Xe800d操作与保养手册 en Omm

XE750D/XE800D Hydraulic Excavator Operation and Maintenance Manual
XUZHOU XUGONG MINING MACHINERY CO., LTD.

XE750D/XE800D Hydraulic Excavator
Operation and Maintenance Manual
Preface
This manual provides rules and guides for safe and efficient operation of this machine. Before operating,
maintaining and servicing this machine, be sure to read through and understand this manual, learn to
correctly operate, maintain and repair your machine; pay attention to safety information & safety signs
and be sure that you understand related safety requirements.
Always follow all the notices specified in this manual during operation, repair and maintenance and bear
in mind that all the accidents are caused by failing to follow basic safety rules in terms of operations and
maintenance.
This symbol refers to safety warnings and shows important safety information.
The moment you catch the sight of this symbol, please keep on alert about potential dangers, read through
the information below this symbol, and inform related operating stuff immediately.
Please keep this manual inside the cab, leaving access to all staff for them to make periodical references.
You can contact Xugong Mining Machinery Co., Ltd or authorized dealers for request of a new manual
once yours is lost or defaced.
This manual should be considered as an integral part to this machine. As a seller, you must attach this
manual to this machine.
This machine is designed to work in following conditions:
Ambient temperature: -15°C～40°C
Altitude: 0m ～ 2000 m
Max.working gradient: 4°
Ground line gradient is confined within 30°.
If it’s necessary to operate this machine out of this gradient, please contact Xugong Mining Machinery
Co., Ltd or authorized dealers.
It’s impossible to predict all the likely and potential risks that may occur during operation or
maintenance, therefore, this manual may not include all the possible safety measures. If you’re going
totake any other measures, please ensure your safety.
Never conduct out-of-range operations and applications under no circumstances.
Important: This is a general manual for models XE750G/XE800GA/XE750D/XE800D, your
machine may lack some functions described in this manual, which you may ignore or consult with
XCMG’s authorized dealer.
Important: If your manual does not fit your machine, please contact your boss, Xugong Mining
Machinery Co., Ltd or its authorized dealer for request of a matching manual. Keep it safety and
read through it.
All the materials, signs and specifications of this manual are the latest ones before publication.
The contents are subject to change without prior notice
EOMZHXE750G/XE800GA/XE750D/XE800D-01
III Preface
Machine Number
Please correctly take down all the numbers for ease of maintenance. In addition, your dealers may need
this information. If this manual is kept in the machine, please record all the numbers or store the Number
Section in other places, so as to find this machine once lost.
These numbers are the specific ID number (series number) of each set of machine and each hydraulic
component, please write down these numbers in corresponding places, so as to immediately find them
once required.
Machine
Model：
Product ID code：
Figure-1
Engine
Model：____________________
Number of manufacturing:
__________________
Figure-2
Walking motor
Model：____________________
Number of manufacturing：
__________________
Figure-3
V Machine Number
Slewing motor
Model：______________________
____________________
Model：______________________
____________________ Figure-4
Hydraulic pump
Model：______________________
____________________
Figure-5
Bucket
Model：______________________
____________________
Figure-6
VI
Table of contents
Preface ............................................................................................................................III
Machine Number.............................................................................................................V
1 Safety .......................................................................................................................... 1-1
1.1 Safety signs......................................................................................................... 1-1
1.2 Safety device..................................................................................................... 1-13
1.3 Safety rules ....................................................................................................... 1-16
1.4 Safe operation ................................................................................................... 1-27
1.5 Safety maintenance instructions ....................................................................... 1-48
1.6 Accessories installations and other safety instructions..................................... 1-56
2 Component Name...................................................................................................... 2-1
2.1 General drawing ................................................................................................ 2-1
2.2 Driver’s cab layout (general instruments)........................................................ 2-2
2.3 Driver’s cab layout (touch screen instrument) ............................................... 2-44
3 Operation ................................................................................................................... 3-1
3.1 General introduction ........................................................................................... 3-1
3.2 New machine operation instructions .................................................................. 3-2
3.3 Pre-boarding preparation and inspection ............................................................ 3-3
3.4 Post-boarding preparation and inspection .......................................................... 3-7
3.5 Running operation ............................................................................................ 3-15
3.6 Working operation ............................................................................................ 3-26
3.7 Shutdown operation .......................................................................................... 3-44
3.8 Fuel and liquids refilling procedure.................................................................. 3-47
3.9 Other operation procedures............................................................................... 3-52
3.10 Fire safety operation procedure ...................................................................... 3-54
4 Lubrication, Maintenance and Repair.................................................................... 4-1
4.1 General introduction ........................................................................................... 4-1
4.2 Lubrication of equipment and devices................................................................ 4-3
4.3 Maintenance and repair..................................................................................... 4-15
4.3.1 Safety regulations ...................................................................................... 4-15
4.3.2 Maintenance............................................................................................... 4-22
4.4 Troubleshooting ................................................................................................ 4-97
4.5 Periodical replacement of components and parts ........................................... 4-162
Table of Contents I
5 Transport, Storage and Protection .......................................................................... 5-1
5.1 Transportation..................................................................................................... 5-1
5.2 Transport and protection................................................................................... 5-11
6 Technical Specifications............................................................................................ 6-1
6.1 Product specifications......................................................................................... 6-1
6.2 Working range .................................................................................................... 6-3
6.3 Hydraulic principle schematics (standard configuration)................................... 6-4
6.4 Hydraulic principle schematics (optional configuration, adding anti-
explosion valve) ............................................................................................. 6-5
6.5 Electric principle schematics .............................................................................. 6-6
7 Appendix .................................................................................................................... 7-1
7.1 Types of crawlers and their applications ............................................................ 7-1
7.2 Types of buckets and their applications.............................................................. 7-2
7.3 Weight of working load ...................................................................................... 7-3
II Table of Contents
Chapter 1 Safety
1.1 Safety signs

Safety Signs
Please have a correct understanding of warnings in safety signs. DANGER, WARNING, or CAUTION
with ” in this manual or on machine safety signs indicates a danger and severity of the danger;
whenever a triangle safety warning sign is seen, relevant staff must read the warning content carefully no
matter which warning it belongs to.
DANGER
——indicates a direct dangerous situation. If not avoided, it may cause death or
very severe injury accidents.
WARNING
——indicates a potential dangerous situation. If not avoided, it may cause death
or severe injury.
CAUTION
——indicates a potential dangerous situation. If not avoided, it may cause light or
moderate degree of injury.
In this manual, except the above-said three grades of danger, the following words indicate very useful
measures that should be taken for protection of the machine.
Notice — addresses staff’s attention to safety indication.
Important — in order to distinguish indication of machine protection from that of personal safety, the word
“Important” is used to indicate a risk that may cause damage to the machine.
and “Note” — is an additional description of individual information.

As it is impossible to list all the potential risks in all working environments, the operator must ensure per-
sonal safety and ensure that the equipment won't be damaged when conducting an operation that’s not
recommended. Any impermissible modification of this machine by the user may cause danger; before
doing so, the user must consult with Xugong Mining Machinery Co., Ltd or authorized dealer; otherwise,
Xugong Mining Machinery Co., Ltd won’t take responsibility for any bad consequences due to such a
modification.
Xugong Mining Machinery Co., Ltd. is not responsible for following equipment damage or unsafe
operations:
• Modify the equipment without permission.
• Run the mode under an abnormal working condition.
• Equipment failure or damage caused by use of non-genuine parts or caused by maintenance conducted
by unauthorized company or individual.
• Exceed the specified range of application.
• Xugong Mining Machinery Co., Ltd. won’t compensate for following equipment damage or unsafe
operations:
Safety 1-1
– Incorrect operation.
– Insufficient maintenance.
– Fuel or lubricating grease that’s not recommended.
Illustrations in this manual are just used to vividly depict the device, the actual device may change accord-
ing to user’s customized configuration. Content, specifications, icons and other contents of this manual
may differ from actual equipment; and such contents, specifications, icons may change with the progress
of product design.
Safety signs and other descriptive signs
Safety signs and other descriptive signs are affixed to more than one place of this machine, the operator
must be fully aware of contents and positions of all the signs and keep to the following requirements:
• Keep safety signs clear, recognizable and complete; if lost, damaged, or words or figures are unclear,
please repair or replace it immediately. Each safety sign and parts numbers of other descriptive signs
are specified in parts atlas.
• When replacing a part with a safety sign or sign indication affixed, make sure the new part has these
signs affixed in corresponding positions.
• Don’t use tools or detergents that may harm these signs to wipe or clean these signs; use a duster,
water and soap instead; don’t use solvent, gasoline or other irritative chemicals to clean the sign,
which may cause them to come off.
Safety signs description
1. Read through warning signs illustrated

in this manual (329900207)
Warning ! Read through maintenance man-

ual before operating, maintaining, disas-
sembling, assembling or transporting the
machine.
329900207
Figure1-1
1-2 Safety
2. Notice on safety belt (329900203)
Warning ! Fasten the seat belt during

operation.
329900203
Figure1-2
3. Warnings signs on keeping off HV line

(329900208)
There is an electric shock risk if the ma-

chine is too close to HV line; keep a safe
distance instead.
329900208
Figure1-3
4. Warning signs on locking front window

(329900202)
There is a risk that front window may fall;

after raising the window, fix it with a lock
pin.
329900202
Figure1-4
Safety 1-3
5. Warning notice on machine start-up

(329901075)
Warning! Read carefully the warning no-

Before starting the engine or operating
tice on the plate before starting the the machine, be sure to honk the horn
in order to check the surroundings situation;
machine. after than, turn the key key to position “ON”
and stay there for 5s.
If the engine fails to start within a starting
time of 15s, be sure to turn the key to
position “OFF”and wait for 2 minutes
before another try
329901075
Figure1-5
6. Warning sign of leaving operator’s

seat. (329900211)
It indicates a potential danger that the

parked machine may accidentally move
and cause extrusion or crush on person.
Before leaving the machine, the operator

329900211
should lower the working device on the
ground, pull safety control lever to locking Figure1-6
position and remove engine key.
7. Warning notice on prohibiting storage of

any articles (329900184)
Warning ! No articles shall be stored here.

NOTIC
Prohibit storing articles here
329900184
Figure1-7
1-4 Safety
8. Warning signs on safety exit

(329900209)
If the operator is under an emergency and

the door and windows fail to open, the op- Emergency
Exit
erator should break the window with an es-
cape hammer and evacuate.
329900209
Figure1-8
9. Warning signs on engine inspection

(329900289)
It’s dangerous to maintain or repair the

fan when it's rotating, which may wring
your hands.
329900289
Figure1-9
10.Warning signs on inspection of engine

and air conditioner (329900291)
It’s dangerous to maintain or repair the

fan when it's rotating, the belt pulley may
wring your hands.
329900291
Figure1-10
Safety 1-5
11.Warning signs of accidental fall

(329900191)
Don't stand on the edge, staff may fall off

engine hood or guard plate.
329900191
Figure1-11
12.Warning signs of staying away from

slewing radius (329900201)
Upper structure may extrude persons with-

in slewing radius; staff should stay away
from slewing radius.
329900201
Figure1-12
13.Lifting and strapping signs (329900225)
Lifting point and strapping point
329900225
Figure1-13
1-6 Safety
14.Warning sign of no stamping

（329900189）
Indicating a danger of fall. Prohibit stand-

ing in here.
329900189
Figure1-14
15.Signs of preventing from being scalded

from hot water or steam (329900190)
It may cause scald injury if auxiliary radia-

tor is opened when it’s hot; check it after
engine cools down.
329900190
Figure1-15
16.Signs of preventing explosion

(329900205)
There is a risk of explosion around fuel

tank; fire is prohibited.
329900205
Figure1-16
Safety 1-7
17.Fuel sign 329900226, 329901334,

329901335)
Diesel only
If water is accumulated water in engine

fuel filter, be sure to drain it from the
filter and fuel tank.
Refer to Operation and Maintenance

Manual for detailed use of oils.
329900226
Figure1-17
S＜ 15 mg/Kg
329901334
Figure1-18
必须使用低硫燃油
ULTRALOW SULFUR FUEL ONLY
329901335
Figure1-19
18.warning notice on crawler adjustment

(329900194)
Crawler may burst out and cause injury

during tension adjustment; read through
operation and maintenance manual before
adjustment.
329900194
Figure1-20
1-8 Safety
19.Warning notice on use of battery

(329900185)
DANGER
Danger! Be cautious of potential dangers
As accumulator liquid vapor is inflammable,
which may be caused by battery. so keep the battery away from sparks and
open flames; If it is stored with metal tools,
battery may explode or catch fire on
occasion of collision.
As the sulfuric acid of accumulator liquid is
toxic, it may corrode skin and clothes, and
can lead to blindness if it enters eyes.
If it splashes on skin, do as below:
1. Rinse skin with water.
2. Use soda or lime to neutralize acidity.
3. Rinse the eye with water for 10-15 minutes
and see a doctor immediately.
329900185
Figure1-21
20.Warning notice on operating on lock

lever (329900212)
Warning ! Be cautious when opening or

closing lock lever.
When the lock lever is unlocked,

improper handling or accidental
touch of the lever may cause the
machine to move, resulting in
severe personal injury and
machine damage.
329900212
Figure1-22
Safety 1-9
21.Warning signs on prohibiting operation

after engine-off (329900220)
If this sign is hung on the control lever of a

working device, the operator shall not start
the engine or contact the control lever.
Figure1-23
22.Operation indicating diagram

(329900233)
Directions of excavator control lever.
329900233
Figure1-24
23.Walking direction (329900222)
Standard walking direction of machine.
329900222
Figure1-25
1-10 Safety
24.Warning on staying away from working

radius of bucket rod (329900284)
There is a danger that staff may get

bumped by the working device of the ma-
chine; stay away from the operative
machine.
329900284
XXXXXXXXX
Figure1-26
25.Hydraulic oil sign (329900228)
329900228
Figure1-27
26.Warning signs on prevention from being

scaled by heated coolant and hydraulic
oil (329900204)
If radiator or hydraulic oil tank cover is

opened when the tank is still hot, heated oil
or water may spray and cause scald injury.
329900204
Figure1-28
Safety 1-11
27.Bucket safety sign (329901047)
This sign indicates a risk of bumping into

the boom, please operate the machine
carefully.
Figure1-29
28.Bucket safety sign (329901747)
This sign indicates a risk of bumping into

the boom cylinder, please operate the ma-
chine carefully.
Figure1-30
29.Warning sign of DEF disposition

(329901333)
This sign indicates that the DEF may be in

recovery process, don’t turn off the power
master switch at this moment.
Figure1-31
1-12 Safety
1.2 Safety device

Uniform and Protective Articles
• Fix long hair, loose clothes or jewelry, in

case they get caught on a control lever or
protrusions, which may cause personal
injury or casualty.
• Don't wear oil-stained clothes, which
may easily catch fire.
• Take precautions according to the nature
of work, such as wearing safety helmet,
protective shoes, thick gloves, reflective
vest, gas-defense mask, safety eye gog-
Figure1-32
gles, ear plug and safety belt, etc. Count
the protective articles before work and
check the condition of each article; re-
member to use them each time.
• The waste gas exhausted from an engine may cause disease or death. When working in a closed area,
make sure a well-functioning ventilation device is applied before operating this machine.
• Don’t apply a tool of inadequate strength to repair the equipment; otherwise, it may break or slip,
cause accidents or can’t meet installation requirement.
• Don't wear loose clothes or jewelry, which may get caught on operative equipment or a protrusive part
of the equipment.
• Operators must be concentrated on operation, don’t listen to the radio or music while working.
• When using a walkie-talkie, better stabilize the talk-back equipment, and try not to accept commands
through an earphone.
Safety 1-13
Extinguisher and first-aid kit
There is a fire-extinguisher bracket in the

cab, ready to install a dry-powder fire-ex-
tinguisher, 0.5 kg in weight and 90mm di-
ameter. Cut off the black cable tie before
installing a fire extinguisher.
Figure1-33
In case of the occurrence of a fire accident or personal injury, please keep the following items in mind:
• If there is a risk of open flame in work-

ing area, please prepare a first-aid kit
and a standby fire extinguisher, ensure
the operator knows how to use them.
• Maintain the fire extinguisher on a regu-
lar basis, and organize training for on-
field staff.
• Put a first-aid packet in the storage box
and put another one on work site. Con-
duct a regular inspection on the first-aid Figure1-34
kits and supplement it if necessary.
• Know how to respond to a fire accident:put the contact numbers of the doctor, ambulance, hospital and
fire station beside the phone.
• If the machine catches a fire, it may cause severe personal injury, even casualties. If an operative ma-
chine catches a fire, the operator should evacuate by taking the following steps:
– Turn engine key to OFF position and turn off the engine.
– If possible, take down the fire extinguisher and put out the fire.
– Escape the machine by handrail and pedal.
The above-stated procedure is the basic escape method, a specific method is subject to the actual condi-
tions; therefore, it’s necessary to conduct a site practice.
1-14 Safety
Emergency hammer
An emergency hammer is included in the

cab for emergency use, for example, if cab
door fails to open, the operator must imme-
diately take the hammer, break rear win-
Emergency
dow glass and escape. Exit
Figure1-35
Protective device: FOPS and ROPS (optional)
If the machine must work under a place

where rocks or chippings may fall, the ma-
chine should be equipped with cab protec-
tive devices: FOPS or ROPS The standard
safety device for this machine is FOPS.
FOPS： Falling Object Protective

Structures
ROPS： Roll-Over Protective

Structures
Figure1-36
It’s not allowed to enhance or modify these structures, such as drilling a hole, welding or installing fas-
teners on them; the protective structure must receive a re-evaluation after suffering from strong impact or
damage. If necessary, re-certify, re-install, even replace these structures.
Don’t randomly disassemble the cab on which FOPS/ROPS are installed; a cab without protective struc-
tures will lose protective functions. If any part of FOPS/ROPS is fractured or has plastic deformation, like
roll-over, struck by falling objects or overturn, please immediately contact XCMG authorized dealers for
repair or replacement.
Replace FOPS/ROPS
• Check mounting seat of protective structures for corrosion or physical damage, if so, please contact
XCMG authorized dealers for repair or replacement.
• Remove original protective devices with a lifting tool, and keep it aside.
Safety 1-15
• Install the bran-new protective structures.
1.3 Safety rules
Carefully read this manual and pay attention to the information in relation to safety signs affixed to this
machine; keep the signs intact; if lost or damaged, replace it immediately. For any questions, please con-
tact Xugong Mining Machinery Co., Ltd. or its authorized dealers.
• Only an officially certified (based on local laws), qualified experienced operator can control this equip-
ment. And only stuff that meet these conditions are entitled to examine and maintain this machine.
• Obey safety regulations, notices and instructions when operating or maintaining the machine.
• Patients and drunks are not allowed to operate or maintain this machine, for they may cause damage to
themselves or others.
• When collaborating with other operators or site commanders, ensure everyone is clear about gesture
signals.
• Ensure all handrails, pedals, engine hood and covers are well-installed; if damaged, place repair
immediately.
• Understand using methods of all the safety parts, such as lock lever and seat belt and correctly operate
them.
• Don't randomly disassemble safety parts, the operator should keep them in good conditions instead.
• Incorrect use of safety parts will cause severe personal injury or casualty.
Deal with anomalies
If any anomaly is found during operation or maintenance (such as noise, vibration, odor, engine exhausts
waste gas or leaks oil, abnormal display on alarm device or monitor), report to superior officer and take
necessary measures; don’t operate the machine before troubleshoot.
Noise protection
• Long-term exposure to heavy noise envi-

ronment may impair or damage hearing.
• Wear a suitable hearing protective ar-
ticle, such as earmuffs or ear plugs, so as
to avoid noise nuisance.
Figure1-37
1-16 Safety
Keep the machine clean
• Water entering electrical system will

cause instrument out of order or machine
failure. It’s forbidden to clean the elec-
trical system with water or steam (sen-
sors or plug-in connectors).
• The operator may slip and fall when
checking or maintaining the vehicle if Figure1-38
it’s stained with mud or oil.
• Always keep the machine clean.
Keep operator’s cab clean
The operator must clear away mud and oil sludge from shoe bottom before entering the cab. If the shoe
bottom is stained with mud or oil sludge, the operator may slip the pedal and cause severe accident.
It’s not allowed to keep transparent bottles in the cab, nor put any transparent decoration over the win-
dow, which may focus sunlight and cause fire accident.
Don’t listen to radio or use ear plug or answer the phone when operating the vehicle.
Don’t put any inflammables in the cab.
Always cover the ashtray after use and put out the cigarette butt and match.
Don’t leave a lighter or match in the cab. Rising temperature will explode the lighter.
Ensure that safety lock lever is pulled in locking position before leaving operator's seat; otherwise, an acci-
dent touch may move the equipment and cause accidents.
Ensure safety before leaving operator's seat
• Before leaving operator' seat (open or

close front or top window, remove or in-
stall lower window) or adjusting the seat,
the operator must lower the machine on-
to the ground and turn off the engine.
• Lock all the equipment, remove engine
key and put it away; minimize the
chance to accidentally touch control lev-
Figure1-39
er, which may suddenly stop the ma-
chine and cause personal injury or
casualty.
Safety 1-17
Ensure safety during on or off the machine
To avoid personal injury during climbing on or off the machine, please follow the requirements below:
• Use the handrail and ladder highlighted

by triangle arrows in the figure when on
or off the machine.
• To ensure safety, working staff must
face the machine and keep three points
(tow foots and one and; two hands and
one foot) of body tightly grasping and
footing on handrail and ladder (including
track shoe).
Figure1-40
• Don't grasp any control lever when

climbing on or off the machine; don’t
walk on the slippery engine hood or cov-
er unless putting on an anti-skid cushion
on it.
• Check handrail and ladder (including
creeper tread) for oil stain, grease or
Figure1-41
mud before climbing on or off the ma-
chine. If there is, clear it away。 Con-
duct a regular check on bolt for
looseness.
• Don’t climb on or off the machine with

hands full.
• Don’t jump on or off the machine.
• Don’t attempt to board or leave the ma-
chine when it’s moving.
• If the machine suddenly moves without
any personnel in it, it’s forbidden to
make attempt to get in and stop it.
Figure1-42
1-18 Safety
No one shall be around the auxiliaries of the machine
Don't sit on or grab the bucket or other ac-

cessories, so as to prevent fall or other
injury.
Figure1-43
Scald prevention
Hot coolant
For prevention of hot coolant splash or va-

por, don’t check or discharge coolant un-
til it totally cools down. Slowly screw off
radiator cover to release internal pressure.
Figure1-44
Hot oil
Before inspecting or discharging heated

oil, maintenance staff should cool down the
temperature of oil tank to the extent that a
hand can touch it without getting injured,
so as to prevent from being injured by
heated oil spray or overheated parts. To re-
duce the internal pressure of oil tank, the
Figure1-45
operator should slowly unscrew the cover
or plug.
Safety 1-19
Fire protection and anti-explosion
Fire accident caused by fuel or engine oil
Fuel, engine oil, coolant and window washing agent are highly inflammable. Obey the following rules to
avoid fire accidents:
• Don’t smoke or use any open flame be-

side fuel or engine oil.
• Turn off the engine before refueling.
• The operator shall stay around the ve-
hicle during oiling or re-filling fuel tank.
• Screw down the cover of fuel tank and
engine oil tank. Figure1-46
• Try to prevent fuel from overflowing on-
to hot surface or electric system
elements.
• Keep the fuel or oil storage room
ventilated.
• Engine oil and fuel should be stored in a
specified place and no one shall ap-
proach without permission.
• Wipe away the overflowed fuel or en-

gine oil after oiling or re-filling fuel.
• Move all inflammables to a safe place
before burnishing or welding.
• Don’t apply inflammable oil to clean
vehicle parts. It’s forbidden to wash
parts with diesel and gasoline for pre-
Figure1-47
vention of fire accident.
• Put oil-stained cloth or other inflamma-
bles into a safe container so as to ensure
safety.
• Don’t weld or cut pipelines containing
inflammable fluid.
Prevent fire accidents due to stacking of inflammables.
1-20 Safety
Clear away leaves, grass, dry wood plate, paper, dust and other inflammables that are piled or stuck onto
the engine, exhaust pipe, muffler, around the battery and inside of engine hood.
Prevention of fire accident caused by electric wire
• Prevent from fire accident caused by wire short circuit.

