repair or replace.
d) Air content in system and fluctuation Drain as appropriate.
of pressure gauge Find out leaks and drain or
e) Excessive opening extent of add
expansion valve Adjust or replace.
4. High pressure on high pressure end
and low pressure on low pressure end
Normal evaporator Clean or replace.
a) Dirty and blocked expansion valve
fan Replace.
b) Dirt and blockage of dryer reservoir
Repair or replace.
c) Blockage of high pressure pipeline
5. Low pressure on both high and low
pressure ends Find out leaks and add
Poor cooling
refrigerant.
effect a) Insufficient refrigerant due to
leakage Adjust or replace.
b) Small opening extent of expansion Repair or replace.
valve Repair or replace.
c) Blockage of low pressure pipeline
d) Blockage of evaporator Repair or replace.
6. Low pressure on high pressure end Repair or close.
and high pressure on low pressure end
a) Malfunction of compressor
7. Heating system valve opened
1. Blockage of inlet and outlet ports Remove blockage material

Insufficient
2. Blockage of air output vent Remove blockage material
evaporator airflow
3. Frosting of evaporator Repair
254
8 Transport, Storage and Protection
8.1 Transport on Public Roads

8.1.1 General Requirements
NOTICE!
− Secure the machine properly while transporting!
− Do not engage untrained or insufficient qualified personnel in loading, transport and unloading the machine.
− Follow rules and regulations for securing loads on traffic vehicles:
− Legal background of regulations related on securing machines on vehicles refer to different EC contries
legislations;
− Additional / deviating requirements may apply in your region!
− Obtain information of legal requirements prior shipping the machine in any other european country.
− Lorries, trailers or semitrailers are most common transport means.

− Regardless the kind of transport vehicle, proper securing and lashing of the machine is mandatory!
− Personnel involved and executing loading, transport and unloading shall be sufficiently trained professionals
− Vehicles, rams, securing and lashing items shall be qualified and certified for the transport tasks.
Fasten and secure the machine on the transport vehicle to ensure safety even in higher driving speeds. The
machine must especially be secured against typically unexpected events intrafic, such as:
o emergency stopping,
o sudden maneuvers
o road unevenness
 Transporting the machine is prohibited if safe transport cannot be provided due to:
o improper or damaged lashing equipment,
o insufficient lashing
o an unsuitable or damaged transport vehicle,
o untrained or unqualified personnel being involved,
WARNING! Be aware of transport hazards!

− Transportation tasks imply a high risk of injury, possible fatalities, and damage to machinery or property.
− Follow the local laws and regulations, when placing or remove machine to the platform of truck or trailer!
− Only qualified personnel shall be involved in loading, transport and unloading the machine!
Insufficiently qualified or not trained personnel is not allowed!
− Do not use slope ramps with inclination over 15°for loading/ unloading of the machine.
− Do not swing on the sloping ramps when loading/unloading vehicles!
255
− Do not steer the machine on the slope-ramp when driving up or down the slope-ramp!
NOTICE! Be aware of transport hazards!

− Do not overload the transport vehicle
− The company/person executing the transport is always responsible for its safe processing.
− Determine the transporting route with regarding to the weight, height, width, and length of the machine.
Approve capacity of bridges!
− Use lifting lugs on the working platform; two lugs on the rear and two on the front. Attach the chains/ ropes to
lifing lugs
− Prior to the transport of machine:
− tie-up the chain or rope to the frame of machine; do not make the chain/ rope to pass through or are pressed
on the hydraulic pipe or hose.
− Place the wedges infront and behind the wheels to fix the machine.
− Fix four corners of machine and front-end equipment to the trailer with a chain or rope.
8.1.2 Transport Requirements
− Obey the appropriate laws that govern the parameters of the load (weight, width, and length).
− Investigate the travel route for obsatcles and clearances.
− Approve machine hight and provided clearances and hight limits on the transport-route for machine with a
cab and ROPS.
− Fold down and secure ROPS or remove it to keep transport height limits
− Approve the clearnce height of the machine on the trailer. Measure the distance between the ground and the
highest point of the machine.
− Remove ice, snow, or other slippery material from the loading dock and from the transport vehicle before you
load the machine. This will help to prevent slippage of the machine.
− Advise the driver of the machine weights and attachments if special permits or guidelines are necessary.
− In the cold weather, be sure to preheat the machine before loading/ unloading it.
 Approve the center of gravity of the machine
256
Center- of- gravity Position X-axis Y-axis

XC6-3514K 1659 1202
Figure 8 - 1: Machines center of gravity
 Before driving the machine to/on a transporter:

− Park the machine under consideration of its center of gravity indicated also on the machine.
− Apply articulation lock and apply lashing for machine safely during transport.
− Esure the loaded vehicle‘s weight or dimensions do not exceed the limits of the transporter.
− Equip the boarding ramps with anti-slip surface before using them.
− Keep the wheels of the machine and the loading area of the transporter (including the used ramps or planks)
clean and free from any slippery substances (e.g.: grease, mud, ice, oil, etc.).
 Proceed as follows to load the machine:

− Drive the machine carefully to the edge of the ramp, keep it in direction of the slope. Lose machine parts shall
be secured or disassembled and stored separately.
− Secure the lose parts of the machine or disassemble and stor them separately.
− Drive the machine slowly and carefully the ramp up on the loading surface.
− Park the machine under consideration of its center of gravity indicated also on the machine.
− Apply articulation lock and apply lashing for machine safely during transport.
− Apply wedges below trailer wheels for safety before you load the machine.
Figure 8-2 Restrict movement
257
8.1.3 Loading and unloading instructions
DANGER! Loading & unloading hazards!

− Risk of serious injuries or death.
− Consider the load distribution on transport vehicle!
− Machine may slip uncontrollable on blank, slippery ramps!
− Ensure ramps are wide enough to enable safe loading/ unloading.
− Not following the instructions hereafter may lead to heavy machine damage and/or serious injuries.
NOTICE! Loading & unloading instructions!

− Make certain that the truck and the trailer are adequate for the machine.
− The truck, the trailer, and the machine must be equipped with the correct safety equipment for transport and
lashing.
− Place the machine always on firm and flat ground.

− Use the platform or slope-ramp for loading/ unloading.
− Prior driving the machine on the lorry, trailer or semi-truck: approve overall permitted weight and
dimensions of loaded vehicle; approve the slope-ramp or platform maximal loading capacity use platforms
and ramps with inclination below 15°. apply an antisslip mats on slippy surface of the ramps and planks
− Clean the ramps, planks, loading areas as well as the wheels of any dirt grease, ice, etc.
− Place the wedge block under the wheels of trailer.
− The centerline of machine shall be on the centerline of trailer.
− Carefully move the machine slowly onto the trainler.
 Proceed as follows to load the machine:

1. Drive the machine carefully to the edge of the ramp, keep it in direction of the slope.
2. Lose machine parts shall be secured or disassembled and stored separately. Secure the lose parts of the
machine or disassemble and stor them separately.
3. Drive the machine slowly and carefully the ramp up on the loading surface.
4. Park the machine under consideration of machine‘s center of gravity indicated also on the machine.
 Loading:
258
Figure 8-3 Loading by driving machine
− Wedge all wheels of the telescopic handler.