• Keep wire connectors clean and tighten them up firmly.
• Conduct a daily inspection on wires and check if they are loose or damaged; timely screw down the
loose connectors or wire clamps, replace or repair the damaged wire.
Prevent fire accidents caused by hydraulic pipeline
Inspect clamps, hoods and cushions that are fixed onto each hose and tube and check if hydraulic pipe
parts become loose during operation; if so, they may rub with each other and thus damage the hose in this
manner, which will finally cause high-pressure oil to spray and further lead to fire accidents.
Prevent fire accidents caused by lighting equipment
• Apply an item of anti-explosive lighting equipment when checking fuel, engine oil, battery electrolyte
or coolant. Without such special ones, ordinary lighting equipment may cause explosion.
• This manual’s specifications must be kept to when vehicle feeds lighting equipment with its own
power.
Actions to deal with emergencies
Leave this vehicle quickly according to the following requirement in case of a fire accident:
• Turn engine switch to OFF position and shut it down.
• Leave the machine by handrails and ladders.
Windscreen cleaning agent
Use alcohol-based cleaning agent. (Don’t use methyl alcohol-base detergents that are harmful to health.)
Prevent falling objects, ejected fragments and intruding objects
Install necessary protective devices for the operator when working in a place where the machine may be
hit by falling objects, ejected fragments or intruding objects.
Safety 1-21
• Install a protective structure and affix a

transparent glass paper to front window
before conducting a crushing or disman-
tling operation.
• When working in a mine and the opera-
tor might be in a risk of being hit by fall-
Figure1-48
ing objects, work staff should install a
protective structure and affix a transpar-
ent glass paper to front window.
• Shut the window when conducting the

above-said operation. Besides, ensure
that other staff is safely off the danger-
ous zone.
• Install a protective structure on the cab
depending on the actual situation; the Figure1-49
above-mentioned work condition is spe-
cific to a classic condition.
Assembly of accessories
• Contact an XCMG dealer before installation of any optional parts or accessories.

• Xugong Mining Machinery Co., Ltd. bears no consequences of any damage, accident or functional fail-
ure caused by installation of any unapproved accessory or optional part.
• Be sure to follow accessory instructions and general instructions specified in this manual for installing
and using such accessory.
• The working device may collide with the cab or other parts of the machine, depending on the types of
such a device or combinations. It's necessary to inspect if any working device to be installed may inter-
fere with each other and cause trouble.
• If the cab glass near the working device is broken, the operator may possibly contact it, so immediately
stop operation and change the glass.
Unapproved modification
Any modification without permission of Xugong Mining Machinery Co., Ltd. may cause danger to a
certain degree. Before starting you modification, please contact Xugong Mining Machinery Co.,
Ltd. or its authorized dealers.
Xugong Mining Machinery Co., Ltd. bears no responsibility for any injury, accident or product failure
caused by unauthorized modification.
1-22 Safety
Operation safety
Safety condition on job site
Conduct a thorough inspection on job site and eliminate potential danger risks before operation.
• It’s possible to cause a fire accident

when working near a pile of inflamma-
bles (a thatch roof, dry leaves and grass),
so the operator must be cautious.
• Check ground condition of the job site
and determine the best operation
method. Figure1-50
• It’s not allowed to operate at a
place that may collapse or rocks may
fall down.
• If a water pipe, gas pipe or power cable is found buried under working ground, please contact related
companies that will mark its route, in order to avoid further damage to the pipe or cable.
• Irrelevant personnel are not permitted to enter without permission; if necessary, work staff should give
warnings.
• Conduct a survey before walking or operating in a shallow pond or soft ground, be aware of the type
and conditions of rock bed, water depth and flow rate.
Safety 1-23
Work on a soft ground
• Avoid walking or operating the machine on cliff edge, roadside or near a deep trench. These zones have
soft ground, the ground may sink if the machine is quite heavy and continuously vibrates during opera-
tion, which may cause the machine to tip over or sink into the earth.
• When working on a dam or near a pre-dredged trench, the ground may subside under the influence of
machine weight and continuous vibration. Before operation, staff should take measures to ensure
ground safety and prevent the machine from overturn or fall.
Never approach high voltage cables
Don’t walk or operate the machine under

high-voltage lines in case of electric shock.
When working near an HV line, please take
the following procedure:
• Inform local electricity company before
working near cables, and they will take
measures to ensure safety.
Figure1-51
• Working near high-voltage cable lines
will possibly get an electric shock, and
even worse consequences may happen.
Keep a safe distance between the vehicle
and any power cable (see the table be-
low). Make a safety operation measure
together with local electricity company
before operation.
• Be prepared with potential accidents: wear rubber shoes and place a layer of rubber cushion on the seat;
be aware that the exposed body part shall not be in contact with any parts of the vehicle.
• A signal man is required if the vehicle is too close to cable.
• Stop anyone who attempts to approach when working near high-voltage cables.
• If the vehicle is too close to or in contact with the cable, for prevention of electric shock, the driver shall
stay in the cab till he confirms that the power has been interrupted. In addition, stop anyone who at-
tempts to approach the machine.
Voltage Min. safe distance

LV 100V,200V 2m
6600V 2m
HV
22kV 3m
1-24 Safety
Voltage Min. safe distance

66kV 4m
154kV 5m
187kV 6m
275kV 7m
500kV 11m
Keep a good vision
• Take an inspection around the machine and clear away obstacles before operating the machine to leave.
• Turn on the work lamp and front lamp of the machine when working in a low-visibility environment;
set a necessary lighting device in work zone.
• Stop the operation when it’s foggy, snowy, rainy or dusty.
Closed area ventilation
• If it must be done to start the engine, dis-

pose of fuel, washing oil or oil paint in a
closed area, the operator must open the
door and windows to ensure good venti-
lation for prevention of gas poisoning.
Figure1-52
• Don’t ignore harmful factors that

won’t immediately act on health; waste
gas and noise are invisible but will cause
disability or permanent damage.
• Without equipped with a special device,
the machine is not allowed to work in a
Figure1-53
closed environment, because a standard
cabin is not fitted with an air filter.
Signalman’s signal and gesture
• Set a mark on the roadside or soft ground; if operator’s sight is confined, please ask a signalman for
assistance. The operator must pay special attention to such marks and follow signalman’s command.
• The signal shall be given by one signal man only.
Safety 1-25
• Make sure the staff is aware of all the signals and gestures before operation.
Prevention of asbestos dust
Inhalation of asbestos dust in excessive amount will cause lung cancer. When dismantling or disposing in-
dustrial waste, the worker possibly inhales asbestos dust, so please stick to the following rules:
• To lower dust of the job site, please

spray water instead of using compressed
air.
• If there is asbestic powder in the air, the
vehicle should be operated at upwind di-
rection, and all staff shall wear a filter
mask.
Figure1-54
• No one shall approach the vehicle during
operation.
• Always obey related laws, regulations
and environment standards during site
operation.
No asbestos is contained in this machine, whereas forged parts may do; therefore, XCMG strongly
recommends using genuine XCMG excavator parts.
1-26 Safety
1.4 Safe operation

Start the engine
If a warning sign is hung on the control

lever, the operator must not start the engine
or contact control lever.
Figure1-55
Inspection before starting the engine
Conduct the following inspections before starting the engine:

• Wipe away dust from glass surface to ensure a good sight line.
• Wipe away dust from front lamp and work lamp and check the lamp condition.
• Check the level of coolant liquid, fuel and engine oil, air filter for blockage or if the cable is damaged.
• Check the oil levels in the hydraulic tank, transfer case and reduction gear.
• Adjust the seat to a proper position and check safety belt and fixation clamps for damage or abrasion.
• Check if the monitor works well; check the angle of working lamp and check if the control lever is
wholly located in the intermediate position.
• Adjust rear view mirror to an angle where the condition behind the vehicle is clearly seen from the seat.
• Inspect the upper and lower area as well as the surroundings and make sure no personnel or obstacle is
there.
Safety 1-27
Wear seat belt
If the machine tips over, the operator may get injured or cast out of the cab, or even crushed by the over-
turned machine, which may cause casualties.
• Carefully check seat belt, belt buckle

and the fastener before operation. If any
degree of abrasion or damage is found
on seat belt, replace the safety belt or
other related parts before operation.
• The operator must sit on the seat and
wear belt seat when the machine is run- Figure1-56
ning, so as to reduce injury risks to the

minimum degree.
Engine start-up safety rules
• Before entering the cab, the operator must walk around the machine and check if there is oil leak, loos-
ened part or improperly adjusted parts or other damage of the excavator.
• To prevent accidents, the operator must make sure all the cover plates and protective devices are ready.
• Check if there is any potential risk around the working area, or other safety-threatening factor.
• It’s forbidden to start the engine during maintenance or repair, or if a warning sign is hung on the con-
trol lever.
• No one is allowed to sit on the machine other than the operating staff.
• The operator must sit on his spot before starting the engine.
• Honk a horn when starting the engine.
• Check if the monitor displays normally before start; when the engine is running, the operator must ad-
vert to any strange sound or potential unsafe factors
• Don't start the vehicle in a way that might cause motor short circuit; otherwise, it may cause safety is-
sue and damage the equipment.
• Don’t get the motor in short circuit before engine start, which is not only dangerous but may damage
the engine.
• It’s necessary to preheat or maintain the vehicle if it hasn’t been operated for long.
Inspect the engine after start
• Slowly move the vehicle to a wide area without obstacles for inspection. No one shall approach the
machine.
1-28 Safety
• Check if the movement is in conformity to the control mode displayed on the instrument; if not, adjust
it to the correct mode.
• Check the operating conditions of the equipment and the movement of the bucket, bucket rod and boom
as well as walking and slewing movements.
• Check if the machine has strange noise, vibration, overheat, odor or abnormal instrument display; check
if it leaks air or oil. Immediately solve the problem as soon as it’s found; otherwise, accidents or fail-
ure may occur. If any anomaly is found, repair it or replace it right away.
Start the engine in cold weather
• Fully preheat the machine; if not, the machine may lag in response, and that may cause an accident.
• If the battery liquid is frozen, don’t charge it or start the machine with other power supply, because
the battery may get burnt if it’s done. The operator must be sure that the battery liquid thaws if he
wants to charge it or start the engine with other power supply.
• When necessary, you are recommended installing a Low Temperature Start Device; please consult Xu-
gong Mining Machinery Co., Ltd. or its dealers.
Operation
Pre-operational safety rules
If the operator fails to check the engine before starting it, any anomaly that can’t be timely detected may
cause personal injury or casualty.
• Keep the door & window clean and en-

sure the window is open or closed.
• Tune the rear view mirror to the best
view-angle and ensure the horn, walking
alarm (if equipped) and other alarming
devices are in good conditions. Drive wheel
• Wear seat belt. Figure1-57
• Inspect the vehicle in a wide place with-
out obstacles; no one shall stay around
the machine or in working area.
• Pre-heat the engine or hydraulic oil.

• Clear away all the obstacles on the route.
• Before moving the machine, inspect its walking state; standard walking state is that the guide wheel is
in front, under the cab while the drive wheel is behind; if the walking state is in opposite position, the
operator must control the lever or pedal in reverse direction.
Safety 1-29
Safety rule on changing direction
• Install the upper structure in a proper po-

sition before walk; the chain wheel must
be at the rear pat of the cab. If the chain
wheel is at the front of the cab, the oper-
ating direction must be reverse (e.g. The
forwarding operation must be changed
into reversing operation; similarly, the
left side should be taken as the right
Figure1-58
side).
• Make sure there is no person or obstacle
in the surroundings before walk.
• Honk a horn before walk to ensure no
one is in the zone.
• The operator must sit on his spot for
operation.
• No one is allowed to sit on the machine

other than the operating staff.
• Check if the walk alarming device (if
equipped) works normally.
• Ensure the cab window or door is
locked.
• As there is an blind area behind the ma-
chine, a signalman is required to provide Figure1-59
assistance when the machine is turning
or slewing. Be especiallycautious to
avoid collide with other machines or
staff. The operator must obey the above-
stated caution items even though
equipped with a rear view mirror.
Safety rules of walk
1-30 Safety
• To avoid any damage to the working de-

Walking status
vice or to avoid instability due to over-
loads, it's better not to exceed the
maximum permissible loads.
• Retract the working device and keep
40cm - 50cm off-ground distance of
bucket bottom.
• The excavator must walk slowly on a 40-50cm
rough road; the operator should avoid (16-20in)
making sharp turns while walking, Figure1-60
which may overturn the machine. If the

working device bumps onto the road sur-
face, it may lose balance and get
damaged.
• If the machine is equipped with an au-

tomatic deceleration device, when walk-
ing on a rough surface or on a slope, the
switch of that device must be turned off
(canceled). If the switch is open, the en-
gine speed will increase and accelerate
the walking speed of the machine all of a
sudden.
• Try to avoid walking the machine on a
bumped road as much as possible. If it
has to walk on such a road, the working
Figure1-61
device shall near the road surface and
the machine should walk at slow speeds.
• Always remember to keep a safe dis-
tance with persons, buildings or other
vehicles when driving or operating the
vehicle in order to avoid collision.
• When crossing a bridge or structure, the
operator must check if the supporting ca-
pacity of that bridge is enough to bear
the weight of the machine. Consult the
Safety 1-31
highway authority for walking on a spe-
cific highway and follow their guidance.
• When operating the machine in a tunnel,

under a bridge or wire or within a height
limited place, the operator must control
the machine carefully and slowly, spe-
cially try not to bump anything with the
working device.
If the machine must work under a place
where rocks or chippings may fall, the
machine should be equipped with cab
protective device FOPS (Falling Object
Protect Structure) (A standard driver’s
cab has FOPS). Figure1-62
Walking on a slope
To prevent overturn or sideslip, please stick to the requirements below:
• When walking on a slope, keep the

bucket bottom 20cm-30cm off the
ground (8-12in). Under an emergency,
the operator may stop the machine by
lowering the working device on the road
surface.
• When walking uphill, adjust the cab to Figure1-63
face the upslope. When walking down-
hill, adjust the cab to face the down
slope. Before walking on a road, the op-
erator must check the harness.
1-32 Safety
• When walking uphill, extend the work-

ing device in front to increase the bal-
ance, keep an off-ground distance of
20cm - 30 cm and walk slowly (see the
right figure).
Figure1-64
• When walking downhill, reduce engine
speed and pull walking control lever in
“intermediate” position.
• Be sure to walk in a straight line when

climbing an uphill slope or downhill
slope; it’s extremely dangerous to
make turns on or cross the slope.
• Don’t make turns on a slope or cross it.
Be sure to drive to a flat ground and Figure1-65
change the direction before going uphill.
• Reduce the speed before walking on

grass, leaves or wet steel plate, because
the machine may slip even the slope de-
gree is tiny.
• If the engine stops on a slope, pull the
control lever to “intermediate” posi-
tion immediately and re-start the engine. Figure1-66
Operation on a slope
• When slewing the machine or operating

the working device on a slope, the ma-
chine may lose balance and tip over.
This may cause severe damage or dam-
age the equipment. Therefore, the opera-
tor must drive to a flat zone and make
Figure1-67
adjustments before conducting such
operations.
• When the bucket is full, never slew the
working device from the upslope side to
Safety 1-33
the down slope. The machine may tip
over.
• If the machine has to walk on a slope,
workers should make a platform of soil
to keep balance of the machine.
Forbidden operations
• Don't excavate the ground surface below

a portion in the midair, the ground may
collapse and falling rocks may hit the
machine.
Figure1-68
• Don’t deeply dig the front ground of

the machine. Otherwise, the ground may
collapse and the machine may fall.
Figure1-69
• Before excavation, adjust the crawler to

be perpendicular to roadside or to the
cliff and adjust the crawler to the rear, so
as to evacuate under emergency.
• It’s forbidden to conduct dismantling
operations under the machine; the ma- Figure1-70
chine may lose balance and tip over.
1-34 Safety
• Operation on a structure may make it

collapse and damage the machine.
Figure1-71
• When dismantling something, it's forbid-

den to remove the specific area that’s
above the machine. Broken pieces or
collapse of the structure may impact the
machine and cause damage.
• It’s forbidden to break any object by
Figure1-72
means of the impulsive force of the
working device. The broken pieces may
fly and cause damage to personnel or to
the working device.
• Normally, it’s easier to make the ma-
chine tip over when the working device
is at one side of the machine than at front
or back.
• When using a crushing machine or other

heavy-duty working device, the machine
may lose balance and tip over. When the
machine is leveling the ground or work-
ing on a slope, don’t abruptly lower,
slew or stop the working device.
Figure1-73
• Don’t abruptly extend or retract the
boom cylinder. Such operations may
form an impulsive force and the machine
may tip over as a result.
• Don’t make the bucket pass over per-
sonnel’ head or over a dumper or over
a driver’s seat of any transportation ve-
hicle. Because the loads may spill, as a
result, the bucket may lower and bump
Safety 1-35
the dumper, which may produce a severe
damage to it.
Operation in snow
• The snowy or frozen road is very slippery. Be extremely cautious to operate the machine. Don't abruptly
operate the control lever. Even a little slope can slip the machine.
• The frozen road may soften as the temperature goes up, which may make the machine tip over.
• If the machine goes into deep snow, it may overturn or get buried in it.
Shut down the engine
• Do not immediately shut down the engine after the machine finishes an on-load running. If you immedi-
ately stop the engine, you may cause engine components overheated and accelerated wear.
• After parking or applying the parking brake, you should allow the engine to slowly idle for 5 minutes
before it comes to a halt. Running the engine can help the heated zone gradually cool down.
• When engine shuts down, exhaust gas temperature will exceed the threshold, at this moment, the Delay
Engine Shutdown will work. The Delay Engine Shutdown function will work at least 5 minutes till the
whole engine and system components cool down. At this time, do not turn off main power switch.
Parking
• Park the vehicle on a solid and flat

ground.
• Find a place without falling rocks or one
that may not collapse to park the
machine.
• Lower the entire working device onto
Figure1-74
the ground.
• Before leaving the machine, pull the safe

lock lever ① to “lock” position before
shutting down the engine. To prevent un- Free position
approved staff from moving the ma-

chine, the operator must close the cab
1
door and lock all the devices. Take out Locking position
the key and carry it or put it in a speci-

fied place. Figure1-75
1-36 Safety
If the machine has to be parked on a

slope, do as below:
°
120
• Slew the bucket to face the down slope,
and insert it into the earth.
• Put a cushion under the crawler to stop
Figure1-76
the machine.
Transport
The machine can be dismantled into several parts for ease of transportation; please contact an XCMG au-
thorized dealer for such a conduct.
Vehicle transportation
Please keep to the following specifications when transporting the excavator on a towing car.
• Select a towing car and determine the route in accordance with the weight, width and length of the ma-
chine; if necessary, please contact an authorized dealer to dismantle the working device.
• Before passing a bridge or a structure, the supporting capacity of this structure must be figured out; to
pass a road, the machine must receive an inspection by the highway authority and follow their guide.
Battery
To prevent battery risks
As battery liquid contains sulfuric acid, it may produce highly flammable and explosive hydrogen. The
following notes must be kept to for prevention of damage or fire accident due to improper operation:
• If the densitometer displays black, please

charge; if it's bright, please change the
battery.
• Please wear eye goggles and rubber
gloves before operation on battery.
• No smoking or playing with open flame
near the battery.
• Once sulfuric acid splashes on clothes or Figure1-77
skin, rinse the part with water.

• If sulfuric acid enters eyes, rinse the eye
with water and go to a doctor.
Safety 1-37
As sparks may be produced during operation on battery, turn the key switch onto “Close” position and
turn power master switch to “O” position, and do as below:
• Don’t let any tool or metal object touch the area between two terminals. Don’t leave any tool or met-
al object beside the battery.
• To remove the battery, first disconnect the negative (-) terminal (ground side); to install the battery,
firstly, connect the positive (+) terminal, and then the grounding connection.
• As flammable explosive hydrogen will be produced when the battery is being charged; before charging
it, remove the battery from the machine and put it at a well-ventilated place.
• Fix the battery to the original place.
Battery switch
Pull battery switch to “OFF” position in the following conditions:

• The machine has been stored for over 1 month.
• Repair the electrical system.
• Dispose the battery.
• Replace the fuse and fuse link.
• Connect an auxiliary cable.
Don’t disconnect battery switch unless
the engine has been stopped one minute
ago. Never OFF the battery switch when OFF
RGENC
EM E
engine is running; otherwise, may the elec-
O
N
trical system be damaged.
STOP
Once the battery is disconnected, the

power of the whole electrical system is cut Figure1-78
off, the data stored for radio setting may
get lost; reset it under such circumstances.
Ensure the switch is at “ON” position
before starting the engine.
1-38 Safety
WARNING!
When the indicator lamp turns on as shown in the right
figure, after shutting down the engine, do not turn off the
power master switch until the indicator lamp is off. When the
indicator lamp is on and the power master switch is turned
off, the SCR system will not remove DEF from the pipeline. If
not removed, the DEF will freeze and damage engine pump
and the wiring.
Safety 1-39
Start the engine with auxiliary cable (auxiliary start socket)
Figure 1-79
This machine has a standard engine auxiliary start socket, you can jump start the faulty machine from an-
other machine that has an auxiliary start socket or an auxiliary power pack.
• Turn the start key of the faulty machine to position OFF, pull the safety lever to OFF state and turn off
all accessories.
• Turn on the power switch of the faulty machine.
Move the other machine (which serves as the supply power) to close to the faulty machine. The auxili-
ary start cable should approach the supply power of both machines. Do not let each machine get into
touch.
• Stop the engine of the running machine (which serves as the supply power )
• Connect the proper auxiliary start cable to the auxiliary start socket of the faulty machine.
• Connect the other end of the auxiliary start cable to the auxiliary start socket or auxiliary power pack of
the machine which serves as the supply power.
• Wait at least for 5 minutes for the power of the faulty machine to be charged.
• Try to start the stagnant engine.
• When the engine of the faulty machine has been successfully started, immediately cut off the auxiliary
start cable from the machine which serves as the supply power.
• Disconnect the other end of the auxiliary start cable from the faulty machine.
• Initiate a fault analysis on the start charging system of the faulty machine as required. Inspect the ma-
chine, ensure that the engine works well and charging system is in good condition.
• When an auxiliary cable is used to connect the normal vehicle with the breakdown one, battery voltage
of the former vehicle shall be the same with the latter.
1-40 Safety
Start the engine with auxiliary cable
Wrong connection of auxiliary cable may cause battery explosion, therefore follow the rules below:
• It requires two people collaboration to

start the engine with auxiliary cable (one
person sits on driver’s seat while the
other operates on the battery).
• When starting the faulty machine with
another machine, do not let each ma-
chine get into touch.
• Turn the key switches of both vehicles to
OFF position before connecting the aux-
Figure1-80
iliary cable. Otherwise, a sudden move-
ment of the vehicle may cause danger
once vehicle is powered up.
• When connecting an auxiliary cable, re-
member to connect the positive pole (+)
first. Before removing the auxiliary ca-
ble, disconnect the cable from the earth
(earth side wire) or negative pole (-).
• When removing the auxiliary cable, be

careful not to let auxiliary cable clips
contact with each other, neither let the
cable clip contact with the vehicle.
• Remember to wear eye goggles and a
pair of rubber gloves before starting the
engine with an auxiliary cable.
• When an auxiliary cable is used to con-
nect the normal vehicle with the break- Figure1-81
down one, battery voltage of the former
vehicle shall be the same with the latter.
DPF regeneration
DPF refers to Diesel Particulate Filter (referred to as DPF below), regeneration means to increase exhaust
gas temperature within a given time. XCMG Regeneration System (XRS for short below) is used to re-
move the smoke from DPF and heat up SCR system.
Safety 1-41
Regarding detailed DPF information, please refer to engine operation and maintenance manual.
DPF regeneration has two working modes: initiative regeneration and automatic
regeneration.
Initiative regeneration:
Initiative regeneration: make a long press on the left armrest for 5s, to start the initiative regener-
ation mode;
Prohibit regeneration: make a long press on the right armrest for 5s, to stop the initiative regenera-
tion mode;
WARNING!
When it turns on, it indicates an initiative regeneration requirement, please finish
regeneration a.s.a.p. If initiative regeneration has not yet been finished, engine will derate; when
this situation keeps worsening, DPF will be damaged.
Once the smoke collected by DPF comes to a critical value, regeneration will be locked. At this
moment, only an XCMG dealer can restart the regeneration. To be sure, when this situation
occurs, DPF might have been damaged already.
Automatic regeneration:
• Use the automatic control function of the machine to determine the optimal time of executing the auto-
matic regeneration.
• Automatic regeneration may take place during the entire engine operation cycle.
• When automatic regeneration has been executed, the regeneration indicator lamp will be turned on. Re-
generation interruption is acceptable. When regeneration is in process, if you need to stop it, you may
press the “Prohibit regeneration” switch.
CAUTION!
• If regeneration is in process, the low-idling engine may speed up in order to maintain this regen-
eration process.
• When the automatic regeneration is in process, if the machine resumes to work, the regeneration
may stop. The machine will keep monitoring, so as to determine the optimal time of re-starting
the regeneration.
1-42 Safety
SCR pre-warning system
SCR is short for Selective Catalytic Reduction and SCR pre-warning system is used to reduce engine
NOX (nitrogen oxide) emissions. Diesel Exhaust Fluid is shortened as DEF, commonly known as Vehicle
AdBlue, which serves as a reducing agent, is drawn from DEF tank and injected into the exhaust pipe.
Under the function of selective catalyst, the NOX contained in the exhaust gas will be reduced into nitro-
gen and water.
Regarding detailed SCR information, please refer to engine operation and maintenance manual.
WARNING!
• If the engine is running with load, abruptly stopping it may cause SCR components to be over-
heated and damage engine system.
• When DEF is in low level, please replenish it immediately. A low-level DEF will cause engine
derate.
• When engine is turned off, if power indicator lamp is on, do not turn off the power master switch;
otherwise, DEF will freeze and damage engine pump and the wiring.
Traction
Safety rules on traction
If the faulty machine cannot be towed in a correct way, or if the steel rope is mistakenly selected or in-
spected, severe damage or loss of life may be caused.
• Please wear leather gloves when using

the steel rope.
• Fix the steel rope on the machine frame.
Figure1-82
Safety 1-43
• Don't stand between the towing machine

and the one that's being towed during the
process.
• Don’t attempt to tow a machine on a
slope.
Figure1-83
• Abandon the steel rope that has broken

strands (A), reduced diameter (B) or is A
twisted (C). During the towing process,
B
such ropes may break and cause danger.
Figure1-84
1-44 Safety
Lift objects with bucket
Safety rules on lifting
• Don’t lift anything on a slope, soft

ground or in any environment that fails
to stabilize the machine.
• Only apply the standard rope.
• Keep observing the lifting work and ad-
vert to any possibility that may tip over
the machine.
• Before slewing the machine or turning
around, check if there is any one or ob- Figure1-85
stacles around.
• Don’t abruptly start, slew or stop the

machine and try to avoid jiggling.
• Don’t pull or lift objects towards the
machine or towards both sides of the
machine.
• The operator shall not leave the seat
when lifting objects.
• In principle, it’s forbidden to lift ob-
jects with the machine, as is extremely Figure1-86
dangerous.
Safety 1-45
WARNING!
• Select a proper auxiliary device, as the type of auxiliary device varies with machine type.
• Without special announcements, a standard configured machine is not allowed to lift, unless a
special device is fitted!
• Without special announcements, a standard configured machine is not allowed to lift round
logs, unless a special device is fitted!
• Before lifting operation, ensure that the working mode suffices to lift the loads (refer to Elevating
Capacity Table in next page).
• The working mode for lifting operation must be excavation mode (high speed position), ensure
the specific working mode enables the machine to lift the loads.
• When the machine is used to lift round logs, the function shall be supported by other special pro-
tective devices, please contact an authorized dealer of Xugong Mining Machinery Co., Ltd.
Table 1-1 Table 1-1 Elevating Capacity Table
Load of the
Point-of-load maximum extension Load radius of Load radius of
height distance front end side face
Boom - 7m Bucket - none

Bucket rod - 2.57m Track shoe - 650mm
3m 4.5m 6.0m 7.5m 9.0m
9.0m *14189 *14189 6.89
7.5m *17598 *17598 *11821 *11821 8.05
6.0m *20965 *20965 *18141 17274 *10712 *10712 8.80
4.5m *23403 23118 *19244 16574 *16975 12491 *9688 *9688 9.25
3.0m *25616 21754 *20371 15851 *17335 12159 *9668 *9668 9.44
1.5m *26760 20848 *21075 15280 *17463 11870 *10851 *10851 9.37
Ground *30982 *30982 *26560 20426 *20996 14953 *15832 11760 *11555 *11555 9.07
-1.5m *26997 *26997 *31626 *31626 *24981 20386 *19732 14916 *15083 12828 8.47
-3.0m *31944 *31944 *27071 *27071 *21611 20717 *15885 15363 *15715 15297 7.53
-4.5m *19354 *19354 *14052 *14052 *13549 *13549 6.09
1-46 Safety
CAUTION!
1. * The load is limited to hydraulic lifting capacity other than tipping load.
2. To calculate the net lifting load, weight of lifting chain and auxiliary lifting devices should be
deducted from the rated load. Lifting capacity is based on the excavator that’s on the same sol-
id level ground. The user should factor in operation mode, like soft or uneven ground. Before op-
erating the machine, the operator should be clearly aware of User’s Manual and Safety
Operation Manual.
3. Operation capacity refers to the one that is not intervened by external upward pushing force.
4. The above-stated load complies with Hydraulic Excavator Lifting Capacity Standard ISO
10567: 2007. The displayed operation capacity does not exceed 75% of the tipping load or 87%
of the hydraulic lifting capacity.
5. The net lifting load above has ±5% tolerance.
6. Operation capacity only applies to machines manufactured and assembled by original equipment
manufacturers.
Safety 1-47
1.5 Safety maintenance instructions

Warning sign
• By all means hang the warning sign of

“Operation Forbidden” on the control
lever of the cab, warning others that the
machine is under maintenance; if neces-
sary, place an extra warning sign around
the machine.
Figure1-87
• When the warning sign is no longer
used, place it in a tool box.
• When the machine is under maintenance,
if the engine or control lever is being op-
erated at this moment, the machine may
get damaged or injure the surrounding
persons.
Keep working area clean
• Don’t scatter the hammer crusher or other tools on the working area.
• Remove grease, oil or other slippery matters and keep the working area clean, ensuring safety work;
otherwise, staff may slip, fall and get injured.
• Don’t wash the skylight of the cab with clean water as it’s made of organic glass (polycarbonate),
and neither use any basic solvent. If some basic solvents like benzene, toluene and methanol are used, it
may cause chemical reaction, decompose or dissolve the glass and cause aging of polycarbonate.
A signalman must be designated to assist a cooperative task.
• When repairing, dismantling the machine or installing a working device, a signalman must be desig-
nated and his direction must be followed.
• If team members fail to understand each other, in this situation, severe accidents may occur.
Shut down the engine before maintenance.
1-48 Safety
• Park the machine on solid flat ground.

• Find a place where there is no falling
rocks, collapse or danger of being
immersed.
• Lower the entire working device onto
ground and shut down the engine.
Figure1-88
• Put a cushion under the crawler to stop
the machine from moving.
When the engine is running, two persons are required to carry out the maintenance.
Don’t maintain a running engine for prevention of injury. If the maintenance work must be carried out
on a running engine, at least two persons are required and they must follow the regulations below:
• One person is required to always sit on

the operator’s seat and is ready to shut-
down the engine at any time. All the
members should keep in contact.
• Pull the safe lock lever to “Lock”
position.
• When an operation is about to be carried
out near rotating parts like a fan or fan
belt, special attention should be paid to Figure1-89
avoid being caught by such rotating
parts.
• It’s strictly forbidden to touch any con-
trol lever; if it must be done, the operator
should send a signal to others, informing
them to leave this place.
• It’s not allowed to leave or insert any
tool or other objects in the fan or fan
belt; otherwise, the part will break and
fly out.
Safety 1-49
Using proper tools
Ensure to use proper tools instead of dam-

aged, low-quality, defective tools, as they
may cause severe personal injury.
Figure1-90
Accumulator
Accumulator is filled with high pressure nitrogen.

Careless operations on the accumulator may cause explosion, resulting in severe injury or damage. There-
fore, the following notes must be kept to:
• Don’t disassemble the accumulator.

• Don't approach the accumulator to fire
sources.
• Don’t drill or weld the accumulator or
use a welding torch on it.
• Don’t bump or roll the accumulator;
don’t subject it to any impact.
• The accumulator gas must be discharged
before disposal. Please contact the dealer
Figure1-91
of Xugong Mining Machinery Co., Ltd.
for gas-discharging operation.
Personnel
Only well-trained staff are qualified to maintain or repair the machine and untrained persons are not admit-
ted in the area. If necessary, designate an observer.
1-50 Safety
Accessory
• A signalman is required to assist in dis-

assembling or installing auxiliary
devices.
• Place removed parts on a firmly sup-
ported place so that the part won’t fall.
Measures should be taken to prevent im-
permissible staff from entering the stor-
age place.
Figure1-92
Work under the vehicle
• If the maintenance must be done under-

neath the machine or the working device,
support them with cushion blocks and
props that have sufficient load-bearing
capacity.
• If the track shoe is off ground and the
machine is supported by only the work-
ing device, under this circumstance, the
working device or the machine may sud-
denly fall upon accidental touch of con-
trol lever or hydraulic pipeline. When
Figure1-93
the machine is not firmly supported by
cushion blocks or props, it’s forbidden
to work under the machine.
Noise
• Too loud machine noise will cause temporary or permanent hearing problem.
• When maintenance staff is about to be exposed to long-term noise, remember to wear ear plugs and the
like.
When using a hammer
Safety 1-51
When hammering, the pin may fly outandmetal particles may shoot out and cause dire injury. Obey fol-
lowing steps:
• If you’re hammering hard metal parts,

like pins, bucket tooth, blades or bear-
ings, crushed particles may fly out and
cause danger, so please wear eye goggles
and gloves.
• When hammering a pin or bucket tooth,
particles may fly out; therefore, please
ensure no one is in the surroundings so
as to avoid personal injury.
• If hammering a pin with strong force,
the pin may fly out and injure surround-
Figure1-94
ing people.
Welding work
Select a proper device and the welder must be qualified.
Remove battery terminals
Before repairing electrical system or welding, remember to disconnect the negative terminal (-) from the
battery and turn off the positive-pole power master switch for prevention of flowing current.
Be cautious when adjusting crawler tension with high-pressure lubricating grease.
• When being injected into crawler tension

adjustment system, the lubricating
grease is under high pressure. Failing to
follow standard maintenance procedure
during adjustment operations will cause
the grease drain plug ① to fly out and
result in severe consequences.
• When unscrewing the grease drain plug
① in order to slacken crawler tension,
be certain to unscrew at most one turn of Figure1-95
the plug and do it gently.
1-52 Safety
• Don’t approach your face, hand, foot

or any other body part to the drain plug
①.
Don’t remove the buffer spring
The buffer spring assembly, which contains

a high pressure spring, is designed to lessen
the impact force of tension pulley. If the
spring is removed incorrectly, it will fly out
and cause dire consequences.
Figure1-96
Safety rules regarding high pressure oils
As hydraulic system is always under pressure, when inspecting or replacing hydraulic pipeline or hoses,
be sure to check if the oil line has residual pressure. If it still has, such inspection or replacement may
cause severe damage or personal injury; follow the stipulation below to avoid any damage:
• If the area around the hydraulic pipeline

or hose is wet, be sure to inspect if the
line has burst or become swollen. Be cer-
tain to wear eye goggles and leather
gloves before conducting hydraulic pipe
inspection.
• High pressure oil leaking from orifices
will penetrate skin, and direct contact
with eyes will cause blindness. If the
high pressure oil hits the skin or enters
eyes, clean the skin or eyes with clear
Figure1-97
water and go to a doctor immediately.
Safety 1-53
Safety operations relating high-pressure hose
If the hose leaks oil, it may involve into a fire accident or an operation failure, causing severe injury or
damage. If a loose screw is found, stop operation immediately, and tighten the screw with specified torque.
If any damage is found on the hose, immediately stop operation, and contact with XCMG’s dealer.
Replace the hose if any of following cases is found:
• Hydraulic hose connector is damaged or leaking.
• The cladding is abraded or breaks or enhanced steel wire is exposed.
• The cladding has swollen somewhere.
• The movable part is twisted or crushed.
• The cladding contains impurities.
Waste
To prevent pollution, special attention should be paid to the disposal method of waste：
• Collect machine oils with a container;

don’t straight pour it on the ground, in
the sewer, river, sea or lake.
• Follow laws and regulations in order to
dispose harmful matters like engine oil,
fuel, antifreeze, solvent, filter element
and batteries.
Figure1-98
Maintain an air conditioner
If refrigerant enters the eyes, it may cause eye blindness; if it comes in contact with the skin, it may cause
frostbite.
Compressed air
• When cleaning the air conditioner with compressed air, there is a possibility that the person may be in-
jured by flying particles or the machine may be damaged.
• Be sure to wear eye goggles, dust mask, gloves and other protective articles before cleaning filter ele-
ment or radiator with compressed air.
1-54 Safety
Periodical replacement of crucial parts
• For long-term safe operation, it’s necessary to periodically add oil and maintain the machine; to fur-
ther enhance safety, replace safety-related parts, such as hydraulic hose and seat belt on a regular basis.
• If exceeding specified time, components material will naturally age. Repeatedly use of such components
will cause deterioration abrasion and damage. As a result, these components may cause failure and lead
to severe personal injury or machine damage. It’s difficult to judge by external inspection or touch
how long can these components be further used, so be sure to replace them regularly.
• If crucial parts are found defective, even if their life span isn’t over, replacement or repair is still
needed to be conducted.
Safety 1-55
1.6 Accessories installations and other safety instructions
• Contact an XCMG dealer before installation of any optional parts or accessories.

• Xugong Mining Machinery Co., Ltd. bears no consequences of any damage, accident or functional fail-
ure caused by installation of any unapproved accessory or optional part.
• Be sure to follow accessory instructions and general instructions specified in this manual for installing
and using such accessory. Xugong Mining Machinery Co., Ltd. bears no responsibility for any damage,
accident or functional failure caused by failing to follow related operation manuals of accessories or op-
tional parts.
• The working device may bump the cab or other parts of the machine if combined with a different op-
tional part or type; before using an unfamiliar working device, inspect if it interferes with the machine
and be cautious with the operation.
Unapproved modification
• Any modification without permission of Xugong Mining Machinery Co., Ltd. may cause a certain de-
gree of danger. Please contact our dealer before starting any modification.
• Xugong Mining Machinery Co., Ltd. bears no responsibility for any injury, accident or product failure
caused by unauthorized modification.
Remove counterweight and front-end working device
• Warning: Removing counterweight or front-end working device will affect machine balance and
cause accidental movement and fatal consequence.
• Only when upper structure and lower structure are arranged on the same direction can its coun-
terweight and front-end working device be removed. Don’t slew upper structure once the coun-
terweight and front-end working device are removed.
1-56 Safety
Figure 1-99
Fuel quick filling device (option)
Low-temperature start device (option)
Figure 1-100 Figure 1-1 Fuel quick filling device (option)
Safety 1-57
Figure 1-101 Figure 1-2 Low-temperature start device (option)
WARNING!
Only use fuel quick filling device and low-temperature start device that are recommended by
Xugong Mining Machinery Co., Ltd. Fuel quick filling device and low-temperature start device
that are not recommended by Xugong Mining Machinery Co., Ltd. may damage your machine.
Please contact the dealer of Xugong Mining Machinery Co., Ltd.
CAUTION!
The maximum filling capacity of fuel quick filling device is 800L/min.
When ambient temperature is be -15℃, we recommend installing low-temperature start device
that can ensure a normal engine start.
Before use, be sure to read the user's manual and know all the warnings in it; otherwise, don’t
operate or use these optional parts.
1-58 Safety
Hydraulic shears (optional)
Figure 1-102
WARNING!
Only use the hydraulic shears recommended by Xugong Mining Machinery Co., Ltd. Hydraulic
shears that are not recommended by Xugong Mining Machinery Co., Ltd. may damage your
machine. Please contact the dealer of Xugong Mining Machinery Co., Ltd. For detailed
information.
WARNING!
• Unless you've read hydraulic shears operation and maintenance manual and know the included
warnings; otherwise, do not operate or use the tool.
• Failing to observe instructions or warnings may cause injury or death.
• To avoid injury, ensure no person is around the hydraulic shears. To avoid injury, ensure
you’re in control of the hydraulic shears all the time. When using this tool, ensure all the staff
is at least 10 meters away.
• Close all the windows. Ensure all security guards are in place. Wear all necessary protective de-
vices. Operate the tool according to its operation and maintenance manual.
• To avoid damaging the machine structure, do not place the cutting blade of hydraulic shears on
the ground and break the road by moving the machine.
Safety 1-59
WARNING!
• Staff may be severely injured or die when removing any pipeline or container that contains
some gas, flammable materials or dangerous chemicals. Before determined to clear above-said
dangerous materials, do not execute any dismantling work.
• Observe all the regulations regarding removal and disposal procedures.
Hydraulic hammer (option)
Figure 1-103
WARNING!
Only use the hydraulic hammer recommended by Xugong Mining Machinery Co., Ltd. Hydraulic
hammers that are not recommended by Xugong Mining Machinery Co., Ltd. may damage your
machine. Please contact the dealer of Xugong Mining Machinery Co., Ltd. For detailed
information.
Unless you've read hydraulic hammer operation and maintenance manual and know the included warn-
ings; otherwise, do not operate or use the tool.
Notes on usage
• Only use hydraulic hammer to break rocks, concretes and other hard objects.
• Before operating the hydraulic hammer, place the machine on a flat and stable ground zone.
• Close all the windows before using the hydraulic hammer. Xugong Mining Machinery Co., Ltd. recom-
mends installing an additional shield for the front window to avoid flying debris.
1-60 Safety
CAUTION!
To avoid damaging the machine or hydraulic hammer, please observe following operations:
• Don’t try to fully bury the hammer into rocks or concrete to damage it.
• Don’t apply piercing force onto the hammer in order to move the tool away from materials.
• It is not allowed for the hydraulic hammer to keep working towards one position for over 15s;
instead, you’re recommended to change positions and repeat. Failing to change the position of
hydraulic hammer will cause overheated hydraulic oil, which may damage the accumulator.
• Don't break rocks or other hard objects by use of hydraulic hammer's descending force. As it
may damage machine structure.
• Don't move rocks or other hard objects by using the left and right sides or back side of hydraulic
hammer. As this will cause damage to not only the hammer, but also the working device and oil
cylinder.
• Don’t operate hydraulic hammer to fully extend or retract with any oil cylinder. As it may
damage machine structure and reduce its life span.
• Don't use hydraulic hammer to lift loads.
• Don't operate the hydraulic hammer in water. Operating the hydraulic hammer underwater may
cause severe system damage.
• Before operating the hydraulic hammer, place the upper structure on the position as shown in
the figure below. Any other operating position may cause the machine to lose stability and result
in damage.
4 2
Figure 1-104
Safety 1-61
1-62 Safety
Chapter 2 Component Name
2.1 General drawing
Handrail
Hydraulic
Arm Boom Bucket Cab Tool box Fuel tank oil tank
Chassis
Figure 2-1
CAUTION!
The main component drawings may contain optional devices or auxiliary working devices; consult
the authorized dealer for additionally fitted optional parts.
Only apply the optional parts or auxiliary working devices recommended by Xugong Mining Machinery
Co., Ltd.; any impermissible parts may fail to match with this machine and cause danger; XCMG bears no
responsibility for any injury, accidents or product failure caused by unauthorized modification.
Refer to the user’s manual of each auxiliary device for the specific functions, working environment and
maintenance details. This Manual can be considered as a supplementary to the operation and maintenance
manual of this machine and it is of equal importance with the latter, please take care of it.
Component Name 2-1