− Prepare enough ropes to prevent the telescopic handler from skidding during transporting.
Figure 8-5 Front lifted point

− Use provided tie down locations to secure the machine.
− Fasten securely the chains to the left-hand and right-hand rear tie down locations on the rear frame.
259
Figure 8-6 Rear lifted point
 After machine is placed on the trailer/ truck:

− Apply the parking brake.
− Stop the engine.
− Remove the key.
− Place the joystick is in NEUTRAL position.
− Turn the battery switch to the ―O‖ position.
− Lock all doors, hoods and access panels.
 Place wedge blocks at the front and rear of each tire of the machine.
− Apply articulation lock and
− Apply lashing for machine safely.during transport (see next Section)
8.1.4 Transport Lashing
DANGER! Transport Hazards!

− Risk of serious injury or death.
− Secure the machine properly while transport machine.
260
WARNING! Transport Hazards!

− Engage only qualified personnel in loading, transport and unloading the machine.
− Do not overload the transport vehicle!
NOTICE! Transport Hazards!

 Company/person executing the transport is always responsible for the safe transport.
− Prior to the transportation: tie the chain or rope to the frame of machine; do not make the chain or rope
pass through or pressed on the hydraulic pipe or hose.
− Place the wedges infront and behind the wheels to fix the machine.
− Fix four corners of machine and front-end equipment to the trailer with a chain or rope.
− The machine shipping weight that is listed is the weight of the most common configuration of the machine.
− If attachments have been installed on your machine, the weight of your machine and the center of gravity of
your machine may vary.
− Use only the specified locations for lashing the machine.
− Do not use any other locations in order to fasten the machine.
 Before transport drive, fix the chassis safely on the transport vehicle and take all other
necessary safety protection measures.
− Adjust the rigging as shown below to prevent damage of the steel chains.
− Lash the machine safely on the transporting vehicle as indicated hereafter.
− Use chains or ropes strong enough to sustain the total weight of the machine to secure the chassis and the
working platform reliably.
− Apply chains or ropes with sufficient load-bearing capacity! In advance provide at least 5 peaces of lashing
chains/ ropes.
− Avoid any damage to the chains/ ropes due to the rigging!
Figure 8-9 Lashing on the trailer
 Lashing the machine
261
There may be more than one way to fasten the machine. Local regualtions should be used to determine the best
method. Obey all local and regional governmental regualtions.
− Do not use handles or steps in order to fasten the machine.
− Do not use the work tool to fasten the machine.
− Do not wrap chains around the rear axle to fasten the machine.
− Avoid using the front axle as a fastening support whenever possible.
− Use properly rated ropes and shackles for fastening the machine.
− Fix the telescopic handler to anchorage position. The anchorage positions on the telescopic handler are
labelled.
− Location of anchorage hole plates:
(1) Front lashing point (2) Rear lashing point

Figure 8-10 Lashing point
− Use the front eyes and the rear rear eyes that are provided on the lower frame of your machine.
− Avoid routing ropes over tires.
− Avoid contact with the work tool to prevent false tension.
− Fasten machine at all four locactions.
− Fasten machine at all four locactions.
8.2 Lifting the machine
DANGER! Life-threatening hazards in lifting task
 Risk of serious injuries, including death - Do not overload the crane.

− Determine the optimum load distribution to ensure safety during the process!
− Follow the instructions for use of the loading crane precisely to avoid accidents.
− Comply with the limitations given by the crane‘s technical data.
− Do not stand beneath the load or the crane‘s boom.
− Restrict the access to the lifting space to any unauthorised or uninvolved person.
Lifting the machine is prohibited unless all necessary safety requirements are fulfilled.
Not following the instructions hereafter may lead to heavy machine damage and/or serious injuries.
262
WARNING! Lifting hazards!

Prepare a plan for lifting of the machine. The improper lift of the machine can result in people injury and damage
to the machine, therefore before lifting the machine, lock the frame to prevent the machine from turning.
− Retract the locking bar when the lifting performance finished.
− Improper lashing can allow the load to shift or fail and cause injury or damage.
− Use only properly rated ropes/slings with lift and tie down points provided.
− Follow the instructions manual for the proper securing the machine. Refer to operation and maintenance
manual Section 10: Technical Specifications and Performance Data
CAUTION! Lifting hazards!
− When lifting the machine, make sure that there is nobody standing under the lifted machine.
− The improper lifting or fastening will cause load movement and personal injuries or machine damage.
− Install the steering lock bar before lifting
− The operating weight will vary according to different working devices.
 All the remaining tasks as positioning, securing and lashing the machine on the transport vehicle remain the
same as those previously described in Sections 8.1.1.
− Drive the machine in the required position.
− Before lifting machine ensure all precautions mentioned in cranes safety and operation manual are met,
including securing the potential danger zone.
− Use only permitted tools, lugs, ropes, etc. and ensure grounds stability as required for the crane.
− The crane's load table must correspond to the machine to be lifted.
− Drive the machine in the required position.
− When the telescopic handler has to be moved into a ship or other place, use the lifting lugs (also lashing
points) which is located on front and rear frame.
263
Figure 8-12 Lifting the machine

 Lifting eye-plates:
(1) Front lifting point (2) Rear lifting point

Figure 8-13 Lisfting and Lashing points
− Ensure that the lift arms are in fully lowered positon before lifting the machine.
− Check all of the laws that govern the load characteristics (height, wieght, and length).
− When lifting the telescopic handler, the rope only can pass through the lifting lugs.
 Lifting the machine

− Do not use the work tool for a lifting point.
264
− Do not use handles or steps in order to lift the machine.

− The machine shipping weight that is listed is the weight of the most common configuration of the machine.
− If attachments have been installed on your machine,the weight of your machine and the center of gravity of
your machine may vary.
Figure 8-14 rear lifting point lashing point detail
Figure 8-15 front lifting point detail

 Lifting Point – In order to lift the machine, attach the lifting devices to the
lifting points.
(The lifting points are identified by a label that shows a hook.)
− Use properly rated ropes and properly rated slings to lift the machine.
− Remove structures above the rear lifting points as necessary in order to route lifting cables to the lifting
points.
− Position the crane or the lifting device in order to lift the machine in a level position.
− The width of the spreader bar (if required) must be sufficient to prevent the lifting cables or the lifting straps
from contacting the machine.
− Do not allow any personnel in the area around the machine.
− Engage the parking brake before you sling the machine and before you secure the machine with tie-downs.
− Install the frame lock pin prior to lifting the machine.
− Attach two lifting cables to the rear of the machine. There is one lifting eye on each side of the rear of the
machine.
− Connect the four lifting cables to the spreader bars. The spreader bars must be centered over the machine.(if
required)
265
− If equipped, secure any attachments.

− Lift the machine, move the machine to the desired position.
− When the machines is positioned, place the blocks behind the tires.
8.3 Driving on the public roads
DANGER! Life-threatening hazards by driving machine!
− Risk of serious injuries, including death

− Pay attention to the traffic conditions and driving speed.
− Check with the proper officials in order to obtain the required licenses and other similar items before roading
the machine.
− Comply with the limitations given by technical data.
− Complete a thorough daily inspection before you mount the machine and before you start the engine.
− During the transport of machine on the road, learn of and follow all the local laws and regulations.
− Drivin the machines is prohibited unless all necessary safety requirements are fulfilled.
− Carry the work tool as low to the ground as possible.

− Disable the controls for the work tool when the machine is roaded.
− Observe the conditions of transport route in advance, e.g. size, weight limit and traffic regulations.
NOTICE! Traveling on road hazard!
− When traveling on road, lock all equipment by appropriate mechanical blocks (if required), lock always the
control levers by the appropriate locks or close the hydraulic cut off lever.
− In the event of slowing-down of the traffic, move the machine to the curb of the road.
− Drive the machine on the road for 45min and then stop the machine for 15min to cool down the tires. When
moving, the tire pressure increases. This is normal and it must not be decreased.
− Check the instrumentation frequently to monitor its operaton.
− In the event a ―rhythmical motion‖ occurs, it becomes necessary to slow-down the machine with the brakes to
stop the phenomenon and resume traveling at a lower speed.
− Have an escort vehicle warning other road users of your presence on the road with adequate signals (flashing
lights, board etc.)
− On-road regulations:
− Equipment and accessories blocked;
− Cutting edges and teeth protected;
− Compulsory operation of approved flashing lights even if it is not required the use of lighting devices;
− Traveling on road only if empty;
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− Work controls locked (if required);

− Traveling on road can occur providing that the personnel of the Company help the operator, but not from the
machine itself.
8.4 Parking, Storage and Protection
NOTICE! Parking and storage hazards!
− Starter batteries suffer self discharge over time the machine is not in use.
− They may not function depending on the duration of their storage, the ambient temperature, and their own
condition and age.
 To store the machine safely:

− Park it on even ground.
− If parking on a ramp is inevitable, park it facing to the inclination slope
− Alternatively, you can use stoppers to secure the machine.
− Ensure propulsion joystick is in park position and engine switched off.
− Empty the water tank and ensure all spray water lines are empty.
8.4.1 Parking
 Stopping the machine
NOTICE! Parking and storage hazards!
− Do not engage the parking brake while the machine is moving unless the primary service brake fails.
− The use of the parking brake as a service brake in regular operation will cause severe damage to the brake
system.
− Park the machine on a level surface. If necessary to park on a block the wheels.
− Apply the service brakes in order to stop the machine.
− Move the transmission control to the NEUTRAL position.
− Lower the work tool to the ground and apply slight downward pressure.
− Allow the engine to run for 2 minutes before shutting down.
− Turn the engine ignition switch to the OFF position and remove the key.
− Do not turn off the battery power isolator switch until the delay power off indicator is off(2 minutes).
− Turn the battery isolator switch to the ―O‖ position.
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 Equipment lowering with engine stopped
WARNING! Parking and storage hazards!

− Personal injury or death may occur from failure to adhere to the following warnings.
− Keep all personnel away from the boom drop area when lowering the boom with the engine stopped.
− Keep all personnel away from the front linkage when lowering the boom.
− Turn the engine start switch to the ON position.

− Move the hydraulic lockout control to the UNLOCKED position.
− Push the lift ocntrol to the LOWER position in order to lower the bucket or the work tool to the ground. The
lift control will retrun to the HOLD position when the control lever is released.
− Turn the engine start switch to the OFF position.
 Leaving the machine

− Ensure that the engine is shut down and all lights are OFF before leaving the cab. (Marker lights, hazard
lights, and head lights will remain ON when the ignition switch is turned OFF).
− Use ladder and handrails while leaving the cab. Face towards the telescopic handler and use both hands.
Ensure that the ladder is free of foreign materials before leaving the cab.
− Inspect the engine compartment for debris. Clean out any debris and paper in order to avoid a fire.
− Remove all flammable debris in order to reduce a fire hazard. Dispose of all debris properly.
− Always turn the battery isolator switch to OFF position before leaving the machine.
− If the telescopic handler is to be unused for >1 month, place the battery disconnect switch to OFF position.
8.4.2 Daily and short-term storage and protection
 Daily parking
− Park the telescopic handler on a place, with its bucket resting on the ground horizontally. Try your best to
park the telescopic handler on a dry place, and avoid of moisture. If the machine has to be kept outside, a
shelter cloth must be used to cover it.
− Turn the ignition switch to ―OFF‖ position, take out the key, and keep it in a safe place.
− Withdraw the ignition key and then place the joysticks to neutral position.
− Make sure to apply the parking brake.
− Lock all the parts that have locking key. Pull out the keys and keep them safely.
− In winter or cold weather (when the ambient temperature below 0°C), antifreeze addition must be applied into
the cooling water. Cooling water must be drained out completely for those machines without antifreeze
addition in the cooling system, so that the engine can be protected from being cracked by ice.
 Daily protection
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− Check the machine, repair the worn and damaged parts. If necessary, attach new parts.
− Clean the air filter element.
− If possible, retract all the hydraulic cylinders; if impossible, apply the grease to the exposed rod of hydraulic
cylinder.
− Lubricate all the lubrication points.
− Clean the machine.
− After charging the battery up, remove the battery and store it at dry and safe place. If not, separate the
connection of battery negative-pole cable on the wiring terminal (-)
− If the cooling system is emptied, be sure to hang a nameplate ―No Water of Radiator‖ in conspicuous
position.
− Apply the paint to desired positions to avoid rusting.
8.4.3 Mid-term storage (up to 4 weeks)
NOTICE! Hazard from starter batteries!
− Starter batteries suffer self discharge.

− Starting may not be possible depending on storage duration, batteries condition and temperatures.
− While temperatures may fall below freezing point, insert antifreeze agent into the spray system.
− In case the machine needs to be stored for up to 2 months, carry out the following tasks additionally to those
mentioned above:
− Inspect and fill up all lubricants and fluids except water, in particular:
o engine oil,
o hydraulic oil,
o Coolant, including required protective fluids,
o Fuel.
− Grease all lubrication points.