Please refer to the corresponding operation and maintenance requirements specified in this manual for the
safety requirement and operation of auxiliary working device.
2.2 Driver’s cab layout (general instruments)

Driver’s cab
Figure 2-2 Driver's cab layout diagram
1 Left control lever 2 Horn switch (top of left control lever) 3 Left-walk control lever 4 Left-walk pedal
5 Right-walk pedal 6 Right-walk control lever 7 Switch (standby) 8 Right control lever 9 Monitor
10 Engine key switch 11 Engine throttle knob 12 Working lamp switch 13 Silence switch
14 Wiper switch 15 Washer switch 16 Regeneration and prohibit regeneration switch (exclusive for
XE750G/XE800GA) 17 Cigar lighter18 Air conditioner controller 19 Radio 20 Safety lock lever
Table 2-1 Illustrated number list
No. Name Symbol Function

Extend & retract bucket rod and
1 Left control lever slew upper structure
Horn switch (on top Press this switch to honk the horn
2
of control lever)
Left walk control Control left crawler to march

3 forward and backward
lever
Control left crawler to march

4 Left walk pedal forward and backward
2-2 Component Name

Table 2-1 Illustrated number list(continued)

Control right crawler to march
5 Right walk pedal forward and backward
Right walk control Control right crawler to march

6 forward and backward
lever
Reserved function
7 Switch (standby)
Raise and lower the boom and

8 Right control lever control the bucket to dig and
unload.
Operate, display and alarm (see
9 Monitor
detailed introduction below)
Key switch for OFF
POWER
Start, run and shutdown the engine
10 START
engine
Engine rotation L H Regulate engine rotation speed
11
speed knob
Control boom lamp, turntable
Working lamp
12 lamp, cab roof lamp and
switch
counterweight lamp.
Silence the walking siren
13 Silence switch
Control the front-window wiper of

14 Wiper switch the cab
Wiper washer Control the front-window washer

15
switch of the cab
Regeneration and Control stage-4 engine after-

prohibit treatment system to force
regeneration switch regenerate and prohibit
16
(exclusive for regeneration
XE750G/
XE800GA)
Light cigarette and serves as a 24V
17 Cigarette lighter standby power source
Component Name 2-3

Table 2-1 Illustrated number list(continued)

Control A/C
18 A/C controller
Listen to a broadcast and play MP3

19 Radio
Safety locking lever Hydraulic pilot oil control

20
sign
Monitor and switch
Figure 2-3 Monitor illustration

Status information icon Display overall machine running
1 /
bar status
Fuel level indicator
2 / Display fuel level
gauge
Fault information and Display overall machine fault and
3 /
fault code fault code
4 Present gear / Display current working gears
5 Working hour / Display current working hours
Engine coolant
6 / Display engine coolant temperature
temperature
2-4 Component Name


Hydraulic oil
7 / Display hydraulic oil temperature
temperature
Video display area of rear-view
8 Video display area /
camera
9 Function key icon bar / Function key icon area
Status information icon
CAUTION!
The operator can acquire the crane working state by checking the information icons on the upper
part of the screen. The operator must have a good understanding of each icon as well as their indi-
cating meanings before operation, so that correct judgment may be made on occurrence of each
icon.
1. Accessory tool status icon
Bucket mode
Special tool mode 1
Special tool mode 2

2. Walking speed icon
Low walking speed mode
High walking speed mode

3. Automatic idle speed icon
Engine automatic idle function activated

4. Lubrication icon
Lubrication function activated

5. Engine fault icon
Fault level: One Flash indication: Yellow flash Buzzer: On. System needs maintaining.
Fault level: Two Flash indication: Red flash Buzzer: On. Engine component damaged, please stop and
repair it.
Fault level: Three Flash indication:Red constantly on Buzzer: On. Stop the engine immediately and re-
pair it.
6. DPF regeneration in-process and prohibit regeneration
Component Name 2-5

DPF regeneration in-process
DPFregeneration prohibited
7. DPF requiring regeneration warning
DPF requiring regeneration warning

8. Siren erasure
It shows when the siren is erased
Function key icon
There are 9 function key icons in the bar, F1-F4 are multiplex and F5 is switch key.
F1: Fan reverse/idle key icon
Press F1 to enter into fan reverse interface.
Press F1 auto idle key to start Prohibiting Auto Idle function; when auto idle function is acti-
vated, Auto Idle icon will appear on the status information icon bar on top of the interface. (Auto idle al-
lowed by default).
After auto idle function is activated, if control lever and walk control lever are at neutral position and cur-
rent throttle gear is greater than the 3rd gear, then, 4 seconds later, system will automatically reduce the
throttle to idle.
F2: Engine fault/high/low walking speed key icon
Press F2 to inquire current engine fault information
Press F2 to select low/high walking speed mode

F3: Maintain/video key icon
Press F3 to inquire maintenance information under current working status

F4: system function/erasure key icon
Press F4 to enter into system function main menu.
Press F4 to turn off system alarm buzzer

F5: Switch key icon
Press F5 to switch key icons
2-6 Component Name

Monitor operating instructions
1. Press F1 in main interface to enter into fan reverse setting, shown as below:
Figure 2-4
Component Name 2-7

2. Press F4 in main interface to enter into system function main menu, shown as below:
Figure 2-5
F1: Move up
F2: Move down
F3: Confirm the option and go to the next interface
F4: Back to the previous interface
F5: Return to main interface
2-8 Component Name

Main Menu contains three functions: Use Information Inquiry, User Information Setting and System In-
formation Management.
1) Use Information Inquiry

In Main Menu, click Use Information Inquiry and enter into information inquiry interface, see the fig-
ure below:
Figure 2-6 Use information inquiry interface
Use Information Inquiry Interface contains four functions: Operation Information Inquiry, Fault In-
formation Inquiry, Maintenance Information Inquiry and Service Information Inquiry.
In Operation Information Inquiry Interface, you may inquire the basic running information of the
whole machine; in Fault Information Inquiry Interface, you may inquire system fault code and corre-
sponding fault description; in this interface, the operator can press F1 to enter into Engine Fault Infor-
mation Inquiry Interface; press F1 again to back to Fault Information Inquiry Interface;
Component Name 2-9

In Maintenance Information Inquiry Interface, you can inquire maintenance information of different
working hours like 8-hour, 250-hour, 500-hour, 1000-hour, 2000-hour, 5000-hour, 6000-hour and
1000-hour period.
In service information inquiry interface, you may find company website and 24-hour service hotline.
2) User Information Setting

In Main Menu, select User Information Setting and enter into the interface below:
Figure 2-7 User Information Setting Interface
User Information Setting Interface contains six functions: System Time Setting, Brightness Setting,
System Language Setting, Phase Hour Setting, Accessory Mode Setting and Video Access Setting.
2-10 Component Name

①See System Time Setting shown in the figure below:
Figure 2-8 System time setting interface
F1: Move Left;

F2: Increase Selected Value;
F3: Decrease Selected Value;
F4: Start using Time Setting Option;
F5: Return to Main Interface
Component Name 2-11

②See Brightness Setting Interface shown in the figure below:
Figure 2-9 Brightness setting interface
F1: Reduce Brightness;

F2: Increase Brightness;
F3: Page Up;
F4: Page Down;
F5: Back to Main Interface
2-12 Component Name

③See System Language Setting Interface shown in the figure below:
Figure 2-10 System language setting interface
F1: Move up
F2: Move down
F3: Confirm the selected language
Component Name 2-13

④See Phase Hour Setting Interface shown in the figure below:
Change
password
Figure 2-11 Phase hour setting interface
F1： Change password

F2：Reset phase hour
F4： Back to the previous interface
F5：Return to main interface
2-14 Component Name

⑤See Accessory Mode Selection Interface in the figure below:
Figure 2-12 Accessory Mode Selection Interface
F1: Move up
F2: Move down
F3: Confirm the option
Component Name 2-15

CAUTION!
After changing the accessory, be sure to change the accessory mode in this interface, so as to
provide larger productivity and use less fuel consumption.
⑥See Video Access Interface shown in the figure below:
Figure 2-13 Video access setting interface
F1: Move up
F2: Move down
F3: Confirm the option
2-16 Component Name


CAUTION!
After canceling video access, there will be a big blind zone behind the excavator, which will
easily cause dangers.
3) System Information Management

Enter into Main Menu, and select “System Information Management”; enter into password verifi-
cation interface, input correct password and confirm it, then you’ll go to System Information Man-
agement Interface shown as below:
Component Name 2-17

Figure 2-14 System Information Management Interface
F1: Move up
F2: Move down
F3: Confirm the option and go to the next interface
There are eight options displayed on System Information Management Interface that are: “Control-
ler Port”, “Operation Information Inquiry”, “History Fault Inquiry”, “System Parameter Set-
ting”, “GPS Information Management”, “Working Time Resetting”, “System Program
Update” and “Machine Information Inquiry”.
2-18 Component Name

In Controller Port Inquiry Interface, you may inquire controller port input information and port output
information and acquire controller port input data and output data; this function is primarily designed
to check the correctness of sensors data and controller's control data.
In Operation Information Inquiry Interface, you may inquire engine system information and hydraulic
system information.
In Fault History Inquiry Interface, you may inquire system fault code, time of occurrence and corre-
sponding fault description; In History Fault Inquiry Interface, you may Press F4 to enter into engine
history fault inquiry interface.
System Parameter Setting Interface displays following functional options: “Main Pump Study”,
“Throttle Self-study”, “Hour Meter Alteration”, “Walking Hour Meter Alteration”, “Slew-
ing Hour Meter Alteration” and “Power Proportion Setting” and so on. The operator can choose
the desired option according to this interface. Among all the functional options, Main Pump Study
function is designed to calibrate, after replacement of the main pump, the parameters of main pump
proportional valve. Power Proportion Setting function is designed to properly reduce main pump
power in order to match engine derating for prevention of engine blocking run.
In GPS Information Management Interface, you can select “GPS Status Inquiry”, “GPS Installa-
tion Setting” and “GPS Monitoring Design”, etc.
CAUTION!
For excavators about to be sold to special places, the GPS must be removed first:firstly, select
Removal in GPS Installation Setting Interface; secondly, remove GPS hardware; failing to fol-
low this sequence will cause the whole machine unable to ignite.
In Working Time Resetting Interface, you can reset the working time data recorded by the controller.
CAUTION!
Working Time Resetting function can only reset the time displayed on the instrument, the
actual working time of the whole machine is still being stored; privately resetting working
time will affect the warranty.
In System Program Update Interface, you may update display panel program, display panel font li-
brary, display panel graph library and controller program.
In Machine Information Inquiry Interface you may inquire Display Hardware Version, Display Soft-
ware Version and Controller Software Version, etc.
Component Name 2-19

CAUTION!
To replace the display or controller, be sure the hardware version and software version are
consistent.
Air conditioner control panel
Figure 2-15
No. Name No. Name

Fan speed setting
1 OFF switch 2
switch
Temperature setting Blow air mode setting
3 4
switch switch
Automatic mode setting Interior and exterior air
5 6
switch changeover switch
7 Display monitor 8 Air conditioner switch
9 Light sensor
OFF switch
Turn off the fan and air conditioner. Press this button, and the setting temperature and air volume dis-
played on the monitor, and the light above auto mode setting switch as well as air conditioner switch are
all cut off and stop working.
Press OFF button and the light above fresh/recirculation selection switch won’t go off, which is
normal.
2-20 Component Name

Fan speed setting switch
Adjust air volume. Air volume has 6 adjustment levels. The display monitor shows the setting air volume.
• Press ∧ switch to increase air volume.
• Press ∨ switch to decrease air volume.
• When auto mode is activated, air volume adjustment is automatic.
• Display (7) monitor shows the setting air volume.
A: Liquid crystal display

A B
B: Air volume
a
a: Air volume “Low” b
b: Air volume “Moderate 1”
c
d
c: Air volume “Moderate 2” e
d: Air volume “Moderate 3” f
Figure2-16
e: Air volume “Moderate 4”
f: Air volume “High”
Temperature setting switch
Set in-cab temperature. Temperature adjusting range is between 18℃ and 32℃.
• Press ∧ switch to increase setting temperature.
• Press ∨ switch to decrease setting temperature.
• The normally set temperature is 25℃.
• For temperature adjustment, each level is 0.5℃.
• Display monitor.
Monitor display (℃) Adjust temperature
18.0 Maximum cooling

Adjust driver's cab temperature to the setting
8.5～31.5
temperature.
32.0 Maximum heating
Blow air mode setting switch
Select air vent.
Component Name 2-21

• Press this switch to electrify the display monitor. And shows the flow direction of air coming from the
vent.
• If auto mode setting is activated, the air vent will be automatically selected.
A: Rear air vent
A
C
B1: front air vent B1
C: Foot air vent

D
D: Front window air vent B2
B2: Front window air vent Figure2-17
Air vent diagram
Liquid Air vent

crystal Air vent
Remarks
dis- type A B C D
play
Blow air Automatic
from front ○ mode cannot
direction. select
Air comes
from front
○ ○
and rear
directions
Air comes
from front,
○ ○ ○
rear and foot
bottom.
Air comes
from foot ○
bottom.
2-22 Component Name

Liquid Air vent

crystal Air vent
Remarks
dis- type A B C D
play
Air comes Automatic
from foot mode cannot
bottom and ○ ○ select
defrosting
vent
Air comes Automatic
from mode cannot
○
defrosting select
vent
○ means air comes from this vent.
Automatic mode setting switch
Air volume, air vent and interior/exterior air changeover are automatically selected according to the setting
temperature.
• Press automatic mode setting switch, the top light on automatic switch turns on.
• Press automatic mode setting switch, use temperature setting switch to set the temperature, and then, air
conditioner will automatically run.
• When automatic mode is switched to manual mode, you may operate each switch to re-set air volume,
air vent and interior/exterior air changeover mode.
When manual mode is activated, the top light on automatic switch turns off.
Interior and exterior air changeover switch
Connect the air source between in-cab air circulation outdoor air inlet.
• Press interior/exterior air changeover switch, the light on top of the switch will turn on, indicating that
air has come.
• During auto mode operation period, interior air (recirculation air) and outdoor air (fresh air) will be au-
tomatically selected.
Exterior air is cut off, only in-cab air is in recirculation.

Recirculating air
Used for quick heating/cooling of the cab air, or when outdoor air is dirty.
Component Name 2-23

Outdoor air comes into driver’s cab

Fresh air
Used to intake fresh air and defrost.
Display monitor
Display monitor shows temperature setting, air volume and air vent situations.
• Press OFF switch and the temperature and air volume data will disappear, operation stops.
Air conditioner switch
Used to control air conditioner (cooling, dehumidification and heating) to work (ON) or stop (off)
• Press air conditioner switch and the air conditioner will turn on, the top light of the switch comes on.
• Press air conditioner switch again and the air conditioner will turn off, the top light of the switch goes
off.
• When the fan stops, air conditioner won't be activated.
Solar sensor
Solar sensor automatically regulates the flow volume of air vent, and matches it with sunlight intensity.
Besides, by sensing the change in sunlight intensity, it can in advance detect changes of the affected in-cab
temperature and adjust it.
Notices on use of air conditioner
• Remember to always turn on the air conditioner when engine is running in low speed. Never
start the air conditioner when engine is running high; otherwise, the air conditioner will result in
fault.
• If water enters the control panel or the solar sensor, unexpected failure will occur; therefore,
don’t let water enter these components. Besides, don’t approach fire to these parts.
• To fully manifest the automatic operation effect of air conditioner, always keep the solar sensor
clean; don’t leave any articles near the sensor.
2-24 Component Name

Ventilation
• When air conditioner has run for a long period of time, turn the switch to “Fresh air” position, and
ventilate and cool the air at an one-hour interval.
• If you smoke under a running air conditioner, the smoke will hurt your eyes; so, open the window for
ventilation, and turn the switch to “Fresh air” position. The machine will cool the air and the smoke
will be extracted at the same time.
Temperature control
Cooling temperature should be such a degree when entering the driver’s cab, the operator should only
feel a little cooling (5℃～6℃ lower than outdoor temperature).
This temperature is the fittest to your health. Therefore, always pay attention to adjust the temperature.
Inspect and repair machine equipment fitted with an air conditioner.
To inspect any machine or equipment fitted with an air conditioner, ensure to inspect and adjust the belt
tension of air conditioner compressor, clean and check the fresh air/recirculation device.
Component Name 2-25

Radio
Figure 2-18 Radio control panel
No. Name No. Name

1 Power/mode switch key 2 Mute / equal loudness
Wave band / Station
3 4 Preset station key
automatic saving key
5 Display screen 6 VOL+/- volume adjustment key
SEL Sound effect / clock Radio station search and MP3
7 8
setting key selection key
9 USB port
Power/mode switch key
Power switch: make a short press on this key to turn it on; make a long press on this key to turn it
off.
Switch mode: briefly press this key to shift between Radio ◀＝▶ MP3 mode (◀＝▶ IN is an optional
function).
Note: a short press lasts less than 2 seconds; a long press lasts longer than 2 seconds.
Mute / equal loudness key
A short press: Mute ON/OFF.

A long press: Loudness ON / OFF.
Wave band / station automatic saving key
A short press: shift between FM1/FM2/AM1/AM2.
2-26 Component Name

A long press: it automatic searches from the low-frequency station within the current wave band; all the
stations searched will be orderly saved in preset station.
Preset station key
To listen to radio, make a short press on the key to select corresponding preset radio station. Make a long
press on this key to save the received frequency to related preset station.
When playing MP3,
<1/PAUSE> Pause/Play
<2/SCN> Scan/Play
<3/RPT> Repeat/Play
<4/RDM> Random/Play
<6/DISP> Display track number/time
Display screen
Display received wave band, frequency and preset number.
VOL+/- volume adjustment key
Press VOL+/- key to increase or decrease volume.
SEL Sound effect / clock setting key
Briefly press this key to show clock; make a short press on this key in a period of 5s and you will enter in-
to sound effect setting.
When time is shown, make a long press on this key to enter into clock adjustment.
Failing to press this key in 5s, it will return to show play message.
◀◀/▶▶ Radio station search and MP3 selection key
To listen to radio, press this key to search stations forward or backward.

To play MP3, press this key to orderly select tracks and quickly select tracks.
USB port
Used for USB connection.
Component Name 2-27

Indoor switches
Figure 2-19 Driver's cab switches layout
No. Name No. Name

1 Key switch for engine 2 Engine rotation speed knob
3 Working lamp switch 4 Silence switch

5 Wiper switch 6 Wiper washer switch
Regeneration and prohibit regeneration switch
7 8 Horn switch
(exclusive for XE750G/XE800GA)
9 Force increase switch (not available on XE750G/XE800GA/XE750D/XE800D)
Key switch for engine
Start or cut off the engine.
OFF position
2-28 Component Name

Insert or extract the key to cut off all the

switches of electrical system and stop the
engine.
Figure2-20
ON position
When engine is running, ensure that the key is always at position ON.
START position
This is the engine start position. When starting the engine, maintain the key at this position. After engine
has started, immediately release the key to let it return to position ON.
Engine rotation speed knob
Control engine speed and output.

• Low idle position (MIN): fully turns
leftward.
• High idle position (MAX): fully turns
rightward.
Figure2-21
When turning engine speed knob, it is normal that

the engine speed keeps unchanged when the knob is
being turned between MIN position and MAX
position.
Component Name 2-29

Working lamp switch
Press this switch and boom lamp turns on,

ON
the backlight of all the in-cab switches turn
on, the turntable platform lighting lamp
turns on, counterweight lamp turns on and OFF
cab top lamp turns on.
Figure2-22
Silence switch
After walking for 13s, press this switch and ON

the walking siren stops alarming.
OFF
Figure2-23
Wiper switch
Press this switch once, the front window

ON
wiper contentiously swings at low speed.
Press this switch againandthe front window
wiper will contentiously swing at high OFF
speed. When the switch returns to zero po-

sition, the wiper returns to its original
position.
Figure2-24
2-30 Component Name

Washer switch
Constantly press this switch will activate Spray water

the sprayer to sprinkle water on front win-
dow glass; release this button and the
spraying process stops.
Figure2-25
Regeneration and prohibit regeneration switch (exclusive for XE750G/XE800GA)
Press regeneration switch to activate after-

treatment initiative regeneration system;
press prohibit regeneration switch and the
system will be prohibited.
Figure2-26
Horn switch
Press the button on top of left control lever

and the horn will sound.
Figure2-27
Force increase switch (not available on XE750G/XE800GA/XE750D/XE800D)
Component Name 2-31

Press the switch on top of right control lev-

er to activate touch-type force increase
function. Press this switch (chick sound)
and you can increase hydraulic system
pressure, enhance output power and in-
crease excavating force. Whereas, don’t
exceed the act for over 8s for prevention of
damaging hydraulic system.
Figure2-28
CAUTION!
This function is not available on some types of machine; please contact the dealer of Xugong
Mining Machinery Co., Ltd. for detailed information.
Seat
3
4
1
2
Figure 2-29 Driver's cab seat
2-32 Component Name

No. Name No. Name

Seat-sliding control Body weight
1 2
lever adjustment lever
Seat backrest Armrest angle
3 inclination adjustment 4 adjustment knob
lever
WARNING!
• Safety locking lever must be pull to locking position before starting the engine or leaving opera-
tor’s seat; otherwise, accidental touch of the control lever may cause fatal consequences.
• Ensure to adjust operator’s seat to a proper and comfortable position before starting the
engine.
• It’s strictly forbidden to adjust the seat during operating the machine.
• Ensure that there is no any object within the sliding range of operator’s seat.
• Only one person is allowed to sit in operator’s seat.
• Only authorized qualified persons can install and maintain operator’s seat.
Slide operator’s seat
To pull or push operator’s seat, the person must hold seat-sliding control lever and raise it, and then slide
the seat forward or backward; don’t let go of the lever until the seat reaches a desired position; range of
adjustment is 0mm - 160mm.
Adjust the height of operator’s seat
The height of operator's seat can be adjusted through its inclination angle in accordance with operator’s
weight and the working environment.
Adjust weight
Rotate body weight adjustment lever rightward so as to increase suspending power; rotate the lever left-
ward so as to decrease suspending power; inspect weight display panel before adjusting operator’s seat;
adjusting range is 50 kg - 120 kg.
Adjust the angle of seat backrest
Pull seat backrest inclination adjustment lever so as to deflect the seat forward or backward; adjusting
range is 66° -72°.
Component Name 2-33