− Secure greasing points with the respective caps.
− Grease all plain metal surfaces (i.e.: cylinder tubes)
− Clean the machine with an appropriate cleaning agent and dry it with soft rags.
8.4.4 Long-term Storage (Longer than 1 month)
 Storage place
− Commonly store in the ventilated and dry warehouse.
− If the device is stored in open air, park it on the concrete ground easy to drain the water, cover and fix the
canvas or hood, and store it at the place that can‘t be invaded by natural disaster and without corrosive or
harmful substance or gas.
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− In case a long-term storage is required, carry out the following tasks additionally to those mentioned above:
− Park the machine in a protected, dry and ventilated place on even ground, stable enough to sustain its weight.
− Use the hydraulic functions of moving, raising and lowering boom arm 5 to 10 minutes every month to
lubricate all the parts. Check the level of coolant and lubrication state before the operation.
− Check the appearance quality, protection side and anti-corrosion substances, and etc. at regular intervals.
− If storage period significantly extends 2 months, you should remove starter battery and store it separately
 Cover the machine with a tarpaulin in case the parking place has no shelting roof.
 If storage period significantly exceeds 4 weeks, remove the starter battery from the machine and store it
separately to prevent self-discharge.
 Regular Maintenance during storage period:

− Carry out maintenances according to the instructions:
 Once every month:

− Charge the battery
− Connect battery and let engine run for 30 minutes
− Grease all lubrication points
− Grease all plain metal surfaces
− Inspect machine on leakage and take measures if necessary
 Every 3 moths (additionally to the previous):

− Look out for exterior damage and corrosion indications.
− Drain the fuel/water separator if necessary.
− Grease all hinges.
 Storage of tires
− As a general principle, the tires must be stored in a warehouse accessible only by authorized personnel. If tires
have to be stored outdoors, set a protective fence surrounding the storing area. Notes which show ―No
Entrance‖ or any other proper warnings should be posted.
− Tires should be stored in clean, dry area. Moisture will speed up tire oxidation. Oil or polluted dirt will make
tires corrode more quickly. Tires under storage should be covered with canvas, plastic or similar protective
material. Incorrect tire storage will seriously affect their quality and service life.
− Put tires on the flat ground vertically, and fix them by means of wedges, so as to prevent them falling down
even if it touched by somebody disapproved. If a tire is placed on the ground by its side, then it may be
pressed flat, which, being as a result, will worsen its quality. The tires under storage should be turned once
every month. (Turn 90°).
8.4.5 Use preparation after storage
1. Run the engine idle for about 30 minutes and propel slowly for another 30 minutes to enable hydraulic oil to
heat up.
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2. Remove the covers.

3. Clear the protection materials that have been applied on exposed parts.
4. Charge, install and connect the battery.
5. Check lubricants, fuel and coolant levels are sufficient.
6. Drain the inclusions and mixed water out of the hydraulic oil tank and fuel tank.
7. Dismantle the pneumatic cylinder of the engine, and lubricate the valve and rocker shaft. And check the
performance of each valve.
8. Apply the grease to each hinged position.
9. Fill in the coolant as per the specification.
10. Adjust the inflation pressure of the tires in accordance with the road condition.
11. Follow the checking procedures before operation
8.4.6 Oil and Water supplying
NOTICE! Oil and water supply hazard!
− Clean the oil and allowe to settle for 72 hours.

The cleanliness of the hydraulic system should reach -18/15 (GB/T 14039) or NAS9 (American Standard).
Non-compliance may cause the bucket to fall and cause excessive abrasion to the pump.
− Oil injector and related parts must be clean and preventative measures must be taken to avoid water or dirt
getting into oil.
− Keep the machine level when checking the oil level.
− Under different ambient temperatures, use oil with different viscosity and trademarks, observe with the
relative instructions.
− Different kinds of oil cannot be mixed or substituted together; nonobservance may cause rubber elements to
have early abrasion and aging.
− Check any oil leakage in the system after oil injecting.
CAUTION! Hazards during storage!

− Avoid scalding when checking or replacing oil and cooling liquid.
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8.4.6.1 Viscosity of lubricants
℃ ℉
Chamber or system Oil viscosity
Mini Maxi Mini Maxi
SAE 0W-40 −40 40 -40 104
Engine crankcase SAE 10W-30 -18 40 0 104
SAE 15W-40 -9.5 50 15 122
SAE 10W -20 40 -4 104
SAE 30 0 50 32 122
ISO 46 multi-grade -30 45 -22 113
Hydraulic system SAE10W-30 -20 40 -4 104
SAE15W-40 -15 50 5 122
SAE0W-40 -40 40 -40 104
SAE 0W-20 -40 40 -40 104
SAE 0W-20 -40 10 -40 50
SAE 10W -20 10 -4 50

Power shift transmission
SAE 30 0 35 32 95
SAE 50 10 50 50 122
SAE 0W-20 -40 10 -40 50
SAE 10W -20 10 -4 50

Drive axle
SAE 30 0 35 32 95
SAE 50 10 50 50 122
8.4.6.2 Fill the hydraulic oil into hydraulic oil tank
Check the oil level in the hydraulic oil tank. The oil level must be above the middle of the oil dipstick. When
necessary, replenish it with the new oil.
CAUTION! Hazards during storage!

− When checking oil level, the bucket should be placed on the ground horizontally and the engine should be
stopped.
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8.4.6.3 Replace with new oil by doing the following
− Remove the material from the inside of working device.

− Fully retract the working device of the machine and stop the engine.
− Unscrew the oil drainage plug on the bottom of oil tank to drain the used oil.
− Fill sufficient hydraulic oil through the oil filter (till the oil level is above the lower limit of oil level gauge.).
− Start and idle the engine, slowly operate the lifting of boom - lowering of boom - extending of boom -
retracting of boom in turn, and then stop the engine.
− Unscrew the oil drainage plug on the bottom of oil tank to drain the used oil.
− Fill hydraulic oil through the oil filler port filter, till the oil level reaches the center of oil leveler.
− Start and idle the engine, slowly operate the lifting of boom - lowering of boom - extending of boom -
retracting of boom in turn for 2~3 times respectively, and then idle the engine for 5min to bleed the air from
the system.
− Lower the forks levelly onto the ground, stop the engine, check the hydraulic oil level, and re-add hydraulic
oil till the oil level reaches specified level.
WARNING! Hazards during storage!

− After the stop of engine and pump, the pressure of the hydraulic oil will remain in the hydraulic system of this
machine.
− To prevent possible harms, relieve the pressure of hydraulic system before operating any connector, hose, or
hydraulic part.
− Before the start of maintenance, lower all attachments onto the ground.
− Properly support the attachment and lifting cylinder, if it‘s necessary to operate, test, or adjust the hydraulic
system with the attachment lifted.
− The liquid or pressure leaking from the leakage hole as tiny as a pinhole can penetrate human tissues to cause
serious injuries or even death.
− Ensure to use a wooden plate or paper board to check for presence of leakage.
8.4.6.4 Oil Filling of Drivetrain
 Filling oil to gearbox

− Fill the oil into the gearbox through oil pipe. Check the oil level via the gearbox observation port.
 Filling oil to both front & rear axle

− Unscrew the oil filler/observation plug and check the oil level. If the oil level is close to the oil filler plug, the
oil level is full. If the oil level is low, add new oil.
 Replacing with new oil

− Unscrew the drain plugs on the center bottom of axle housing of the front drive axle and on the end faces of
sides of the two wheels to discharge the oil, and use a vessel to hold it.
− After the oil is exhausted, screw on the drain plug on the center bottom of axle housing of the front drive axle.
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− Start the engine, push down the parking brake button, and drive the machine slowly, till the indicating arrow
of the oil filler port is horizontal. Then, stop the engine, shift the gearshift joystick to neutral gear, and pull up
the parking brake button.
− Unscrew the main driving (examination) oil filler plug on the axle housing of the front drive axle and the plug
of view hole on the end of arrow of wheel side of both end faces.
− Inject the new oil from the place of oil filler plug of wheel side (examination) and oil filler plug of main drive
(examination) until the moment that the oil overflows from the oil filler of main drive in the axle housing and
the oil overflows from the view hole wheel side.
− Screw the five spout plugs mentioned above.
− Replace the gear oil of rear drive axle as per above-mentioned procedure.
8.4.6.5 Filling oil to engine
 Checking the oil level