Adjust armrest angle
Armrest can be adjusted leftward and rightward by turning armrest angle adjustment knob to correspond-
ing directions; first gently lift the armrest and then turn the knob to adjust the armrest to a proper angle.
Adjust headrest angle
Headrest can be adjusted forward and backward, upward and downward by holding both sides of the
headrest.
Headrest
Armrest
Figure 2-30
Seat belt
WARNING!
• Always buckle up the seat belt to secure operator's safety.
• Before starting to operate the machine, the operator should adjust the seat to a proper position
and then buckle up the belt.
• Neither tie the belt through stomach nor stand up to operate the excavator.
• Inspect the condition of the belt and its fixing bracket before buckling it up.
• Immediately replace the twisted, kinked and over stretched seat belt.
• It’s strictly forbidden to privately modify the seat belt and its fixture.
• This seat belt is limited to an adult.
• Ensure the seat belt is correctly installed.
• No matter what condition the seat belt is in, replace it every three years.
2-34 Component Name
Component Name 2-35

How to use the belt
• Before operating the excavator, ensure

2 1
that you’ve correctly buckled the seat
belt.
• Regularly check how seriously are the
belt (1) and lock latch ②abraded; if very
seriously worn or fractured, replace it.
• Before use, ensure the seat belt (1) is not
kinked or twisted.
• Insert the metal end of seat belt (1) into
the lock latch ② and gently pull it so as Figure2-31
to ensure it is locked in the latch.
• Press the button (3) on the latch ② and

you can release the seat belt.
Notices on washing the seat belt

• Use soft soap water to clean it.
• Stretch the belt to dry it and then release
it.
• Ensure the seat belt is correctly installed. 2 3
Figure2-32
2-36 Component Name

Fire extinguisher
• Fire extinguisher, hung on left rear side

of the cab, is fixed by two pipe clips and
a supporting disc; it’s prepared for only
fire accident.
• Regularly inspect the fire extinguisher
and replace it every year.
E
• The fire extinguisher must be in accord-
ance with local regulations, so when the
machine is exported to any other states
or regions, be sure to replace it with one
that is certified by local government.
Figure2-33
• Ensure the fire extinguisher is saturated.
Driver’s cab roof lamp
Cab roof lamp is located at back of the sky-

light on the internal roof. Turn the switch 1
(1) to turn on or off the roof lamp.
Figure2-34
Component Name 2-37

Cigar lighter
Cigarette lighter is fixed on the trim panel

at left-rear of the cab.
• Turn engine key switch to position ON.
• Hold down the button of cigarette lighter
and then release it.
• Seconds later, the cigarette lighter will
bounce; then you can take it out and use
it.
Figure2-35
• After use, push the cigarette lighter to its
original position with proper force.
CAUTION!
• The cigarette lighter serves as a 24V externally connected DC power.
• It’s strictly forbidden to use non-24V devices.
• When engine is in cutoff state, don’t use externally connected device for long, as the battery will
run out.
Ashtray
Ashtray is located on the front of right arm-

rest of the cab. Regularly clean the ashtray.
Figure2-36
Emergency hammer and emergency exit
Emergency hammer (G), hung at the right-rear side of the cab, is only for emergency use; if lost, prepare a
new one immediately.
2-38 Component Name

The cab has two emergency exits: door and window. When there is an emergency, the operator must use
the hammer to break the back windshield and evacuate, no matter what type of the back windshield
F — Door
G — Emergency hammer F G H
H — Rear windshield
Figure2-37
Information pack
Information pack is at the back side of op-

erator’s seat, which contains an Operation
and Maintenance Manual for reference.
Figure2-38
Component Name 2-39

Driver’s cab window
Open front window
• Lower the working device on the ground

and then turn off the engine.
• Hold the two handles (A), pull out hard
and push upward, so as to open the front
window. A
• Open the window and lock it
immediately.
Figure2-39
Close the window

and slowly pull it down.
B
• Tightly install the window and then fix it
onto the locks (B).
Figure2-40
Cab door locking system
With this system, the operator can keep cab door open.
Operator pushes cab door outward. Ensure that cab door is fixed on lock (C). Press the handle (D) inside
the cab and you can release cab door.
2-40 Component Name

D
Figure 2-41
Safety locking lever
Safety locking lever is designed to prevent misoperation.
CAUTION!
If safety locking lever (1) is not completely pulled to its locking position, pilot oil line won’t be cut
off.
1 1
Unlocking position. Locking position
Figure 2-42
• Before leaving the cab, pull the safety locking lever (1) to its locking position.
• Before starting the engine, ensure that the safety locking lever (1) has been pulled to its locking
position.
Component Name 2-41

Control lever
Refer to “Operation” chapter for details.
Controller
Controller is located in the rear electrical box of the cab.

• Don’t spoil water or any other liquid on the controller.
• For any anomaly, please contact XCMG authorized dealer for repair.
Battery switch
Battery switch, located on the left side of turntable platform, connects or disconnects the power supply be-
tween the battery and electrical system of the machine.
• “O”: “OFF” position, current is cut

off.
• “I”: ON position, the current is
flowing.
Ensure the switch is at “ON” posi-

tion before starting the engine.
Figure2-43
Cover with lock
Use a key to open and close the lock of the cover.
Lock operation procedure:

• Clockwise turn the cover on the lock.
• Insert the key and clockwise turn the 3
key to position “Open”, and open the
cover.
“2” Start “3” Lock
2
Figure2-44
2-42 Component Name

Accumulator
Accumulator is located inside of the pump chamber.
WARNING!
As the accumulator contains pressurized nitrogen, improper operation may cause explosion, severe
injury or death.
When operating the accumulator, strictly obey following requirements:

• As the residual pressure of the control pipeline cannot be fully relieved, when removing hydraulic devi-
ces, don’t stand at oil injection direction, and the bolt must be unscrewed slowly.
• Don't remove the accumulator.
• Don't approach the accumulator to open flame or expose it to fire.
• Don’t drill or weld the accumulator.
• Don’t bump or roll so as to avoid impacting the accumulator.
• When disposing the accumulator, the gas must be relieved; please contact XCMG authorized dealer.
Steps to relieve the pressure of accumulator:
1. Place the front working device on the ground.
2. Turn off the vehicle engine.
3. Turn engine key switch to position “ON”.
4. First, pull safety locking lever to START position; and then pull and push all the control levers and ped-
als of other accessory equipment in order to release the pressure from hydraulic pipeline.
5. Pull the safety lock lever to “Lock” position.
6. Turn engine key switch to position “OFF”.
Component Name 2-43

2.3 Driver’s cab layout (touch screen instrument)

Driver’s cab
4 5 6 7
8
3
9
2
10
1
11
12
Figure 2-45 Driver's cab layout
No. Name No. Name No. Name

Left walk control
1 Safety lock lever 5 9 Right control lever
lever
Left control Right walk control
2 6 10 Right auxiliary armrest
lever lever
Horn switch (on
3 top of left 7 Right walk pedal 11 Right armrest
control lever)
4 Left walk pedal 8 Monitor 12 Left armrest
2-44 Component Name

1 Safety lock lever Hydraulic pilot oil control
Extend & retract bucket rod

2 Left control lever
and slew upper structure
Horn switch (on top of Press this switch to honk

3
control lever) the horn
Control left crawler to

4 Left walk pedal march forward and
backward
Control left crawler to
5 Left walk control lever march forward and
backward
Control right crawler to
6 Right walk control lever march forward and
backward
Control right crawler to
7 Right walk pedal march forward and
backward
Operate, display and alarm
8 Monitor (see detailed introduction
below)
Raise and lower the boom
9 Right control lever and control the bucket to
dig and unload.
Various operational buttons
10 Right auxiliary armrest (see detailed introduction
below)
Various operational buttons
11 Right armrest (see detailed introduction
below)
Reserved buttons (see
12 Left armrest detailed introduction
below)
Component Name 2-45

Monitor
• Main Interface
Figure 2-46 Monitor main interface
No. Name Function

1 Image identification function, can recognize driver's
Image identification zone
identity and give fatigue alert.
2 State display zone Display various warnings and status information
3 Instruments display zone
4 Camera image display Observe rear construction surroundings
zone
5 Key navigation zone Operation key
2-46 Component Name

• Image identification zone (1)
Figure 2-47
Table 2-3
No. Name No. Name

mage identification Infrared inductive
1.1 1.2
camera sensor
Image identification function, can recognize driver's identity and give fatigue alert.
Component Name 2-47

• Status information zone (2)
Figure 2-48
N-
Name No. Name
o.
Excavation mode High speed travel

2.1 2.2
ATT1 Special tool mode 1
Low speed travel
ATT2 Special tool mode 1
Display the present
2.3 2.4 AUTO
Automatic idle speed
clock n/min
Automatic
2.5 2.6 Walking alarm erasure
lubrication
DPF regeneration in-process

DPF requiring
2.7 2.8
regeneration warning
DPF regeneration prohibited
Yellow Level 1 engine fault warning, this icon flashes;

flash maintain the system.
Red Level 2 engine fault warning, this icon flashes;

2.9 flash stop and troubleshoot.
Red
Level 3 engine fault warning, this icon stays on;
normally
stop without delay and troubleshoot.
on
2-48 Component Name

• Instruments display zone (3)
Figure 2-49
No. Name Remarks

Engine coolant temperature When temperature is in red zone, stop without
3.1
gauge delay and troubleshoot.
When fuel level is in red zone, refuel the tank
3.2 Fuel level gauge
immediately.
When hydraulic oil temperature is in red zone,
3.3 Hydraulic oil temperature gauge
stop without delay and troubleshoot.
Working hour meter Display engine total working hours
Display the corresponding shift position of

Engine throttle shift position
throttle knob
Fault warning indication Immediately check detailed fault content.
Air filter blockage warning Clean or replace it right away
3.4 If charging warning occurs when engine’s

- + Charging warning
running, immediately check it.
Hydraulic oil filter blockage

Inspect it at once
warning
Low engine oil pressure

Stop the engine and inspect it.
warning
After-treatment exhaust system
Inspect it at once
fault
When DEF liquid level is in red zone, replenish
3.5 DEF level gauge
it at once.
Component Name 2-49

• Camera image display zone (4)
Figure 2-50
This zone shows image of the camera installed on the counterweight, and the operator can observe the
rear construction environment.
• Key navigation zone (5)
Figure 2-51
No. Name No. Name

5.1 Fan reverse 5.2 Maintenance alert
5.3 ECM fault inquiry 5.4 Automatic idle speed
5.5 Application menu
2-50 Component Name

Application menu
Figure 2-52
Application menu or APP includes following contents:
No. Name No. Name
1 Operation information 2 Fault information
3 Maintenance service 4 Machine setting
5 Air conditioner 6 Multi-media
6 GPS 8 System setting
9 Back to screen main interface 10 Back to the previous menu
Component Name 2-51

• Operation information
In operation information interface, you may inquire following parameters:
Engine rotation speed: rpm

Engine coolant temperature: ℃
Fuel level: %
AdBlue level: %
System voltage: V
Phase working hour: H
• Fault information
In fault information interface, you may inquire following parameters:
No. Wire Code Time of occurrence

marking
01 000 A506 2020-07-10 09:21
Controller fault
information Fault description:
Data recorder anomaly alarm
No. CODE SPN FMI OC

01 1389 5246 15 1
Engine fault
Fault description:
information
After-treatment SCR operator induction severity: high
- Lowest severity (1)
Internal gas sensor status Normal

External gas sensor status Normal
Receive coolant signal status Normal
Air conditioner
fault information Solar radiation sensor status Normal
Pressure status Normal
Mode blow air door status Normal
Mixed air door status Normal
2-52 Component Name

• Maintenance service
On maintenance service menu, you may inquire following information:
Service Tel: 400-110-9999

Service Tel
Website: http://www.xcmg.com
8-hour maintenance information
Maintenance
guide
Machine model: XE750G/XE800GA/XE750D/XE800D
Display serial number:
Display hardware version number: V1.01
Machine
Display software version number: V1.03
information
Controller software version number: V2.1
SWPN:5781942-00*SWDE:2506F-
Engine software version number:
T4F-IND-PROD7.1*SWDT:FEB19*
Component Name 2-53

• Machine setting
In machine setting menu, you may set following contents:
Time Setting
Language setting
2-54 Component Name

Brightness setting
1. Automatic setting: automatic adjustment in accordance with

headlight
2. Display brightness adjustment
3. Control panel backlight brightness adjustment
Code recognition Face recognition
Operator manually inputs
identification code:
Identification setting
Phase hour Requires XCMG’s authorization to access this function

Switch box brightness setting Please set switch box backlight brightness:
Component Name 2-55

Hand lever mode setting

（Temporarily unavailable on
XE750G/XE800GA/XE750D/
XE800D
Accessory mode selection
2-56 Component Name

Air conditioner
Air conditioner setting includes following contents:
Figure 2-53
No. Name Notes

Temperature °F Indicated in Fahrenheit degree
1
mode ℃ Indicated in Fahrenheit degree
Air comes from front direction.
Air comes from front and rear directions.
Air comes from front and foot bottom.

2 Air outlet mode
Air comes from foot bottom.
Air comes from defrosting vent
Component Name 2-57

No. Name Notes

Air comes from defrosting vent and foot bottom
Air outlet mode Air outlet modes shifting

3
adjustment MODE
Outdoor air comes into driver’s cab
Interior and ex-
4 terior
Air circulates inside the cab
recirculation
Air volume Adjust air volume.

5
adjustment
Temperature Adjust temperature
6 16.5℃
adjustment
Turn on or off the air conditioner
7 Switch
Turn on air conditioner automatic mode

8 Automatic mode
AUTO
Turn on air conditioner cooling mode

9 AC mode
2-58 Component Name

Notices on use of air conditioner:
• Remember to always turn on the air conditioner when engine is running in low speed. Never start
the air conditioner when engine is running high; otherwise, the air conditioner will result in
fault.
• If water enters the control panel or the solar sensor, unexpected failure will occur; therefore,
don’t let water enter these components. Besides, don’t approach fire to these parts.
• To fully manifest the automatic operation effect of air conditioner, always keep the solar sensor
clean; don’t leave any articles near the sensor.
Ventilation
• When air conditioner has run for a long period of time, turn the switch to “Fresh air” position, and
ventilate and cool the air at an one-hour interval.
• If you smoke under a running air conditioner, the smoke will hurt your eyes; so, open the window for
ventilation, and turn the switch to “Fresh air” position. The machine will cool the air and the smoke
will be extracted at the same time.
Temperature control
Cooling temperature should be such a degree when entering the driver’s cab, the operator should only
feel a little cooling (5℃ ～ 6℃ lower than outdoor temperature). This temperature is the fittest to your
health. Therefore, always pay attention to adjust the temperature.
Inspect and repair machine equipment fitted with an air conditioner.
To inspect any machine or equipment fitted with an air conditioner, ensure to inspect and adjust the belt
tension of air conditioner compressor, clean and check the fresh air/recirculation device.
Component Name 2-59

Multi-media
• Multi-media setting includes following contents:
Figure 2-54
No. Name No. Name

1 Signal source/setting 2 FM mode
3 Channel adjustment 4 Stored channel
5 Equalizer 6 Volume adjustment
7 Switch
2-60 Component Name

GPS
GPS setting includes following contents:
Positioning status:
Longitude:
Latitude:
Altitude:
GPS status inquiry
Number of satellites:
Angle of deflection:
GPS installation status:
GPS monitoring status:
GPS installation setting: Requires XCMG’s authorization to access this function
GPS installation setting: Requires XCMG’s authorization to access this function
System setting
System setting requires XCMG’s authorization to access this function.
Component Name 2-61

Left armrest
3
1 2
Figure 2-55
No. Name
1 Reserve
2 Reserve
3 Reserve
2-62 Component Name

Right armrest
2 3
Figure 2-56
No. Name
1 Key switch for engine
2 USB port
3 Audio frequency input interface
Component Name 2-63

Right auxiliary armrest
11 2
12 3
13 4
14 6
15 7
10
Figure 2-57
2-64 Component Name

No. Name No. Name

1 Engine rotation speed knob 2 Working lamp switch
3 Wiper washer switch 4 Instrument alarm silence switch
5 Monitor operation knob 6 Air conditioner switch
7 Monitor function switch 8 Walking alarm silence switch
9 DPF Regeneration switch 10 12V power source
11 Travel mode 12 Wiper switch

13 Multi-media silence switch 14 Multi-media switch
Monitor main interface
15
switch
Component Name 2-65

Seat
6
9
5
10
4
3 1+2 11
Figure 2-58 Driver's cab seat
No. Name No. Name

Body weight
1 2 Height adjustment
adjustment
Shock absorber Front/back adjustment (seat
3 4
adjustment cushion + backrest)
Cushion depth Seat cushion angle
5 6
adjustment adjustment
7 Headrest adjustment 8 Seat cushion heating switch
9 Waist support 10 Backrest adjustment

Front/back adjustment (seat cushion +
11
backrest + armrest box)
2-66 Component Name

WARNING!
• Safety locking lever must be pull to locking position before starting the engine or leaving opera-
tor’s seat; otherwise, accidental touch of the control lever may cause fatal consequences.
• Ensure to adjust operator’s seat to a proper and comfortable position before starting the
engine.
• It’s strictly forbidden to adjust the seat during operating the machine.
• Ensure that there is no any object within the sliding range of operator’s seat.
• Only one person is allowed to sit in operator’s seat.
• Only authorized qualified persons can install and maintain operator’s seat.
Seat operation and function
• Body weight adjustment
To adjust operator’s weight, the vehicle

must stop and the driver must be sitting on
the seat, and then pull the lever (arrow) of
self-weight and height adjuster to achieve
weight adjustment setting. In the whole
process, the driver must be sitting on the
seat.
1
Figure2-59
CAUTION!
Before weight adjustment being performed, the
shock absorber must be adjusted to a "soft"
position.
• Height adjustment
Component Name 2-67

This seat height setting mechanism is air-

acting type, which allows for continuous
adjustment.
This seat height can be fully ad-

justed upward and downward by pulling
and pushing the adjustment lever (ar-
row). To adjust to top end and bottom
2
Figure2-60
end, the height will be automatically ad-
justed for purpose of ensuring a mini-
mum elastic trip.
CAUTION!
Before height adjustment being performed, the
shock absorber must be adjusted to a "soft"
position.
2-68 Component Name

• Shock absorber adjustment
A seat shock absorber device can be ad-

justed to adapt to a variety of road and non-
road driving conditions. A seat shock ab-
sorber device can be adjusted to adapt to a
variety of road and non-road driving condi-
tions, so as to reach the most comfortable
passenger’s experience.
Rotate the lever to the desired posi-

tion and release it. There are 5 adjusting
levels in total. Figure2-61
• Front/back adjustment (seat cushion + backrest)

Lift lock rod to adjust seat cushion and
backrest forward and backward, release the
rod to lock in that position.
After seat front/rear position adjust-

ment is completed, the lock rod must be
stuck in the locking position where a
sound will be heard. After locking up in
that position, the driver's seat won’t
move.
Figure2-62
CAUTION!
Do not operate lock rod during drive.
CAUTION!
Do not use your leg to operate the lock rod.
Component Name 2-69

• Cushion depth adjustment
Pinch tight the switch shown in the figure

with index finger and thumb and do not let
go; at the same time, pull and push it for-
ward or backward to achieve seat cushion
depth adjustment; release the switch after
finishing the adjustment, and you will hear
a sound, which indicates that the seat cush-
ion won’t move any longer.
Figure2-63
CAUTION!
Do not start this operation when the machine is
running.
• Seat cushion angle adjustment

Pinch tight the switch shown in the figure with index finger and thumb and do not let go; at the same
time, pull and press it upward or downward to achieve seat cushion angle adjustment; release the switch
after finishing the adjustment, and you will hear a sound, which indicates that the seat cushion won’t
move any longer.
2-70 Component Name

• Headrest adjustment
Headrest height can be adjusted separately:

gradually pull the headrest up till it reaches
the end position.
Remove the headrest, pull it up till

it stops at the end position, and the pull
it out.
Figure2-64
• Seat cushion heating
Press the switch to turn on or off seat heat-

ing function.
Figure2-65
• Waist support
Adjust the height and curvature of waist

support by turning the lever adjuster to-
wards left or right. + -
This function increases seat comfort

and enhances driving performance.
Figure2-66
Component Name 2-71

• Backrest adjustment
Adjust backrest by lifting the lock lever for

release of the backrest. To release the back-
rest, do not apply pressure load on the
backrest. Move the backrest to a desired
position by applying or releasing pressure
on or from front or back of the backrest.
Figure2-67
CAUTION!
When the backrest is locked up, it will not move any
more.
• Front/back adjustment (seat cushion + backrest+armrest box)
Lift the lock rod and you’ll be able to

move the upper part of the entire seat, arm-
rest box and control lever forward and
backward, release the rod to lock in that
position.
Figure2-68
2-72 Component Name

Seat belt
WARNING!
• Always buckle up the seat belt to secure operator's safety.
• Before starting to operate the machine, the operator should adjust the seat to a proper position
and then buckle up the belt.
• Neither tie the belt through stomach nor stand up to operate the excavator.
• Inspect the condition of the belt and its fixing bracket before buckling it up
• Immediately replace the twisted, kinked and over stretched seat belt.
• It’s strictly forbidden to privately modify the seat belt and its fixture.
• This seat belt is limited to an adult.
• No matter what condition the seat belt is in, replace it every three years.
How to use the belt
• Before operating the excavator, ensure 2 1

that you’ve correctly buckled the seat
belt.
• Regularly check how seriously are the
belt (1) and lock latch ② abraded; if
very seriously worn or fractured, replace
it.
• Before use, ensure the seat belt (1) is not
kinked or twisted. Figure2-69
• Insert the metal end of seat belt (1) into
the lock latch ② and gently pull it so as
to ensure it has been locked in the latch.
Component Name 2-73

• Press the button (3) on the latch ② and

you can release the seat belt.
2 3
Figure2-70
Notices on washing the seat belt
• Use soft soap water to clean it.

• Stretch the belt to dry it and then release it.
Fire extinguisher
• Fire extinguisher, hung on left rear side

of the cab, is fixed by two pipe clips and Fire extinguisher
a supporting disc; it’s prepared for only
fire accident.
• Regularly inspect the fire extinguisher
and replace it every year.
• The fire extinguisher must be in accord-
ance with local regulations, so when the
machine is exported to any other states
or regions, be sure to replace it with one
that is certified by local government.
• Ensure the fire extinguisher is saturated.
Figure2-71
2-74 Component Name

Driver’s cab roof lamp
Cab roof lamp is located at back of the sky-

light on the internal roof. The switch, Roof lamp
which is integrated within the lamp body,
controls the roof lamp.
Figure2-72
24V power source (10A)
The 24V power source is fixed on the trim

panel at left-rear of the cab.
24V power
Figure2-73
CAUTION!
• It’s strictly forbidden to use non-24V devices.
• When engine is in cutoff state, don’t use externally connected device for long, as the battery will
run out.
• The maximum operating current for the 24V power source is 10A, overloading is prohibited; oth-
erwise, the electrical line will burn, even cause fire.
Component Name 2-75

2-76 Component Name

Emergency hammer and emergency exit
Emergency hammer (G), hung at the right-rear side of the cab, is for emergency use only; if lost, prepare a
new one immediately.
The cab has two emergency exits: door and window. When there is an emergency, the operator must use
the hammer to break the back windshield and evacuate, no matter what type of the back windshield
F — Door
F G H
G — Emergency hammer
H — Rear windshield
Figure2-74
File pocket
File pack is at the back side of operator’s

seat, which contains an Operation and
Maintenance Manual for reference.
File pocket
Figure2-75
Component Name 2-77

Driver’s cab window
Open front window

and push upward, so as to open the front
window.
• Open the window and lock it A
immediately.
Figure2-76
Close the window

and slowly pull it down.
• Tightly install the window and then fix it B
onto the locks (B).
Figure2-77
2-78 Component Name

Cab door locking system
With this system, the operator can keep cab door open.
Operator pushes cab door outward. Ensure that cab door is fixed on lock (C). Press the handle (D) inside
the cab and you can release cab door. The unlock handle can be lifted (E) from outside the cab to lock the
door.
D
Figure 2-78
Figure 2-79
Safety lock lever
Safety locking lever is designed to prevent misoperation.
CAUTION!
If safety locking lever (1) is not completely pulled to its locking position, pilot oil line won’t be cut
off.
Component Name 2-79

1 1
Unlocking position. Locking position
Figure 2-80
• Before leaving the cab, pull the safety locking lever (1) to its locking position.
• Before starting the engine, ensure that the safety locking lever (1) has been pulled to its locking
position.
Control lever
Refer to “Operation” chapter for details.
Controller
Controller is located on the pedant at the rear of the cab.

• Don’t spoil water or any other liquid on the controller.
• For any anomaly, please contact XCMG authorized dealer for repair.
Battery switch
Battery switch, located within the edge beam of turntable platform near the cab, connects or disconnects
the power supply between the battery and electrical system of the machine.
2-80 Component Name

• “OFF” position: current is cut off.

• “ON” position: the current is flowing.
Ensure the switch is at “ON” posi-
tion before starting the engine.
Figure2-81
Cover with lock
Use a key to open and close the lock of the cover.
Lock operation procedure:

• Clockwise turn the cover on the lock.
• Insert the key and clockwise turn the key 3
to position “Open”, and open the
cover.
“2” - Unlock
“3” - Lock up 2
Figure2-82
Accumulator
Accumulator is located beside the main valve of the machine.
WARNING!
As the accumulator contains pressurized nitrogen, improper operation may cause explosion, severe
injury or death.
When operating the accumulator, strictly obey following requirements:

• As the residual pressure of the control pipeline cannot be fully relieved, when removing hydraulic devi-
ces, don’t stand at oil injection direction, and the bolt must be unscrewed slowly.
• Don't remove the accumulator.
• Don't approach the accumulator to open flame or expose it to fire.
Component Name 2-81
• Don’t drill or weld the accumulator.
• Don’t bump or roll so as to avoid impacting the accumulator.
• When disposing the accumulator, the gas must be relieved; please contact XCMG authorized dealer.
Steps to relieve the pressure of accumulator:
1. Place the front working device on the ground.
2. Turn off the vehicle engine.
3. Turn engine key switch to position “ON”.
4. First, pull safety locking lever to START position; and then pull and push all the control levers and ped-
als of other accessory equipment in order to release the pressure from hydraulic pipeline.
5. Pull the safety lock lever to position “Lock”.
6. Turn engine key switch to position “OFF”.
2-82 Component Name

Chapter 3 Operation
3.1 General introduction

Only a certified, qualified experienced operator can control this equipment. And only certified personnel
can inspect and maintain the equipment. Operation notices:
• Read through this manual and understand the content before starting the equipment for the first
operation.
• This manual is an integral part to this machine, keep this manual at hand; if lost, damaged or unable to
read, please replace it.
• Take a careful inspection before starting this equipment and strictly follow safety rules to operate it.
• Don’t directly run the engine at high speed in low temperatures. The normal working temperature is
50℃～ 80℃, if below 25℃, the operator should preheat the machine till the temperature rises to nor-
mal level.
• Long-acting anti-rust antifreeze has been added into water radiator before delivery; if the machine will
be left unused for a long period, drain out the antifreeze so as to prevent from corrosion.
• When in cold winter, winter type lubricating oil and diesel should be used for a diesel engine. Both oil
type and details about engine cold start are specified in this manual and diesel engine instructions.
• Be sure to use clean hydraulic oil of the same brand for this machine; a different brand must not be
used.
• Pay attention to the cleanness of hydraulic oil: if it has aged, deteriorated or is not clean enough, replace
it. Normally, hydraulic oil should be replaced after the running-in period.
• Lead sealing has been applied to crucial hydraulic components; it’s not allowed to privately remove
the seal within warranty period; otherwise, your warranty request will be rejected.
• Although the equipment has gone through strict inspection and adjustment before delivery, the
new machine must undergo a running-in period in order to gain a longer service life. The run-
ning-in period is 200 hours; the working mode for the first 50 hours can only adopt Mode L (light
load digging mode) and engine power must be confined in 80% in order to avoid excessive idling;
inspect all the indicator lamps and instruments on a regular basis; maintain the equipment every-
day and focus on liquid leak; in the initial 50-hour or when working in muddy situations, lubri-
cate the pin of working device on an 8-hour basis; after the initial 50-hour period, inspect
fasteners, maintain the machine and replace lubricants for the diesel engine.
Operation 3-1
3.2 New machine operation instructions

Scopes of application
Altitude: 0m～2,000m
Ambient temperature: -15°C～40°C
Workplace: non-swamp, the working ground pressure is higher than the equipment’s.
Working object: soil below III and loose materials
Although all the excavators will go through inspection and adjustment before delivery, following require-
ments must be followed during running-in period; otherwise, the equipment will be damaged or function
impaired.
Time Load
First 50 hours Maintain 60%-80% of full load
After 200 hours Full load
If the machine is under full load during the initial 200-hour running-in period, it will bring negative influ-
ence onto machine’s life span and safety operation and finally cause machine failure.
• Start the engine till it reaches 80% of its full capacity.
• Avoid engine excessive idling.
• During running period, frequently inspect indicator lamps and the display for anomaly.
CAUTION!
Check coolant, fuel, engine oil and hydraulic oil for leakage on a daily basis. Check lubricant
everyday and refill it when necessary. During operation, always pay attention to the monitor and
keep on the alert to alarming signals. Try to prevent the engine from operating out of capacity.
Keep to 80% of full load before engine temperature and other components rise to working level.
Focus on the status of working device during operation. Check if wires and terminals are loose, if
instruments work well, or if battery liquid is adequate.
Lubricant and filter element
• Replace walking reducer gear oil after the first 250 working hours.
• Replace slewing reducer gear oil after the first 250 working hours.
Refer to “Lubrication, Maintenance and Repair” in this manual for replacement of lubricant and
grease.
3-2 Operation
3.3 Pre-boarding preparation and inspection

Obey safety regulations
Carefully read and understand all the safety

signs affixed on the machine and obey all
the safety related requirements specified in
this manual. When necessary, install, main-
tain and replace safety signs. If safety signs
or this manual is defaced or lost, please
purchase from XCMG authorized dealers
Figure3-1
(write down Machine Number and Deliv-
ery Date).
Learn to correctly safely operate this machine and only well-trained staff is qualified to operate maintain
this machine.
Keep to all the safety related requirements, warnings and rules during operation and maintenance.
Any unapproved modification will possibly cause damage to the machine and affect its safety and life
span, so the machine must be kept under proper working conditions.
Safety instructions are basic safety regulations; however, they may not contain all the potential dangers
that you’ll encounter; for any problem, please consult your superior leader before operating and main-
taining this machine.
Don’t operate the machine if you’re not well, tired after taking medication or not yet used to the envi-
ronment, as these situations may reduce your reaction to deal with emergencies and cause accident.
When cooperating with other operators or on-site managerial staff, ensure all of you are aware of the
working environment and sign language.
Keep on alert to all the factors that may influence safety.
Investigate jobsite beforehand
When working along a ditch or road

shoulder, the vehicle may overturn and
cause severe casualty. Take an early inves-
tigation to landforms and road conditions
of the jobsite, places that may collapse dur-
ing operation are river band, stacked mate-
rials. The machine may tip over whereon.
Figure3-2
Make an operation plan, use a proper machine and select a favorable jobsite.
Operation 3-3
Consolidate road surface, ditch and road shoulder when necessary, and keep a safe distance with these
places.
A signalman may be required when working on a slope or road shoulder. If a working area is subject to
falling rocks or rubble, ensure the machine has FOPS (Falling Object Protective System).
Consolidate the soft groundwork before working on it. Be extremely cautious when working on frozen soil
as it will soften and become slippery as temperature rises. Keep on the alert for fire accidents when work-
ing near flammables like dry grass.
Preparations for emergencies
Place a first-aid kit and fire extinguisher

nearby just in case.
Read through and understand the in-

structions affixed to fire extinguisher.
To secure the access to the fire extin-

guisher, especially under emergencies, be
sure to inspect and maintain the extin-
guisher according to specified inspection
intervals of this manual.
Make a strategy to react to emergen-

cies such as a fire accident. Figure3-3
Put a list of emergency contacts near

the phone, including doctor, ambulance,
hospital and fire brigade.
Work clothes and personal protective equipment
• Wear tight clothes and personal protective articles.
3-4 Operation
You may need following protective

articles:
Hard helmet
Safety shoes
Safety glasses, eye goggles and face

mask
Thick gloves Figure3-4
Hearing protector
Reflective coat
Raincoat and other water-proof

gears
Mask or filter type mask

See to it to wear work clothes and protective articles before operation, and never try your fortune.
• Tie up long hair; avoid wearing loose clothes, jewelry or other articles that may get hooked on control
lever or other parts, causing casualty accident.
• Don't wear oil-stained clothes, which may easily catch fire.
• Be sure to wear goggles, helmet, safety shoes and gloves when entering working areas.
• Don’t apply a tool of inadequate strength to repair the equipment. Otherwise, it may break or slip,
cause accidents or fail to meet installation requirements.
• Don’t ignore harmful factors that

won’t immediately act on health. Waste
gas and noise are invisible but will cause
disability or permanent damage.
• Long-term exposure to heavy noise envi-
ronment may impair or damage hearing.
Wear suitable hearing protective articles,
such as earmuffs or ear plugs, so as to
avoid noise nuisance. Figure3-5
Operation 3-5
Indoor ventilation
Exhausted engine gas may cause loss of consciousness, making them drop their guards, get out of hand
and cause fatal consequences.
• Before starting the engine in an enclosed area, ensure the place is well ventilated.
• Be cautious of open window or door, as exhausted gas may enter the cab by wind and cause danger.
Machine inspection
• To avoid injury, take an inspection

around the machine on a daily basis or
each time before starting the machine.
Take a walk around the machine, care-
fully inspecting it.
• When taking an inspection around the
machine, be sure to check every item of
the checklist specified in “Pre-start In-
spection” in following chapters.
Figure3-6
1. Electrical system - whether there are damaged wires, loose connectors or lost terminals.
2. Fuel system - drain water and impurities from fuel tank and water-oil-separator.
3. Hydraulic system - whether there is leaking hydraulic oil, damaged pipeline, twisted hose or interfered
components.
4. Liquid level - check following liquid level: hydraulic oil, engine radiator liquid and engine oil; add or
reduce when necessary.
5. Structural parts and crawler - carefully inspect boom, bucket rod, bucket and metal sheets; and check
whether crawler is bent, damaged or has missing parts.
6. Fasteners - check whether fasteners are loose or have missing parts.
7. Protective device - check whether protective devices and baffle plates are damaged or lost.
8. Lubrication system - regularly or daily maintain this system according to working hours shown on mon-
itor display.
9. Safety - take an inspection around the machine and ensure there is no person or obstacle on, under or
around the machine.
3-6 Operation
3.4 Post-boarding preparation and inspection

Adjust operator’s seat
Sitting on an improperly-mounted seat, the operator will soon feel fatigued, which may cause
misoperation.
• Re-arrange the seat once a new operator

takes over the job.
• When leaning on the seat, the operator
must be able to depress the pedal to the
floor and correctly operate the control
lever; if unable to do so, re-adjust the
seat by moving it upward, downward,
backward and forward.
Figure3-7
Wear seat belt
If the machine tips over, the operator may get injured or cast out of the cab, or even crushed by the over-
turned machine and cause casualties.
• Carefully check seat belt, belt buckle

and the fixing part before operation. If
any degree of abrasion or damage is
found on seat belt, replace the safety belt
or other parts before operation.
• The operator must always sit on the seat
and wear belt seat when machine is run-
ning, so as to minimize injury risks.
Figure3-8
• No matter what condition the seat belt is
in, replace it every three years.
Operation 3-7
The operator must sit on his spot for operation.
Incorrect engine operation will cause the machine out of control, leading to fatal consequences.
• Only start the engine by sitting on the

driver’s seat.
• Never start the engine when sitting on
the crawler or ground.
• Never start the engine by short-circuiting
the motor terminals.
• Ensure all control levers are in the neu- Figure3-9
tral position before starting the engine.
Inspection before starting the engine
• Electrical control system: check if there are abraded or cracked wires and loose connectors.
• Never start the engine by short-circuiting the motor terminals.
• Ensure all control levers are in the neutral position before starting the engine.
• Structural parts and crawler - carefully inspect boom, bucket and metal sheets; and check whether
crawler is bent, damaged or has missing parts.
• Fasteners: check if there are any loose or missing parts
• Fuel system: drain water or sediments out of the fuel tank.
• Hydraulic system: check for leakage, twisted hoses and pipelines, or rubbing between hoses and other
parts.
• Lubrication: inspect according to lubrication schedule and lubricating points.
• Protective devices: inspect safeguard devices and mud guards.
• Safety: keep surrounding people away from the machine and also remove obstacles.
Inspect driver’s cab before starting the engine
3-8 Operation
• Ensure that the safety lock lever is at

“Lock” position and all the control
levers are at neutral position.
• To check indicator lamps: turn the key
switch to START position, engine charg-
ing alarm indicator lamp and engine oil
pressure warning lamp will light up;
meanwhile, machine system will auto-
Figure3-10
matically test whether to preheat the
temperature; if it is necessary, the pre-
heating indicator lamp will light up.
• To adjust the seat, the best sitting posture should be that the driver, sitting on the seat and leaning to the
backrest, can depress foot pedals to the floor, push the control lever to the end, and is able to fasten the
belt.
Important: monitor displays machine's operating state. If the indicator lamp is faulty, when an
anomaly occurs, system will only give sound alarm. Therefore, if an indicator lamp is in fault, repair
it immediately. After inspection, if AC generator indicator lamp, engine oil pressure indicator lamp
won’t light up, and machine system doesn’t give sound alarm, suggesting that the machine is ab-
normal, at this time, repair it immediately.
To avoid bringing damage to monitor display, remember to use a wet cloth to wipe the monitor or
switches instead of sharp objects such as a screwdriver, which may scratch the display.
Start the engine
WARNING!
• Honk the horn before starting the engine, ensuring no person or obstacle is in slewing area.
• Don't touch any switch when starting the engine.
Operation 3-9
• Pull safety lock lever to LOCK position

• Turn engine rotation speed knob to low-
speed idle position.
• Honk the horn to alarm surrounding
people.
• Turn key switch to START (ON)
position.
Figure3-11
• Important: try to avoid damaging the starting motor. To avoid damaging starting motor, do not
exceed 10s each time you operate the start switch. If the engine fails to start, turn the key switch
to OFF position, wait for 30s and try again. After a start failure, it will damage the starting motor
if the operator directly turns the key to restart the motor without waiting for the motor comes to
a full stop.
• Once engine starts, immediately release the key switch and it will automatically return to “ON”
position.
• Don’t attempt to start the engine with short-circuit starter terminal.
3-10 Operation
Cold start
CAUTION!
• In cold winter, idle the engine for 8-10 minutes till water temperature rises to 40℃-50℃; besides,
it is necessary to inspect engine oil level and coolant level.
• Avoid long idling the engine in zero-load state (over 10 minutes). Idle the engine (1100 rpm - 1300
rpm) in cold weather will increase engine oil consumption, intensify abrasion and cause severe
damage; besides, the unburned tar and carbon will gather on valve guide and valve, choking the
valve and damaging the turbocharger.
Preheating after starting the engine
WARNING!
If any fault is found or improper operation is done, stop the engine immediately. Before work, help
the equipment reach its normal working temperature, this is especially important in winter.
Important: the most favorable working temperature of hydraulic oil is 50℃～70℃. If hydraulic oil
is below 30℃, excessive operation will severely damage hydraulic components. Before work, heat up
hydraulic oil to 25℃. After preheating the oil, don’t abruptly move the control lever nor increase
engine rotation speed; don’t run the engine in idle state or in high speed for 20 successive minutes.
Raise hydraulic system temperature in cold weather
Idle the engine in zero-load state for 5-10 minutes. Run the engine at moderate speed in zero-load state for
5-10 minutes. Pull safety locking lever to START; slowly move the lever and move boom, bucket rod and
bucket cylinder 5 times; time interval is 30s; the purpose is to circulate hydraulic oil without load.
CAUTION!
Don’t hold the pressure within the cylinder for over 20s.
Raise the entire working device, control the lever to slew the machine clockwise and counterclockwise
(separately) for 3times. Slew upper structure till it becomes vertical with chassis; support the machine with
bucket till crawler comes slightly off the ground.
Operate the walk control lever to forward and backward move the crawler of this side for 2 cycles, one at
low speed and one at high speed; after that, lower the crawler onto ground and then slew upper structure
till it becomes vertical with the other side of chassis; repeat the aforesaid operation.
Operation 3-11
Important: operate the machine with lower-than-usual load & speed till engine and hydraulic sys-
tem reach normal working temperature.
3-12 Operation
Start with booster storage battery (booster wire).
WARNING!
When battery is being used or charged, it will generate explosive gas. Therefore, flame or spark is
forbidden around the battery. Charge the battery at a well-ventilated place.
Be sure to wear protective goggles when starting a device with jumper.

Improper jumper start procedure will lead to explosion and cause personal injury.
It must be started on dry and hard ground. Don’t start it on steel plate ground as it is grounded.
When starting it by connecting with another device, ensure the two devices are not in contact.
To charge it, first connect the positive pole of the assistant battery to the positive pole of supply battery.
And then connect the negative pole of the assistant battery to the rack of supply battery.
To install the battery, first connect the positive wire; to remove the battery, first disconnect the negative
wire.
WARNING!
The voltage of this machine 24V, negative polarity grounded. Auxiliary start should be done by use
of a same-capacity 24V booster battery.
If the battery is supplying power when the machine is being started, please take following measures to
start the machine with auxiliary battery or booster battery.
Connect booster battery
• Shutdown the engine of the machine a

whose booster battery will be connected.
Red
• Connect one end of the red wire (a) to
the positive pole of excavator battery
and connect the other end of the red wire d
c
(a) to the positive pole (c) of booster
battery.
e
• Connect one end of the black wire (b) to Black
b
the negative pole of booster battery and
Figure3-12
connect the other end of the black wire
(b) to upper frame of the machine and
ground it (e). To connect to the upper
frame, be sure to keep away from the
storage battery as far as possible. Don’t
Operation 3-13
directly connect to the negative pole of
battery.
• Start the engine.
Disconnect booster battery
Remove the negative connection (b) of black wire from the machine frame.
Remove the other end of the negative connection (b) of black wire from booster battery.
Remove the positive connection (a) of the red wire from booster battery.
Remove the other end of positive connection (a) of the red wire from excavator battery.
Inspect the engine after start
Inspect engine water temperature, fuel level and engine oil pressure according to their corresponding in-
struments, indicator lamp and monitor.
After starting the engine, if following indicator lamps on the monitor won’t light up or if engine sound
and exhaust gas are strange, please immediately shut down the engine and trouble shoot. After starting the
engine, please confirm:
1. AC generator indicator lamp goes off.
2. Engine oil pressure indicator lamp goes off.
3. Engine gives out normal sound and exhaust gas.
Inspect the level gauge of hydraulic oil tank and ensure the level is within specified range.
Check whether fuel, engine oil or coolant leaks.
Important: The purpose of this inspection is to make sure that the engine won’t get damaged.
3-14 Operation
3.5 Running operation

Carefully drive the machine.
Important:
• In cold weather, place the machine on solid hard ground in case of freezing the crawler onto
ground. Remove impurities out of crawler, wheels and racks.
• If crawler is frozen to the ground, slowly lift the crawler with boom, carefully move the machine,
preventing drive wheel and crawler from bearing load, which may cause damage.
• If the engine abruptly stops under no-load state, please remove the load first, and then re-start
the engine.
• Try to find flat ground, operate the machine in a straight line as much as possible and try to avoid
changing of operation or direction.
• When walking on uneven ground, please slow down engine speed so as to reduce the risk of dam-
aging chassis.
Operation 3-15
Inspection machine walking direction
• Wrong operation on walk pedal/control

lever may cause severe casualty.
• Before operation, have a clear picture Guide roller
about the relationship between chassis Driver’s cab
position and operator’s position. If the
walking motor is at the front of the cab,
after pushing control lever or depressing
foot pedal, the machine will move
backwards.
Walking motor
Figure3-13
CAUTION!
Standard walking position should be: guide wheels
are in the front of the machine while walking motor
and drive wheels are at the back of the machine. If
the walking motor and drive wheels at in the front of
the machine, control of walk pedal will be reverse.
Before operation, be certain about positions of the
walking motor.
There is an arrow affixed on the side

frame of chassis, indicating the front direc-
tion of this machine.
Arrow sign
Figure3-14
The excavator should not make a continuous and long walk.
3-16 Operation
• The time the excavator takes to walk on flat, regular and soft ground should not exceed 2 continu-
ous hours; if it has to, the excavator should make at least a 20-minute stop before marching on;
• The time the excavator takes to walk on uneven and hard earth should not exceed 1 hour and the
operator must keep low walking speed; if it has to, then the excavator should make at least a 20-
minute stop before marching on.
WARNING!
Xugong Mining Machinery Co., Ltd. bears no responsibility for any damage caused by a long term
walk, as it violates this regulation.
Don't lift any passengers
• The passenger will easily get injured,

like being hit by objects or cast out of
the machine.
• Only the operator is allowed in this pas-
senger and any other passenger is
forbidden.
• The passenger may block operator’s
sight, which may cause problems. Figure3-15
Operation 3-17
Drive the machine with foot pedals
• Straight walk: move the two control levers or foot pedals towards the same direction to achieve a
straight walk.
Figure 3-16 Forward walk Reverse
• Left turn (forward): move forward the right control lever or the right foot pedal.
• Left turn (backward): move backward the left control lever or the left foot pedal.
Left turn (forward) Left turn (backward)

Figure 3-17
• Right turn (forward): move forward the left control lever or the left foot pedal.
• Right turn (backward): move backward the right control lever or the right foot pedal.
3-18 Operation
Right turn (forward) Right turn (backward)
Figure 3-18
• Pivot turn (spin leftward): move backward the left control lever or the left foot pedal, meanwhile, move
forward the right control lever or the right foot pedal.
• Pivot turn (spin rightward): move forward the left control lever or the left foot pedal, meanwhile, move
backward the right control lever or the right foot pedal.
Pivot turn (spin leftward) Pivot turn (spin rightward)
Figure 3-19
• Brake: when control lever, walk pedal are at neutral position, which means, when the control lever and
walk pedal are not operated (see C in the figure), walk brake will automatically stop the machine.
Operation 3-19
A
D
A C
B
D
C
B
Figure 3-20
Note: During a long journey, to rest the feet, the operator can place the feet on the protruding
parts (refer to D in the figure) of the pedals. To achieve smooth operation, an absorber has been
fitted on walk pilot valve. In cold weather, operating force will increase; in this case, the operator
can first pull the safety locking lever to its locking position (“LOCK”), and then operate the control
lever for several times.
CAUTION!
Roll-over will cause casualty accident. Don't frequently change the way of walking especially on a
descent, where, if the way of walking is changed to quick mode, it’ll cause very serious
consequences. Stop the machine before changing the way of walking.
Select a proper way of walking (fast/slow) by operating the switches on the monitor; each press will shift
the walking method.
1. High speed: indication icon changes to high speed icon.