− Check the oil level before working or after the engine has stopped running for 15 minutes.
− Pull out the oil-dipstick and clean its end, reinsert fully into oil, then pull it out to check the level.
− Check the cleanness of the oil again. If it is found that the oil is over polluted, replace it completely
with the new oil.
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Figure 8-19 Engine oil level

(The oil level is right if the oil surface lies between the upper and lower scale of the dipstick. If the oil level
is below the lower scale, replenish it with new oil until it arrives at the upper scale.)
 Replacing with new oil

− Drain out the used oil from oil-draining plug of the oil pan, and then fill new oil via the oil fill hole until the
oil level reaches to the upper scale.
Figure 8-20 Oil drain and filler

− Run the engine with low speed, and then stop it to check the oil level. Replenish with more new oil if the oil
level is insufficient.
− The oil level should not be over the upper scale.
− Engine oil replacement should only be done while the engine is still hot.
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8.4.6.6 Filling cooling liquid
− If the temperature of engine coolant is too high, first check the coolant quantity in the radiator.Replenish
liquid if fluid level is insufficient. At the same time, check the radiator for blocks and check the hoses for
ware. Be sure to put the radiator cover tightly to prevent cooling fluid evaporating.
− Replacement for the fluid should only be done while the radiator is cold. Firstly open the radiator cover, and
then open the draining valve to drain off the cooling fluid.
− Start the engine after finishing the cooling fluid replacement for making the fluid level drop a little. Then stop
the engine and replenish cooling fluid again if necessary.
− Fill the radiator full with coolant, then run the engine with high speed to make the coolant and circulate
inside the radiator. Fill more coolant while the engine is running. At the same time, drain out the coolant
from draining valve until the clean coolant flows out of the draining valve.
WARNING! Hot fluid hazard!

− Do not open the radiator cover when the engine is running or the engine is still hot. Hot coolant is very
dangerous. If it is necessary to open the cover, use a cloth to cover it in case of coolant spraying.
CAUTION! Hazards from cooling water with anti-freeze
− When the ambient temperature is lower than 0°

C add antifreeze agent into cooling water to prevent water
getting frozen.
− If the telescopic handler is stored for a long time and without anti-freeze, drain out all cooling water
completely.
− Cooling water with anti-freeze does not need to be drained out. High quality anti-freeze should be used.
− In extreme hot weather with temperature up to more than 30°C, engine overheating can occur. Park in an
area with shade if possible.
− To prolong the service life of the engine, run the engine at low speed for 5 minutes at the end of daily work.
Stop the engine after the water temperature has become cool.
− The freezing point of anti-freeze should be 10°
C lower than the lowest temperature of the ambient
temperature.
− The anti-freeze should be replaced every year.
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XC6-3514V Telescopic Handler
9 Cleaning
9.1 Cleaning the Machine
WARNING! Beware of injury hazards while cleaning!
 Risk of slipping and falling

− Do not climb onto the machine when cleaning it with water of any kind (pure, mixed with cleaning agent or
highly pressurised)
− Use another working platform or other means to prevent slipping!
 Injury hazards due to moving parts!
 Rotating parts can cause serious injuries up to death!

− Switch off the engine and remove the starting key from the ignition slott to avoid unintentional engine start.
− Open the engine‘s cover only after it was shut off and has cooled down.
− Keep all protection and safety devices securely fastened to the machine.
− Wear suitable protective clothing and personal protective equipment!
Do not wear loose clothing or jewelry that can get caught on or sucked into rotating machine parts and lead
to painful injury.
CAUTION! Beware of injury hazards!
 Burn hazard due to hot engine parts!

− Wear the required protective equipment and clothing when starting to clean the machine before it has cooled
down.
− Start cleaning the engine and the combi cooler only when the engine has been switched off and has cooled
down completely.
− Wear suitable protective clothing when using a compressed air cleaning device.
 Hazard due to missing warning labels

− Cleaning with high pressurised air or water may wash off or deteriorate the safety warning labels stuck on the
machine body.
− Keep all safety warning labels legible and unscathed when cleaning.
− Have any damaged or illegible labels replaced before resuming operation.
− Refer to the Sections 3.8 and specifically to 4.8.2.1 for detailed information about attached warning labels. If
necessary, specify the language.
− Use mild cleaning agents and water to clean the safety labels.
− Do not to use cleaning agents containing solvents.
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NOTICE! Risk of Property damage!
Machinery damage caused by cleaning work:

 High pressure water can penetrate seals to intrude the electrical system cause short circuits and disable
the controls.
− Do not clean any of the cabin interior of the cabin or the engine compartment with a high-pressure air/water
cleaner or a steam jet.
Environmental damage:
− Only carry out the cleaning process inside washing bays and places provided for this task to prevent
damaging the the environment.
− Clean the machine, the engine and the combi cooler only if an oil separator is available.
− Cleaning the machine without an oil separator may cause environmental damage.
Property damage
 Damage may occur when cleaning with a high-pressurised cleaner.

− Use a high-pressurised cleaner at least 6 weeks after putting the machine into service.
− Do not use high-pressure cleaners on insulation material.
− Do not spray into the openings of the air filter or the exhaust.
− Remove frost, dirt, liquids, tools and other foreign objects from the platform, the walkways and the steps.
− Different cleaning methods are recommended, depending on the degree and type of contamination.
− Follow the instructions and recommendations below:
 The wrong choice of cleaning equipment and/or agents may have an impact on both the operating
safety of the machine and the health of the persons cleaning the machine.
 Using unsuitable cleaning agents will damage the surfaces of the machine!
 Insuficient or incorrect application of preservation agents will also damage the machine!
− Neither use any aggressive or abrasive cleaning agents, nor any phosphate- or solvent-based cleaners.
− Only use cleaning agents with a pH value blow 12.
− Ensure that the cleaning agent/water-ratio does not exceed 3%.
− Only rinse with pure, and not not salted water.
− Only involve authorized and qualified personnel for the machine preservation process.
− Make sure that the recurring inspection cleaning intervals are stricktly observed.
 Dry cleaning with compressed air:

− Use oil-free compressed air to cleanin minor dry-dust contaminations.
− Compressed air and/or a high-pressure cleaner can be used to blow out dirt and/or hot water residues.
− Limit the air pressure to 205 kPa (~ 2 bar) when cleaning without attaching a nozzle.
− Wear the poper PPE for cleaning work with compressed air and/or a high-pressure cleaner (i.e.: protective
clothing, safety shoes, goggles and protective mask.
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− Including the PPE, use an effective deflector shield for particles.

− Carry out this work carefully and without haste.
− Do not direct the compressed air towards other persons, especially not on their skin.
− Do not clean your clothing with compressed air
− When cleaning with air, allow the machine to cool down to minimize the possibility that blowed fine dirt
deposits will ignite in contact with hot surfaces.
 Cleaning with water and detergents:

− In case of minor dust contamination in combination with oil and fuel:
− Use neutral or alkaline cleaning agents only.
− Apply the cleaning agent with a brush.
− Allow cleaning agent to soak in and spray it off with pure water later.
− Lubricate the Telescopic handler after the cleaning process.
− The maximum water pressure for cleaning must be less than 275 kPa (~2,5 bar)
− Never spray water directly on electrical connections, connections and components. When cleaning with air,
allow the machine to cool so that the likelihood that fine dirt deposits will ignite if they are deposited again on
hot again on hot surfaces.
 Cleaning with washing solvents

− Ensure adequate room ventilation.
− Wear suitable protective clothing.
− Do not use flammable liquids, such as gas or diesel.
 Cleaning with a high-pressure cleaner or steam jet. In case of heavy dirt contamination with durst
mixed with oil and fuel.
− Cover all electric parts to avoid damaging them.
− Do not directly expose electrical components and damping material to the jet.
− Plug in the vent filter of the hydraulic oil tank, as well as the filler caps for the fuel and hydraulic oil tank.
− Protect the following components from moisture:
 Electrical components (e.g.: alternator)
 Control devices and seals.
 Filters (e.g.: for air intake, etc.)
 Cleaning with a high-pressurized cleaner:

− Keep the nozzle of the high-pressure cleaner at least 0,5 m away from the surface it is uised on.
− Make sure the spraying pressure stays below 100 bar.
− Apply a spraying temperature of max 80 to 90°C.
− Use neutral or alkaline cleaning agents only.
− Use a metal-less brush or similar to remove tough-adhering dirt.
− Lubricate the telescopic handler after cleaning (refer to maintenance section)
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 Using volatile and easily flammable anticorrosion agents, inhibitors, sprays etc.:
WARNING! Fire, explosion and inhalation hazards!
 Highly flamable and volatile cleaning solvents, agents, inhibitors and sprays in closed compartments or
rooms always present danger of fire or even explosion.
− Provide constant extensive fresh air ventilation while cleaning with solvents.
− Only use protected lights (if necessary)
− Do not smoke, use open fire or crate sparks (e.g.: due to electrostatic discharges or possible short circuit
caused by uncovered live cables).
 Risk of explosion due to possible sparks!
− Do not use objects containing metal!
− Especially adopt metal-free brushes.
NOTICE! Risk of property damage!
 Cleaning with solvents may damage the tires and/or electrical parts!
− Do not use solvents, gasoline or other aggressive chemicals.
9.2 The detailed cleaning process

This type of machine has 3 areas which should be cleaned independently: operation platform, outer
surfasces of the machine and engine compartments.
9.2.1 Cleaning the driver's cabin
 Care instructions for the driver's platform

Only use a small dose of dishwashing detergent mixed in warm water to clean the following parts: the steering
wheel, the center console, the instrument panel and the floor of the platform.
 Do not use abrasive agents and/or pieces of cloth

Recommended tools for the cleaning process: broom; vacuum cleaner; damp cloth; metal-free brush; A bucket
filled with a warm and low-concentrated water-soap solution.
9.2.2 Cleaning the exterior of the machine
The following tools are recommended to clean the exterior of the machine: High-pressure cleaner;
Steam jet.
Excessive pressure from the cleaning device can damage the safety warning labels and cause
the formation of film foils on machine surfaces by forcing water underneath the sticker labels.
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− The same risk applies for the perforated film foils on windows, and are just as critical of a problem.
− Follow these steps to keep the stickers stuck on the machine, even after cleaning.
o Only use a wide-spray pattern nozzle to clean machines.
o Adjust maximum pressure within 100 bar.
o Use water with maximum temperature of 50°C.
o Keep the nozzle always perpendicular to the label/ film foils at a minimum distance between 30~40cm.
 Do not direct a stream of water at a sharp angle to the edge of any labels or film foils.
9.2.3 Cleaning the engine compartment.
 Cleaning the engine compartment:

− Park the machine in a wash bay or place.
− Stop the engine.
− Clean the machine.
 Cleaning the cooler(s)

− This area includes the separate or combination cooler for the engine, the hydraulic oil cooler and the
condenser of the heating and air-conditioning system.
− After cleaning, warm up the engine so that water residues can evaporate and rust formation is avoided.
− Check for any lose screws connecting the protection devices to the machine once a day and retighten any if
necessary.
CAUTION! Hazards from cleaning!
− Avoid environmental pollution by contaminated wastewater.
− While cleaning the machine with pressurized water avoid electrical installations and components, cables and
connectors. Do not hold the water jet of the high-pressure cleaner directly on the seals.
− Do not use harsh detergents on plastic surfaces.
− Clean the machine with moderate pressurized water and high-pressure hose.
− Use wet cleaning rags with commercially available cleaning agents wherever necessary.
− Use biologic degradable emulsions to remove asphalt leftover.
− Clean the cab windows and clean all lamps to ensure optimum visual field.
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10 Technical Specifications/Performance Data
10.1 Operating limits

XC6-3514K telescopic handler is equipped with high performance parts and is applied with
high-strength structure of innovative technologies to guarantee the stable quality and reliability of
the machine. It‘s a really highly efficient machine. This machine can be equipped with diversified
attachments, including forks, bucket, hook, and aerial work platform. No matter for new building,
roof, and covering constructions or renovation and repair works, this product is one essential tool
for modern buildings.
− The machine is common engineering machinery, which is not designed to suite the inflammable and
explosive environment and the environment with high-thick dust or poisonous gas.
10.2 Overall dimensions and specifications
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Figure10-1 Overall dimensions
283
Technical Specifications:
Table 10-1 Dimensions and specifications
XC6-3514K
Overall Dimensions
Overall length (Excluding forks), A 6200 mm
Overall width, B 2420 mm
Overall height, C 2500 mm
Wheel base, D 3100 mm
Tread, E 1980 mm
Min. Ground clearance, F 445 mm
Cab width, G 980 mm
Fork length, L 1200 mm
Performance Parameters
Operating weight 10500 kg
Maximum lifting height 13500 mm
Maximum forward reach 9400 mm
Departure angle 34°
Maximum downward tilting angle of boom -3°
Maximum upward tilting angle of boom 71°
Leftward 10°
Lateral angle of frame
Rightward 10°
Backward tilting angle of forks, P1 12°
Forward tilting angle of forks, P2 114°
Minimum turning radius, R1 3920 mm
Minimum trafficability radius, R2 5350 mm
Maximum traveling speed 30 km/h
Max. Tractive force 60 kN
Model BF4M2012-10T3R/3
Engine
Power 72 kW
Tire size 15.5-25-16PR
Front wheel 0.525±0.02 MPa
Inflation pressure of tire
Rear wheel 0.525±0.02 MPa
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10.3 Oil capacity

Table 10-2 Filling oil capacity
Oil Liquid Volume
Parts or system
L
Fuel (diesel) 125
Lubricating oil of engine 9
Transmission oil 3.7
Axle oil 26.2
Hydraulic oil tank 125
Coolant 15
10.4 Nameplates
10.4.1 Machine nameplate
− Record all part numbers properly for future maintenance or reference.