2. Low speed: indication icon changes to low speed icon.
3-20 Operation
High/Low speed
indication icons
Figure 3-21
Operation notices
CAUTION!
In narrow areas, one signalman is required to assist the operator for moving, slewing or operating
the machine. The signalman should stand in front of the machine and give hand signals.
• Before moving the machine, the operator must be clear about how to operate walk pedals/control levers,
so as to move the machine towards correct directions. Walking motor is at the back of the machine, once
depressing the front part of the walk pedal, or pushing forward the control lever, the machine will move
towards the direction of guide wheels.
• Try to find a flat area, drive the machine in a straight line as much as possible and be sure to slightly
and gradually steer it.
• Before walk, inspect the bearing strength of the front road and bridge; consolidate it if necessary.
• To reduce damage to the road, remember to put wood plates on asphalt roads and then walk on the
plates in summer. Be careful with your drive.
• When crossing a rail road, remember to use wood plates so as to reduce damage to the rail.
• Don't let the machine touch any live wire or edges of a bridge.
Operation 3-21
• When crossing a river, the operator should measure the depth with the bucket; if river level is over the
upper edge of drive wheels, stop crossing that river.
• When walking on uneven ground, reduce engine speed and let the machine walk slowly, this will reduce
the possibility of getting damage.
• When the machine is walking, it may fall mud, rocks and metal objects on the surrounding area of the
machine. Don't let people linger there.
• When on a slope, the machine may slip or roll over and cause severe damage or casualty.
• When walking on an ascent or descent, the operator should arrange the bucket toward walking direction
and it should be 0.2 m～0.3 m off the ground (refer to A in the figure).
Figure 3-22
• Once the machine begins to slip or becomes unstable, lower the bucket immediately.
• Crossing a slope diagonally or steering the machine on a slope will cause side slip or roll over; instead,
the operator should arrive at a flat area and then cross the road or steer the machine.
Wrong
Figure 3-23
• Avoid operations that may damage crawler and chassis components.

• In cold weather, before loading and unloading the machine, be sure to clean the snow and ice from the
crawler in case it slips.
Operation on soft ground
• Avoid walking on ground surface without sufficient bearing capacity.

• If the machine works on soft ground or is stuck in the mud, after work, move it to solid ground and re-
member to clean the frame.
3-22 Operation
• Slew upper structure till it becomes vertical with frame and operate the working device so as to get one
side of crawler off ground (refer to “Lift One Side of Crawler off Ground with Boom and Bucket
Rod”)
• Remove the mud by rotating the lifted crawler forward and backward.
If the machine is stuck and engine can still can, operate the boom and bucket rod so as to get the machine
to solid ground, or tow the machine with other equipment, but be sure to correctly use towing rope (refer
to “Short-Distance Towing Machine”)
Lift single-side crawler with boom and bucket rod
CAUTION!
Keep the angle between boom and bucket rod within 90°-110°, and place the arc section of bucket
rod on the ground.
Lift the crawler off ground by rotating

upper structure by 90° or lowering the
bucket; place cushion blocks under chassis 90~
110°
frame to hold the machine.
Figure3-24
Short-distance towing machine
CAUTION!
As steel cable, belt or rope may possibly fracture and cause severe consequences, so it’s not
allowed to tow the machine with damaged chain, abraded steel cable, ring hook, belt or rope.
Always wear gloves during handling of steel cable, belt or rope.
When the machine couldn’t walk but the engine can still work, as shown in the figure, tie a towing cable
to another equipment so as to get the machine move to solid ground; make sure the steel cable must be
fixed on the chassis frame of both machines.
Operation 3-23
Correct Wrong
Wire rope
Shackle
Wire rope
Figure 3-25
Put some protective materials between chassis frame and steel cable to prevent abraded breakage of wire
rope.
3-24 Operation
Important:
1. Before towing, be sure to unlock walking motor; otherwise, the machine will be severely
damaged.
2. Don’t tow the machine through the ring on chassis frame, which is fit for lightweight objects.
(Refer to How to Use Towing Eye).
Operation in water or muddy water
Only when site foundation has sufficient bearing capacity to prevent the machine from sinking (sinking
amount is over upper edge of drive wheels), can the machine work in water (water level should be below
upper edge of drive wheels, refer to A in the figure below).
Figure 3-26
When operating the machine in this kind of environment, be sure to regularly inspect the machine; if nec-
essary, adjust the position of the machine.
Try not to immerse slewing bearing, slewing reduction gear and central joint body.
If slewing bearing, slewing reduction gear and central joint body are immersed in water, be sure to remove
drain valve to clean the muddy water, clean slewing area and reposition the plug; after that, lubricate slew-
ing gears (big and small gears).
Gear oil amount of slewing reduction gear: B
Parameter
Model
A B
XE750G/XE800GA/XE750D/XE800D 1200mm 75 L
Lubricate slewing bearing (refer to Lubrication, Maintenance and Repair.)
Operation 3-25
3.6 Working operation

Control lever (ISO standard backhoe)
WARNING!
Don’t extend any part of your body out of the cab. If you accidentally collide with or touch the
right control lever, your arm will be injured. If window is lost or damaged, immediately repair or
replace it.
• Before operation, be familiar with position and function of every control lever for prevention of person-
al injury due to accidental move of the machine.
• This machine has signs affixed on the right window glass, indicating how to operate control levers and
foot pedals.
Important: when excavating, try to prevent boom cylinder from bumping into crawler. When dig-
ging at crawler side, remember to put drive wheel at the back of machine, so as to increase machine
stability and enhance its performance.
This machine has signs indicating how to operate control levers and walk pedals. Once released, the con-
trol lever will automatically return to neutral position, and then, the machine stops.
1 5
4 3 7 8
2 6
Figure 3-27 Joystick layout
3-26 Operation
4 6
1
3
2
7
5
8
Figure 3-28
No. Movement No. Movement

1 Extend bucket rod 2 Retract bucket rod
3 Right slewing 4 Left slewing
5 Lower the boom 6 Raise the boom
7 Retract the bucket 8 Outward sway bucket
CAUTION!
To start working, slowly move the control lever, inspect the working device and observe slewing
movement.
The control lever structure is in line with ISO standard; don’t change any parts like valves and
electrical wires, which may change the standard setting. There is a joystick operation instruction
sign affixed on the right glass of cab.
Control lever (user defines the operation mode)
The driver can set a different working mode according to habit.
WARNING!
• The default mode for customized operation is prohibition state, if you need to change it, please
contact Xugong Mining Machinery dealers.
• To change the default operation mode, all drivers must fully understand the new customized op-
eration mode and confirm that they will follow it; after that, the new operation sign must be af-
fixed on the original ISO sign to replace it.
• Xugong Mining Machinery Co., Ltd. bears no responsibility for any device damage, personnel
death caused by failure to follow the above-stated regulations.
Operation 3-27
CAUTION!
Never extend any part of your body out of window frame. Accidental touch of the control lever
may injure you. If the window is lost or damaged, replace or repair it. Before operation, be
familiar with the position and function of every control lever.
3-28 Operation
The relations between slewing direction of boom, bucket rod and bucket and control levers are as below:
• Left control lever
1. Extend bucket rod
1
2. Retract bucket rod

4 3
3. Right slewing
4. Left slewing 2
Figure3-29
CAUTION!
Slewing brake function is realized by spring and released by hydraulic power. When control
levers are at neutral position or when the engine stops, the machine will keep braking.
CAUTION!
Slewing brake function is realized by spring and released by hydraulic power. When control
levers are at neutral position or when the engine stops, the machine will keep braking. The pause
phenomenon of a moving bucket rod is not a machine failure. When bucket rod is moving,
accelerated self weight will lead to insufficient oil supply.
• Right control lever

5. Lower the boom 5
6. Raise the boom

7 8
7. Load the bucket
8. Dump the bucket

6
Figure3-30
Operation 3-29
CAUTION!
The button on right control lever is possibly reserved for an accessory device; when no accessory to
be fitted, pressing the button will not trigger any reaction, but that doesn't mean there is no
pressure in the pipeline of that equipment, so be careful with your operation.
3-30 Operation
Safety lock lever
When leaving operator’s seat or entering

the cab, the operator may accidentally
touch the control lever; to prevent this from
happening, a safety locking lever is thus
designed. 1
1-Safety lock lever activation

Figure3-31
CAUTION!
• Always pull safety lock lever fully locking position; otherwise, it will not work.
• Before leaving the machine, first stop the engine and then pull the safety locking lever to locking
position (LOCK).
• Under following circumstances, always check the safety locking lever and ensure it has been
pulled to locking position (LOCK).
Vehicle being transported;
When leaving the machine after work.
Operation about safety locking lever
• Before leaving the machine:

• Place the machine on solid flat ground, lower the bucket onto ground and pull all the control levers to
neutral position, and then correctly shut down the engine.
• Before starting the engine: ensure that the safety locking lever is at locking position.
• After starting the engine: ensure all the control levers and foot pedals are at neutral position, and no any
part of the machine is still; and then pull safety locking lever to unlocking position.
• When all the control levers are at neutral position and the safety locking lever is at unlocking position,
if any part of the machine is moving, meaning that the machine is in fault. On this occasion, immedi-
ately pull the safety locking lever to locking position, stop the engine and trouble shoot or contact
XCMG authorized dealer.
Operation 3-31
Engine speed controller
As shown in the figure, the engine rotation

speed knob on right control box is designed
Low High
to increase or decrease engine speed. speed speed
• Turn the knob clockwise to increase en- 1

gine speed; turn the knob counterclock-
wise to decrease engine speed.
2
• Before putting the engine to stop, always
turn the knob counterclockwise to the
end (low-speed idling), run the engine 1- Key switch 2- Engine rotation
speed knob
for 5 minutes, cool it down, and then
Figure3-32
turn engine key switch to “OFF” posi-
tion so as to stop the engine.
Note: For every working mode, the engine can only run to the highest setting speed of that mode.
Automatic idle speed
In automatic idling state, if all the control levers return to neutral position, it will take about 4 minutes be-
fore engine speed reduces to the automatic idling speed, which will reduce fuel consumption. If any con-
trol lever moves, engine will immediately accelerate to the setting speed of rotation speed knob.
CAUTION!
For some machine types, the automatic idling function is off by default, if you need to activate it in
order to better operate this machine, please turn it on. Please contact the dealer of Xugong Mining
Machinery Co., Ltd.
CAUTION!
Always check the indicator lamp of auto idling state before operation. If the indicator lamp is off,
meaning that the automatic idling function is off work. If the indicator lamp is on, meaning that
the automatic idling function is at work.
• Auto Idling On: auto idling speed indicator is on.

• Auto Idling Off: auto idling speed indicator is off.
3-32 Operation
• When auto idling function is on, you can press Auto Idling Off to deactivate this function.
• When the engine is restarted, auto idling function will restore to default state.
Working mode
By turning the knob, you can change to the desired shift position and its corresponding working mode.
See the figure below for the relation between working mode and shift position:
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
Gear
gear gear gear gear gear gear gear gear gear gear
Mode L S H
• Mode S (standard excavation mode)

This mode gives prior consideration to fuel consumption and is used for general operation. Under this
working mode, Mode S indicator lamp comes on.
• Mode L (light-load excavation and ground leveling mode)
Reduce engine speed, but digging force is kept the same with Mode S. Although output is slightly lower
than Mode S, both fuel consumption and noise are reduced, and is used for light-load works, like level-
ing ground. Under this working mode, Mode L indicator lamp comes on.
• Mode H (forced excavation mode)
Mode H is used for short-time hard ground digging. Under this mode, the excavator can exert its maxi-
mum power and increase working efficiency. Under this working mode, Mode H indicator lamp comes
on.
Note: When the machine is started at throttle 1, the default mode is L.
Backhoe operation
• Operate the bucket to form 45° between

bucket bottom and the ground, and then
place bucket tooth on the ground.
• Use bucket rod as the major digging
force to pull the bucket towards the
machine.
Figure3-33
• When bucket is covered with mud,
quickly move bucket rod and (or bucket)
backward and forward to get rid of the
mud.
Operation 3-33
• When to dig a straight ditch, first make
the crawler parallel to the ditch. And
then when digging a desired depth, move
the machine and keep on digging as
needed.
Important: when lowering the boom, try not to cease abruptly. Otherwise, the impact load gener-
ated from the sudden stop may damage the machine. When operating the bucket rod, try not to ex-
tend bucket-rod cylinder to the end for prevention of damaging the cylinder. When digging the
ground from one fixed angle, avoid collision between bucket tooth and crawler. When digging a deep
ditch, prevent the boom or bucket cylinder hose from bumping the ground.
Leveling operation
Important: don’t push mud with bucket while walking.
To level the ground as shown in the figure:

firstly, place the bucket rod a little ahead of
vertical position and turn the bucket back;
secondly, slowly raise the boom while re-
tracting the bucket rod; once the bucket rod
moves away from the vertical position,
Figure3-34
slowly descend the boom, keeping the
bucket in a stable plane motion. By operat-
ing the boom, bucket rod and bucket simul-
taneously, operator can make leveling
operation more accurate.
Operative skills
• Don’t take walking motion as extra digging force; otherwise, the machine will be damaged.
Wrong Wrong
Figure 3-35
• Don't lift the rear part of machine off ground, taking machine weight as extra digging force; otherwise,
the machine will be damaged.
3-34 Operation
错
Wrong Wrong
Figure 3-36
• Don’t clash the bucket with crawler during digging operation; instead, try to park the machine on level
ground. Don’t use the bucket as a hammer or piling machine, nor attempt to rotate in order to remove
rocks and break walls.
Important: To avoid damaging hydraulic tank, don’t hit the bucket on the ground or compact
the ground when bucket cylinder is fully extended (bucket is fully retracted).
• Before every excavating work, remember to adjust digging length and depth so as to fully load the
bucket and increase rapid cycle yield. To increase productivity, full bucket is more important than
speed.
• Once a trench has been dug up, the operator can dig out rocks from soil layer by pulling up the bucket;
first remove the top soil layer, gradually go deeper and remove one or two layers; don't subject the
bucket to side load, nor attempt to level materials by rotating the bucket or impact objects from side.
Important: don’t attempt to fully extend bucket rod and drop the bucket, trying to penetrate
the ground with bucket tooth and then dig rocks, such an operation will severely damage the
machine.
• When driving out of water, machine inclination should be lower than 15°; don’t immerse the ma-
chine into deep water (normally, water depth cannot exceed the upper edge of carrier wheel). Lubricate
long immersed components with grease till the old grease is squeezed out.
Select a proper track shoe
Important: the track shoe will bend and bolts will become loose when walking on uneven road sur-
face; other chassis components may be damaged too.
Don't use wide track shoe on rocks, sands or chippings, as the wide track shoe is designed for use on soft
ground; regularly check tightness of bolts.
How to use towing eye
There are two towing eyes forged on chassis frame, intended to tow objects with following weight.
Important: When towing materials with the towing eyes on chassis frame, be sure to confirm follow-
ing restrictions and notices; otherwise, the chassis frame and (or) towing eye might be damaged.
Operation 3-35
Max. traction: 100 KN. Towing eye

Chassis frame
Be sure to use the towing eye.
Keep the towing direction the same

with crawler’s.
Wire
Select slow walk mode when the ma-
chine is being towed.
Shackle
Figure3-37
Operation notices
CAUTION!
Inspect the ground of jobsite before starting work.
• If there might be falling rocks on the job-

site, be sure to install a protective device
for the cab.
• If the ground of jobsite is soft, consoli-
date it before work.
• Wear personal protective articles like
tight clothes and helmet when operating
the machine.
• Keep other staff out of operating range
and clear away obstacles. Keep on the
alert to the surroundings during opera-
tion; when working in a narrow area sur-
Figure3-38
rounded by obstacles, be careful not to
bump into the obstacles.
• To load materials on a truck, remember
to raise the bucket over truck compart-
ment from back side of the truck and
3-36 Operation
don’t move the fully loaded bucket

over truck cab or any people.
• Before operating the machine, first fence the slewing radius of machine and stop irrelevant staff from
entering.
Safe operation
CAUTION!
Take measures to prevent roll-over and against ground collapse.
Notice following items:

• Ensure jobsite ground has sufficient bearing capacity and is able to support the machine. When working
near a ditch or on road shoulder, in order to prevent walls from collapsing, crawler should be vertical to
wall surfaces and walking motor should be at the back of the machine; this operating method will help
the machine evacuate immediately.
• If it’s necessary to operate on cliffs or beneath a high bank, be sure to first inspect the working area
and confirm there is no risk of collapsing. If it’s dangerous to work there, then stop the work.
• Working on soft ground may tip over the machine as the ground may collapse. Solidify the soft ground
by putting large steel plates on it before working.
• When working on uneven ground or slopes, to prevent tip-over accident, following measures can be
taken:
1. Reduce engine rotation speed.
2. Select slow walk mode.
3. Slowly operate and focus on machine motion.
Prevent falling rocks and rubble
If a working area is subject to falling rocks

or rubble, ensure the machine has FOPS
(Falling Object Protective System).
Figure3-39
Operation 3-37
Safely move and operate the machine
When moving and operating the machine, surrounding people may be knocked down, please pay attention
to following tips:
• Be extremely careful not to hit the peo-

ple around the machine; the operator
must be aware of the situation before
moving, rotating or operating the
machine.
• Always keep walking alarm and horn in
working state. The alarm and horn may
give out sounds and warn the people Figure3-40
around the machine when starting work.

In narrow areas, one signalman is re-
quired to assist in moving, slewing or
operating the machine. The signalman
should stand in front of the machine and
give hand signals.
• Uniform the hand signals for multi-ma-

chine operation.
When more than one excavator is work-
ing, ensure all operating workers know
the Designate one signal man to organize
the work and ensure all others obey his
command.
Figure3-41
• Take measures to prevent accidents that may be caused by reversing and slewing operations.
When reversing or slewing the upper structure, if someone is near the machine, he will be knocked
down or crushed, causing severe consequences. Following measures can be taken to prevent accidents
caused by reversing and slewing operations:
3-38 Operation
1. Before reversing or slewing the ma-

chine, take a look around the machine
and confirm there is no person stand-
ing near the machine.
2. Always keep walking alarm and horn

in working state. Keep on the alert to
working area and ensure no one is ap-
proaching; before moving the ma-
chine, honk the horn or send an
acoustical signal to surrounding
Figure3-42
people.
3. If your sight is blocked when revers-

ing the machine, please ask a signal-
man for help.
4. Always keep the signalman within

your scope of sight and use local hand
gestures.
5. Only when both the signalman and the

operator clearly understand the signal
can the operator start moving the
machine.
6. Understand the implications of flags,

signals and marks used in the work
and make certain who is the one re-
sponsible to send the signal.
7. Always keep window & door, rear-

view mirror and lamps clean and
Figure3-43
intact.
8. Visibility is always reduced in dusty,

rainy and foggy environment. When
visibility is reduced, the operator
should slow the machine and turn on
lighting lamps.
9. Read and understand all operation

rules specified in this manual.
Operation 3-39
• Never place the bucket over anybody.

Never raise, move or rotate the bucket
over any person or any truck cab. If ma-
terials fall off the bucket, or bumps the
bucket, very severe injury or damage
will result.
Staff will be injured or machine dam-
aged if the bucket bumps into another Figure3-44
bucket.
• Avoid bottom cut.

To ensure successful evacuation from
collapsing ground, the walking motor
should always be arranged behind, and M
the chassis should be vertical to the edge
of trench. If in a situation that the ground
starts collapsing and the machine fails to
evacuate, on this occasion, the operator
should keep himself composed and low-
er down the working device so as to sta- Figure3-45
bilize the machine.
• Prevent tip-over
Don’t attempt to jump out of the tilting
machine; otherwise, severe or fatal
crushing injury will result. As toppling
speed of the machine is faster than your
jump, therefore, be sure to buckle up the
seat belt during operation. Figure3-46
Figure3-47
3-40 Operation
The machine is always at risk of rolling over when operating on a slope, may cause severe casualty acci-
dents. To prevent roll-over, the operator must be extremely aware of following tips:
1. Level the working area of jobsite;
2. Lower the bucket to ground and keep it near the machine.
3. Reduce operating speed in order to prevent roll-over or slip.
4. Avoid steering when walking on a slope.
5. If it’s inevitable to cross a slope, remember not to cross one whose gradient is over 15°.
6. Reduce slewing speed when rotating a loaded bucket.
7. When operating on a frozen area, the ground will soften as the temperature rises, which will put the ma-
chine in an unstable condition.
• Never undercut a high bank.

Raising bank bottom will cause collapse
of bank edge or landslide, leading to se-
vere consequences.
Figure3-48
• Be cautious with excavation.