− Be sure to send a copy of this information to your distributors.
− If this copy of the operation and maintenance manual is kept inside the machine, keep the part numbers in a
separate location.
− This will make it easier to search in the event of damage.
− All numbers collected on this page are the unique identification numbers (serial and part numbers) of each
machine and hydraulic part.
− Fill in these identification numbers in the appropriate places to get a quick overview if necessary.
The telescopic handler label shall be affixed to the rear of the frame left panel of telescopic handler and shall
indicate the product model, main specification, product identification number, manufacture year, and
manufacturer.
In order to be convenient for looking up, please record the code of Product Identification Number (PIN) in the
placard about the machine on the relevant position on the end of the foreword in the manual.
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Figure10-2 Machine nameplate
10.4.2 Engine nameplate
The engine placard shall be fastened on the engine body to mark the engine parameter, discharge, manufacturer
and other information.
Figure10-3 Location of engine nameplate
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10.4.3 Other nameplates
The product form, manufacture number, manufacturer code, boundary dimension and other information shall be
show in the type of placard or coining on the main parts of the machine.
10.4.3.1 Attachment nameplate
 This label is located on the attachment of telescopic handler.
Figure 10-5 Attachment Nameplate
10.5 Emissions
10.5.1 Engine emissions
Refer to the engine label (refer to the Section 10.4.2)

Table 10-4 Engine China-III Emission Limits (GB20891-2014)
Emission
Power range CO HC NOX HC+NOX PM
stage
kW g/kWh g/kWh g/kWh g/kWh g/kWh
China-III 37≤P＜75 5.0 - - 4.7 0.4
287
Table 10-6 Limits of exhaust smoke (77/537/EEC) (GB36886-2018)
Coefficient of light
Type Rate net power (kW) Ringelmann smoke
adsorption(m-1)
Pmax＜19 2.00
Type II 19≤Pmax＜37 1.00 1 (no visible smoke)
Pmax≥37 0.80
10.6 Hydraulic schematics

Table 10-6 Main components list (see Figure10-9/10/11/12)
No Name Specifications Remarks
1 Oil tank 125L
2 Oil suction filter 150 μm/250L/min
3 Level gauge /
4 Plunger pump 52ml/r
5 Traveling pump 75ml/r
6 Traveling motor 105ml/r
7 Multi-way valve 270bar
8 Priority valve (dynamic) 170bar
9 Steering gear 400 mL/r
10 Changeover valve 80L/min
11 Bucket cylinder Φ140/Φ70×368
12 Telescoping cylinder Φ120/Φ90×3750
13 Luffing cylinder Φ160/Φ90×1365
14 Auxiliary cylinder Φ100/Φ50×480
15 Leveling cylinder Φ110/Φ50×165
16 Outrigger cylinder Φ110/Φ60×510
17 Bucket balance valve 170L/min
18 Telescoping balance valve 170L/min
288
No Name Specifications Remarks
19 Luffing balance valve 170L/min
20 Auxiliary balance valve 170L/min
21 Leveling hydraulic lock 60L/min
22 Outrigger balance valve 90L/min
23 Electromagnetic reversing valve 60L/min
24 Accumulator 2L
25 Accumulator 0.75L
26 Two-circuit pedal valve 40bar
27 Double-circuit prefill valve 100/66bar, prefill rate: 10lpm

Electronic control parking brake valve Reducing valve pressure setting:
28
group 55bar
29 Rear brake lamp switch 5bar
30 Accumulator 2L
31 Radiator motor 8.26ml/r
32 Oil suction/return filter 10 μm/250L/min
289
290
Figure10-9 Brake hydraulic system
Figure 10-10 Working hydraulic system
291
Figure 10-11 Traveling hydraulic system
292
Figure10-12 Steering hydraulic system
293
Figure10-13 Independent radiator system
294
XC958 Wh
10.7 Electric schematics
XC958 Wh
XC958 Whe
XC958 W
XC958 W
XC958
XC958 W
11 Decommissioning and Disposal

When the machine is removed from service, local regulations for the machine decommissioning will vary.
Disposal of the machine will vary with local regulations.
Consult the nearest XCMG dealer for additional information.
11.1 Decommissioning and disposal guidelines
CAUTION! Hazards from disposal work
− Improper disassembly increases the risk of accidents.

− Contact your XCMG partner for proper disassembly of the machine.
− Disassemble the machine into its individual parts according to the instructions of your XCMG partner.
11.2 Disposal
NOTICE! Disposal hazards!

− Safety and environmental protection should be in focus.
− Please ensure negative impacts are avoid during disposal of packing materials, cleaning agents, consumables,
components and after end of life, the entire machine.
− Clean all oily and greasy parts before disposal. Oil and grease must not be released into environment.
− Comply with the locally applicable laws when disposing of the unit‘s single parts and consumables.
 Notes:
− Clean all oily and greasy parts.
− Dispose of the components according to their nature (steel, plastic, electric and electronic parts, etc.)
− Dispose of all consumables even biodegradable ones in an environmentally friendly way.
− Contact your XCMG partner regarding the purchase of a new unit.
− Recycling may become easier in case when materials meant for disposal are properly sorted.
11.3 Properly disassemble the unit

11.3.1 Disassembly personnel:
− Have the corresponding qualifications or be authorized.

− Experienced professional technicians or professional engineers.
− Be familiar with the dismantled mobile elevating working platform and its hazards.
302
− Have received corresponding education and training, including learning related courses on the use of special
equipment.
− Be familiar with the relevant work procedures and safety protection measures for the assembly and
disassembly of the mobile elevating working platform.
11.3.2 Precautions for disassembly
 When operating the machine, safety equipment must be used.

− Choose appropriate safety equipment according to the site conditions, such as safety helmets, safety gloves,
safety glasses, safety belts, safety boots, hearing protective devices, etc.
− If the product need to be taken out of service, different regional regulations apply for
decommissioning/disposal the product.
− The product must be disposed of in accordance with the respective regional regulations. Contact your local
XCMG dealer for more information.
− Follow all local regulations for the disposal of materials liquids.
− Improper waste disposal endangers the environment.
− Potentially harmful liquids must be disposed of in accordance with the applicable regulations.
− Always use leak-proof containers when draining fluids. Do not pour used fluids onto the floor, down a drain,
or into a water source.
 XCMG equipment do not contain asbestos!
CAUTION! Hazards from asbest dust!
− Avoid inhaling dust generated dust that may be generated when handling asbestos fiber can be generated.
Inhalation of this dust is harmful to health.
− When handling parts containing asbestos fibers or asbestos debris, during disposal follow these
guidelines.
 Components that may contain asbestos fibers include:

− Brake pads, brake bands, brake linings, clutch plates and some gaskets. The asbestos contained in these parts
is bound or sealed with resin. bound or sealed. Normal handling is is not dangerous as long as no asbestos
dust is generated is produced that can become airborne.
 If asbestos dust is present, the following guidelines must be followed:
− Never use compressed air for cleaning.
− Do not brush on asbestos-containing material.
− Do not grind on asbestos-containing material.
− Clean asbestos-containing material wet.
− You can also use a vacuum cleaner with a HEPA, High Efficiency Particulate Air filter.
 Use an air-suction system for machining during disposal work:
− European Directive 98/391/EWG for Occupational Safety and Health (OSH) by the European Agency for
Safety and Health at Work.
303
− The rules and regulations applicable to the workplace. regulations applicable to the workplace. In the USA,
the Occupational Safety and Health Administration (OSHA) Administration (OSHA) regulations must be
followed. These OSHA regulations can be found in "29 CFR 1910.1001". found.
− In Japan, in addition to the requirements of the Industrial Safety and Health Act, the requirements in
"Ordinance on Prevention of Health Impairment due to Asbestos". must be observed.
− If the dust cannot be kept away in any other way, use an approved dust mask.
− Avoid places where asbestos particles may be in the air. can be in the air.
− When disposing of asbestos, follow the relevant environmental regulations when disposing of asbestos.
11.4 Disposal
 Follow regulations that apply to your region and dispose the materials in a professional safe and
environmentally friendly way. Recycling may become easier in case when materials meant for disposal
are properly sorted.
− Hydraulic accumulators contain high pressure gas and oil. DO NOT disconnect or disassemble any lines or
components of a pressurized accumulator.
− Before servicing or disposing of the accumulator or its components, completely relieve the gas charge
pressure according to the instructions in the service manual must be completely removed.
− Failure to follow the instructions and warnings could result in injury and fatal accidents.
304
12 Warranty
 Warranty conditions applicable to your machine are stated in the contract with your
XCMG partner.
WARNING!
- In the event of personal injury or material damage, the manufacturer is liable only for proven defects in the
system.
- The warranty expires in the following cases:
- In case of improper or unintended use as defined in this Operation and maintenance manual.
- In case of improper operation.
- In case of insufficient care and maintenance.
- Use of wrong consumables.
- When using improper spare parts.
- Maintenance/repair errors by service personnel not authorized by XCMG.
- For unallowed or unapproved technical changes.
- Resulting damage/defects due to delayed warranty request or repair.
- Be stolen.
- Any chage or modification must be agreed in written with the manufacturer.
305
XCMG CONSTRUCTION MACHINERY CO., LTD.
Copyright© 2023.
Printed in China
All rights reserved, in particular the global copyright laws, right of reproduction and right of
distribution.
No part of this publication may be reproduced, translated or used in any form or by any
means – graphic, electronic or mechanical including photocopying, recording, taping or
information storage or retrieval systems – without before permission in writing from the
manufacturer.
No reproduction or translation of this publication, in whole or part, without the written
consent of XCMG CONSTRUCTION MACHINERY CO., LTD.
Any violation of the legal provisions, in particular those relating to copyright protection, will
lead to both civil and criminal prosecution.
XCMG CONSTRUCTION MACHINERY CO., LTD. keeps abreast of the latest technical
developments and constantly improves their products.
For this reason, we may from time to time need to make changes to figures and descriptions in
this documentation which do not reflect products that have already been delivered and that
will not be attached on these machines.
Technical data, dimensions and weights are only given as an indication. Responsibility for
errors or omissions is not accepted. Non-metric weights and measurements are approximate.
Translation of original Operation and Maintenance Manual.
The cover features the machine with possible optional equipment.
Photographs and graphics are symbolic representations and may differ from the actual
products.
The Operation and Maintenance Manual and any amendments to it must be constantly
available at the place of use of the vehicle. Possible amendments are included at the end of the
Operation and Maintenance Manual.
306
XCMG CONSTRUCTION MACHINERY CO., LTD.
Add: No.99 Kunpeng Road, Xuzhou Economic Devalopme t Zone, Xuzhou, Jangsu, China
Tel: +86-516-83111320
Fax: +86-516-83111363
Service hotline: 400-110-9999
Post Code: 221004
Website: http://www.xcmg.com
This publication or parts of it may not be reproduced in any form or by any means,
electronic or mechanical, including photocopying, without the expressed written permission
of XCMG.
Any kind of reproduction, distribution or storage on data media of any type and form not
authorized by XCMG is infringement of copyright and may be prosecuted.
307

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Operation and Maintenance Manual

XCMG Special Construction Machinery Co., Ltd.

- Carefully read the included information before use of the machine.

- Familiarize yourself with its content and.

- This Operation and maintenance manual is an integral part of the machine!

- Keep it on the machine at all times for reference!

- In case of damage or loss of this manual it is mandatory to replace it immediately!

Declaration from The Manufacturer:

XCMG representative‘s contact data:

Sales Tel: +86-516-83111320

Sales Fax: +86-516-83111363

Service Tel: +86-516-87560286

Service Fax: +86-516-83111363

Spare Parts Tel: +86-516-87560286

Spare Parts Fax: +86-516-83111363

Technical Service: +86-516-83111320

Post Code: 221004

Service Hotline: 400-110—9999

Web Sites: http://www.xcmg.com/

Manufacturer XCMG Construction Machinery Co., Ltd.

Date of Issue 202302

Version N°. V01

XCMG Construction Machinery Co., Ltd.©

Any complete or partial reproduction of this document without prior written

1 About this Document ................................................................................................................................10

3.7 How to act in dangerous situations .................................................................................................. 39

4.10.2 General hazards........................................................................................................................ 88

5.8 Operate the machine ...................................................................................................................... 146

8.4.1 Parking ................................................................................................................................... 267

1 About this Document

1.1 Main purpose

This Operation and maintenance manual supports you in:

Before operating, maintaining or repairing any machine part:

NOTICE! Please read the Operation and Maintenance Manual.

 Keep the documentation always complete, up to date and available if needed:

NOTICE! Please read the Operation and Maintenance Manual.

 Operation and maintenance manual is considered as a construction part of the machine!

1.2 Product information

1.3 Target group(s)

This operation and maintenance manual is intended for use by:

1.4 Warning notices

DANGER! Short hazard description!

WARNING! Short hazard description!

CAUTION! Short hazard description!

NOTICE! Short hazard description!

− Indicates a situation that may cause property or environmental damage if ignored.

1.5 Symbols and text-structure of this manual

1.5.1 Additional types of text

1.5.1.1 Instructions for action

 Handling instructions are structured as follows:

— Not-numbered Lists are structured as follows:

– Numbered Lists are structure as follows:

3. (List level 1) …etc.

1.5.2 Additional information

 A dot, if they denote visible parts

 An arrow, when pointing to towards invisible/indicated direction

1.5.2.2 Dimension unit

− Dimensions are given in metric, ISO units.

操作与保养手册伸缩臂叉车XC6 3514K（英文版）

操作与保养手册伸缩臂叉车XC6 3514K（英文版）

操作与保养手册伸缩臂叉车XC6 3514K（英文版）