Accidental cut of underground cable or gas pipe may cause explosion, fire accidents, resulting in severe
casualty accidents.
1. Check positions of underground ca-

ble, gas pipe and water pipe before
excavation.
2. Keep at least a legal distance with

underground cable, gas pipe and water
pipe.
3. If fiber cable is accidentally cut off, Figure3-49

don’t look at the end of fiber able;
otherwise, your eyes will be seriously
impaired.
4. Please straight contact local author-

ities to mark the positions of under-
ground pipelines.
Operation 3-41
• Don’t get working device interfere with machine body.
1. When equipped with a lengthened bucket rod, if the bucket is close to the machine, the bucket rod
may interfere with the machine. Be careful of operating the lengthened bucket rod.
2. When digging diagonally, if boom is fully lowered, it will interfere with the machine. Be careful of
operating the boom.
• Operation notices
1. If the front working device, or other
front parts, bumps into overhead ob-
jects like an overhead bridge, both the
overhead object and the machine will
get damaged, and it may possibly in-
jure the operator.
2. Try to prevent boom or bucket rod

from bumping into overhead objects. Figure3-50
• Avoid power transmission line

1. If the front working device, or other
front parts, bumps into overhead ob-
jects like an overhead bridge, both the
overhead object and the machine will
get damaged, and it may possibly in-
jure the operator.
2. When operating the machine near high

voltage lines, never approach any part
or load of the machine within a dis-
Figure3-51
tance of 3m + 2 times of line insula-
tor’s length.
3. Check and obey all the applicable lo-

cal regulations.
4. Working in wetland will increase the

possibility of being injured by electric
shock, so surrounding staff must stay
away.
• Carefully drive the machine.
3-42 Operation
Important: In cold weather, place the machine on solid hard ground in case of freezing the ma-
chine onto ground. Clean the chippings off the crawler and chassis frame; if the crawler is frozen
to ground, raise the crawler off ground with boom and bucket rod in case of damaging drive
wheels and the crawler.
1. Try to find a flat ground zone, operate the machine in a straight line as much as possible and try to
avoid changing of operation or changing of direction.
2. When walking on uneven ground, please slow down engine speed so as to reduce the possibility of
damaging chassis.
Operation 3-43
3.7 Shutdown operation

Steps to stop the engine
• Place the machine on flat ground.

• Lower the bucket on ground.
• Turn engine rotation speed knob to low-
speed idle position and keep it running
for 5 minutes in order to cool it down.
Important: If engine shutdown proce-
dure is incorrect, turbocharger might
be damaged.
• Turn engine key switch to position Figure3-52
“OFF” and stop the engine.
• Extract engine key switch.
• Always pull safety locking lever to lock-
ing position.
Important: In bad weather, take measures to protect electric components of the cab. After parking
the machine, shut down window, skylight and cab door.
• Shut down windows and cab door.
• Lock up all access doors and cabinet doors.
WARNING!
• Do not immediately shut down the engine after the machine finishes an on-load running. If you
immediately stop the engine, you may cause engine components overheated and accelerated
wear.
• After parking or applying the parking brake, you should allow the engine to slowly idle for 5
minutes before it comes to a halt. Running the engine can help the heated zone gradually cool
down.
• When engine shuts down, exhaust gas temperature will exceed the threshold, at this moment,
the Delay Engine Shutdown will work. The Delay Engine Shutdown function will work at least
5 minutes till the whole engine and system components cool down. At this time, do not turn off
main power switch.
3-44 Operation
Prevent machine out of control
If you attempt to climb on or block a mov-

ing machine, you may get fatally injured.
In order to prevent machine out of

control:
• Park the machine on level ground.
• Never place the machine on slopes. Figure3-53
Notices against theft
• If the machine will be left unattended, shut the door and remove all keys in advance.
• Shut all doors and covers after work.
• Park the machine in a safe place.
• Don’t leave valuable stuff like phone and wallet in the cab.
Park the machine on a slope
If you have to park the machine on a slope:
Park it at a proper distance from other CAUTION!

machines.
Don’t park the machine on a slope as it may roll
Lower the bucket and (or) other work- over and cause personal injury.
ing devices on the ground.
Insert the bucket tooth in the soil,

place two cushion blocks under crawlers to
stabilize the machine in case of rolling
away.
Idle the zero-load engine for 5 mi-

nutes to cool it down. Figure3-54
Stop the engine and extract the key.
Always pull safety locking lever to

locking position.
Shut down windows and cab door.
Operation 3-45
Lock up all access doors and cabinet

doors.
Inspect after stopping the machine
• If coolant or oil leaks, repair it.

• Inspect and trouble shoot front working device and chassis.
• Replenish fuel.
• Remove flammables accumulated on the engine, like leaves and paper.
• Remove the mud stain from crawler and chassis and ensure foot pedals, control levers and the cab are
always kept clean.
Notices on midnight shutdown
• After finishing work of the day, park the

machine on solid level ground instead of
somewhere with falling rocks and likely
collapse or flood.
• Fill up the fuel tank.
• Clean the machine.
• In winter, if the machine doesn’t have
antifreeze or long-life coolant, please 散热器
无水
drain out the water from radiator and en-
gine. After draining the water, put a tag
on a conspicuous place writing “no Figure3-55
water in radiator”.
3-46 Operation
3.8 Fuel and liquids refilling procedure

Fuel system
Recommended fuel grades
Table 3-1 Recommended fuel grade
Time of application Fuel

General 0# （4℃以上）
Winter -10# （-5℃以上）
Cold regions -35# （-29℃以上）
WARNING!
For XE750G/XE800GA, the sulphur content of applicable diesel must be below 0.0015% (mg/kg)
(15PPM). For this type of machine,if sulphur content of applicable diesel is over 15PPM, engine
exhaust control system will be impaired or permanently damaged.
• The fuel for XE750G/XE800GA must confirm to following regulations:

Acceptable fuel specifications for XE750G/XE800GA
Diesel standard Remarks
GB 17691 Chinese vehicle diesel, must accord with VI level.
EN590 Diesel Engine Road Vehicle
ASTM D975 （1D North America Light Diesel, sulphur content must be below 15PPM
S15level）
ASTM D975 （2D North America Moderate Universal Diesel, sulphur content must be
S15level） below 15PPM
JIS K2204 Japan Diesel, must accord with lubrication requirements specified
in Engine Operation Maintenance Manual.
BS 2869: 2010levelA2 or EU off-road diesel. Sulphur content of the diesel for 2011 must be
EU equivalent oil below 10PPM.
Note: the fuels above are recommended, please base on the requirements of Engine Operation
Maintenance Manual.
• For XE750D/XE800D, prohibit using diesels whose sulphur content is above 0.2% (mg/kg)
(2000PPM).
Operation 3-47
For XE750D/XE800D, recommend using diesels whose sulphur content is below 0.05% (mg/kg)
(500PPM). For this type of machine, if sulphur content of applicable diesel is over 500PPM, en-
gine internal components may be corroded, which will largely reduce the replacement cycles of
engine oil and oil filters.
• Xugong Mining Machinery bears no responsibility for any failure or damage caused by use of un-
qualified diesels.
Fuel tank capacity
Table 3-2 Fuel tank capacity table
Model Fuel tank capacity

XE750G/XE800GA/XE750D/XE800D 925L
Filling method

• Low speed idle the engine for 5 minutes.
• Stop the engine and extract the key switch.
• Pull safety locking lever to locking position.
CAUTION!
Dispose fuel with discretion. Turn off the engine before adding fuel; Smoking is forbidden when
filling up fuel tanks or when fuel system is in running state.
Inspect fuel level gauge or the fuel meter on the monitor display. Add fuel if necessary.
Important: Prevent dirt, dust, water or other impurities from entering fuel system.
• To prevent condensation, fill fuel tank after closing the day. Don’t spoil fuel on the machine or
ground; don’t let fuel exceed specified level.
• After adding fuel, recap the fuel tank. Lock the cap with key for prevention of loss or damage.
Diesel Exhaust Fluid (DEF) system
DEF tank capacity
3-48 Operation
Model DEF tank capacity

XE750G/XE800GA 47.2L
WARNING!
• DEF (commonly known as vehicle AdBlue liquid) must accord with GB29518.
• DEF storage requirements:
1. Ambient temperature: -5℃～25℃
2. Keep in dark place
3. Store in an airtight container
4. Touch surface is clean
• As ambient temperature plays a crucial role on DEF life span, please use the DEF within expiry
date.
qualified or expired DEF.
Hydraulic system
Recommended hydraulic oil grade and name
Table 3-3 Hydraulic oil grade and name
Supplier -30～40℃ -20～40℃

Special oil of Xuzhou Xugong Mining Special oil of Xuzhou Xugong Mining
XCMG Machinery Co., Ltd. Machinery Co., Ltd.
（S2 VX 32）（S4 CX 10W）
Remarks Anti-wear hydraulic oil
Hydraulic oil refilling volume
Table 3-4 Hydraulic oil refilling volume table
Model Hydraulic oil tank capacity Hydraulic system

capacity
XE750G/XE800GA/XE750D/XE800D 500L 660L
Operation 3-49
CAUTION!
As to the refilling volume, refers to the amount required to refill hydraulic oil system after the
procedure specified in “Maintenance and Repair - Replacement of Hydraulic Oil” is completed.
WARNING!
Xugong Mining Machinery bears no responsibility for any failure or damage caused by use of
unqualified hydraulic oils.
Engine oil
Recommended engine oil grade and name
Table 3-5 Engine oil grade and name
Supplier -20～30℃ -10～40℃

Special engine oil of Xuzhou Xugong Mining Machinery Co., Ltd.
XCMG
SAE 10W-30 SAE 15W-40
API CK-4
XE750G/XE800GA
Remarks ACEA E9
XE750D/XE800D API CI-4
WARNING!
• API FA-4 is used for road vehicles, and shall not be used for non-road vehicles; do not apply API
FA-4 to this machine.
• Do not apply following oils to XE750G/XE800GA engines: CC, CD, CD-2, CF-4, CG-4, CH-4,
CI-4 and CJ-4, etc.
Do not apply following oils to XE750D/XE800D engines: CC, CD, CD-2, CF-4, CG-4 and CH-4,
etc.
qualified engine oils.
Filling amount
3-50 Operation
Table 3-6 Engine oil refilling volume table
Model Engine oil filling amount

Gearing device
Recommended gear oil grade and name
Table 3-7 Gear oil grade and name
-10～45℃
Supplier
Walking reducer Slewing reducer
Special gear oil (90#) of Xuzhou Xu- Special gear oil (140#) of Xuzhou Xu-
XCMG
gong Mining Machinery Co., Ltd. gong Mining Machinery Co., Ltd.
Remarks API GL-5
Filling amount
Table 3-8 齿轮油加注容量表
Model Parameter
Walking reducer Slewing reducer
XE750G/XE800GA/XE750D/XE800D 15L×2 10.5L×2
WARNING!
unqualified gear oils.
Cooling system
Recommended coolant
Table 3-9 Coolant grade and name table
Supplier -45℃
Special coolant of Xuzhou Xugong Mining Machinery
XCMG
Co., Ltd.
Operation 3-51
Filling amount
Table 3-10 Coolant volume table
Model Coolant volume

WARNING!
unqualified coolants.
CAUTION!
1. Antifreeze is toxic. Swallowing antifreeze will cause severe casualty accident. Once eaten by
mistake, it will cause vomit. Please go to hospital immediately.
2. Antifreeze should be stored in an airtight container with conspicuous marks and should be kept
out of the reach of children.
3. If antifreeze accidentally enters into eyes, rinse with water for 10-15 minutes and go to hospital
for emergency treatment.
4. Observe local regulations for storage or disposal of antifreeze.
3.9 Other operation procedures

Safety regulations on lifting operation (optional)
WARNING!
The excavator doesn’t have a lifting function and it’s very dangerous to lift objects; principally,
it’s forbidden to lift objects with an excavator.
Notes:
3-52 Operation
• Obey local regulations when lifting ob-

jects with an excavator. As steel cable,
belt or rope may possibly fracture and
cause severe consequences, so it’s not
allowed to lift with damaged chain,
abraded steel cable, belt or rope. Objects
must be lifted slowly and cautiously oth-
er than abruptly; neither lift loads over
head nor allow people to approach the Figure3-56
loads.
• To lift objects like round log, the ma-
chine must be equipped with a front pro-
tective device; if there is a potential risk
in this operation, a top protective device
is also required.
• Ensure all the people stay away from the lifting site when the load is being lifted or when it's still on the
ground being fastened by a steel cable until cushion blocks must be put under the load or the machine
must place stably the load on the ground.
• Reposition the upper structure and make walking motor at the back of the machine. Don’t link sling/
chain on bucket tooth; otherwise, the tooth may come off and the lifted object may fall.
• Be sure not to be entangled by the sling.
• Don’t lift or raise a rated weight in strong wind. When the object has a large surface area, watch out
for any gust of wind.
• Wear gloves and strap the object with sling or chain.
• Swing the bucket and retract bucket rod and then connect the sling or chain with bucket hoop; before
start, coordinate with the signalman on hand signals.
• Be clear about the position of each staff member on the working area.
• Connect an inhaul cable on the load and keep away from the dragger.
• Try the weight of load before lifting operation, and then lift it (refer to “Safety - Safe Operation - Ele-
vating Capacity Table”).
• Lift the load 50 mm off the ground or to a desired height.
• Swing the bucket so as to bring the load to one side.
• Keep the load close to the ground and then move it away from machine.
• If the machine starts to lose balance, immediately lower the load onto the ground.
Operation 3-53
3.10 Fire safety operation procedure

Safe disposal of liquid
• Dispose fuel discreetly, because it’s highly flammable. If fuel burns, it will cause explosion and fire
accidents, which will further lead to casualty.
1. Don’t refuel the machine when

you're smoking, or when there are
open flames or sparks are around.
2. Engine must be stopped before refu-

eling the tank.
3. Refuel the machine outdoors.

Figure3-57
4. Static can produce electric sparks near
oil nozzle. When it’s cold, dry or
easy to generate static, in order to
keep grounded, ensure oil nozzle is al-
ways connected with fuel pipe.
• All types of fuel, majority of lubricants and some coolants are flammable.
1. Store flammable liquids in a safe place where there is no fire risk.
2. Don’t burn or puncture pressure vessels.
3. Don’t store oil-stained cloth as they may be lit up or spontaneously burn.
4. Screw down covers of fuel tank and other liquids; don’t start the equipment before tightening the
cover up.
Fire prevention
• Inspect fuel leakage: fuel, hydraulic oil and lubricants may leak and cause fire.
3-54 Operation
1. Inspect whether pipe clips are loose

or lost, whether hoses are kinked,
whether pipes rub each other, whether
oil cooler is damaged, or flange bolt
of oil cooler is loose, which may
cause oil leakage.
2. Tighten, repair or replace pipes, clips,

oil cooler, flange bolt of oil cooler that
is lost, loose or damaged. Figure3-58
3. Don’t bend or knock high-pressure

pipelines
4. Don’t install bent or damaged pipes

or hoses.
• Inspect if there is any short circuit: as it may cause fire accidents

1. Clean and fasten all electrical connections.
2. Before work or after a work period of 8-10 hours, check if cables and wires are slackened, kinked, be-
come hard or crack.
3. Before work or after a work period of 8-10 hours, check if terminal covers are lost or damaged.
4. If cables or wires are found slackened or kinked, don't operate the machine.
• Clean flammables: splashed fuel, hydraulic oil, antifreeze, washing liquid, waste, lubricating grease,
chips, deposited slack coal and other flammables may cause fire. Inspect and clean the machine every
day, remove splashed or deposited flammables in time for prevention of fire accidents.
• Inspect engine key switch: when a fire accident occurs, if the engine fails to stop running, the fire may
become worse, which makes fire fighting difficult. Before operation always inspect the function of key
switch:
1. Start and idle the zero-load engine.
2. Turn engine key switch to OFF position, confirming that the engine has stopped.
3. Be sure to fix any anomaly before operating the machine.
• Inspect engine emergency shutdown switch (if equipped, for option): when a fire accident occurs, if the
air in hydraulic tank couldn’t get released, it will intensify the fire and make fire fighting harder. In-
spect the function of engine emergency shutdown switch at an interval of 250 hours.
1. Start and idle the no-load engine.
2. Press engine emergency shutdown switch.
3. Confirm that the engine has stopped, in the meanwhile, the pressurized air in hydraulic tank has been
released (air exhausting sound can be heard).
Operation 3-55
4. Be sure to fix any anomaly before operating the machine.
• Inspect thermal insulation cover: a damaged or lost thermal insulation cover may cause fire accident. If
the thermal insulation cover is damaged or lost, be sure to repair or replace it before operating the
machine.
Evacuate from a fire emergency
• Under the a fire accident evacuate the

machine by taking following measures:
1. If time permits, turn engine key switch
to OFF position, confirming that the
engine has stopped.
2. If time permits, use a fire extin-
Figure3-59
guisher to put out the fire.
3. Evacuate the machine.
• If cab door or front window fails to open
under emergencies, please crack the
front rear window with crushing hammer
and evacuate from the cab.
Be cautious about exhaust gas
Be cautious about exhaust gases for pre-

vention of suffocation. Engine exhaust gas
may cause disease or death. If the machine
has to work within a building, be sure to
ventilate the space. Use a lengthened ex-
haust pipe to vent the gas or smoke; or
open cab window and bring in fresh out- Figure3-60
door air.
Welding and grinding notices
• Before welding, be sure to disconnect plug-in connectors from controllers.

• Welding may produce gas and flame, therefore:
3-56 Operation
1. Conduct the welding in a well-venti-

lated and fully prepared space. Before
welding, transfer flammables to a safe
place.
2. Only certified welders can do the

Figure3-61
welding; unqualified workers are
strictly forbidden to do the welding.
• Grinding the machine may produce sparks; before grinding, be sure to move all flammables to a safe
place.
• After welding and grinding, re-check if weld area has smoke or other anomaly.
Avoid heating near high-pressure hydraulic pipe
Heating near high-pressure hydraulic pipes may produce flammable spray, which may severely scald you
and surrounding people.
1. Don’t weld or use gas torch near high-

pressure hydraulic pipes or other
flammables.
2. When heat accumulates to a certain de-

gree, high pressure hydraulic pipe will
be cut off at any time. When conducting
Figure3-62
welding work, remember to set tempo-
rary fire-retardant shield sleeves in order
to protect hoses and other materials.
Avoid heating pipes that contain flammable fluids
• Don’t weld or gas-cut pipes or hoses that contain flammable fluids.

• Before welding or gas cutting pipes, eliminate flammable fluids with incombustible solvent.
Remove paint coatings before welding or heating work
• Paint, after being welded or heated by gas torch, will produce toxic gas, and inhaling the gas will cause
nauseous.
• Prevent generation of potential toxic gas and dust.
• To remove the paint, first find a well-ventilated place or do it outdoors.
• Remove paint coatings before welding or heating work.
Operation 3-57
• If using sand paper or grinding wheel to remove paint, please wear a respiratory protective device to
avoid inhaling dust.
• If using solvent or paint remover, please clean paint remover with soap and water before welding. Re-
move solvent, container of paint remover and other flammable objects and spend at least 15 minutes in
dissipating the volatile gas before conducting welding or heating work.
Avoid battery explosion
• Battery gas may explode.

1. Never allow sparks or open flames to
approach the top of the battery.
2. Check the battery capacity with a volt-
meter instead of placing a metal object
on top of terminals.
3. Do not charge a frozen battery; other-
Figure3-63
wise explosion will be caused. Prior to
charging, warm the battery until its
temperature rises to 16℃.
4. Loose terminals will produce sparks,
so ensure all the connectors have been
tightened.
• Battery liquid is toxic and if it explodes,
the liquid may enter eyes and cause
blindness
3-58 Operation
Chapter 4 Lubrication, Maintenance and Repair
4.1 General introduction
WARNING!
Only well-trained and certified workers are qualified to maintain and repair this machine.
CAUTION!
Please carefully read related contents of this manual before doing any maintenance job.
CAUTION!
If a diesel engine is running indoors, ensure the space is well-ventilated.
CAUTION!
Refer to Diesel Engine Manual for any detailed description about the diesel engine, and this
manual, as an accompanying document, is an integral part to the machine.
• Take a record of maintenance and repair, and save the file.

• To an excavator, it’s of importance to be properly maintained so as to function well.
• Keep the machine clean in order to find any leak, loose bolt or loose connection as quickly as possible.
• Be sure to protect the environment! Don’t pollute the environment with oil liquids and other harmful
pollutants.
• Details about regular inspection, maintenance and repair that are specified in this chapter should be
observed.
CAUTION!
Special lubricants should be used if the excavator works in extremely hot or cold weather, please
contact XCMG authorized dealers.
Lubrication, Maintenance and Repair 4-1

CAUTION!
If the requirement about special lubricants can’t be satisfied, please contact XCMG authorized
dealers.
4-2 Lubrication, Maintenance and Repair

4.2 Lubrication of equipment and devices
CAUTION!
Inject a certain amount of high quality lubricants according to requirements. Excessive amount of
lubricants will cause overheat and quicken machine abrasion.
Types of lubricants
Table 4-1 List of lubricants for this machine
Types of lubricants Grade/name Component Volume (L) Remarks

Pin shafts of work-
10
No. 1 Extreme Pres- ing device
sure Lithium Grease
Slewing bearing 2
(winter)
Grease Slewing reducer 2×1 -15～40℃
No. 2 Extreme
Pressure Lithium Oil bath of slewing
75
Grease (summer) gear
Tensioning device 2×1
XE750G CK-4 15W-40机油 -15～40℃
XE800-
Engine CK-4 10W-30机油 -20～30℃
GA Diesel engine 67
oil
XE750D CI-4 15W-40机油 -15～40℃
XE800D CI-4 10W-30机油 -20～30℃
GL-5 85W-140齿轮
Slewing reducer 2×10.5
Lubricating oil 油 -20～40℃
GL-5 80W-90齿轮油 Walking reducer 2×15
CAUTION!
Special lubricants should be used if the excavator works in extremely hot or cold weather, please
contact XCMG authorized dealers.

CAUTION!
If the requirement about special lubricants can’t be satisfied, please contact XCMG authorized
dealers.

Lubrication points
Major injection points of lubricating grease
1 1
23
Figure 4-1
No. Position Qty

Pin shafts for boom, bucket rod, buck-
Working device 11
1 et and connecting rod.
connections
Other 11
2 Slewing reducer 2
Slewing bearing 3
3
Oil bath of slewing gear 1
4 Tensioning device 2

● Working device connections
1. Pin shafts for bucket rod, bucket and

connecting rod
Figure4-2
2. Pin shaft at boom base
Figure4-3

3. Pin shaft between boom and bucket rod,

pin shaft between hydraulic cylinder rod
and bucket rod, pin shaft between bucket
and bottom of hydraulic tank
Figure4-4
4. The bottom of boom hydraulic cylinder
Figure4-5

5. Pin shaft of boom hydraulic cylinder and

pin shaft of bucket-rod hydraulic
cylinder
Figure4-6
●Slewing bearing
Figure4-7
●Oil bath of slewing gear
Filling
port
Figure4-8

●Engine
ADD FULL
Filling scope
Figure4-9
●Walking reducer (two points)
Filler plug
Oil level
check plug
Drain plug
--Lubricating points for

walking reducer: 2
Figure4-10

●Slewing reducer (two points)
1. Lubricating grease (bearing lubrication)
Figure4-11
2. Gear oil (gear lubrication)
Specified scope
Dipstick
——Gear oil filling points for slewing reducer: 2
Figure4-12

Lubricant Injection Period
10000h
6000h
5000h
3000h
2000h
1000h
500h
250h
8h
8h
250h
500h
1000h
2000h
3000h
5000h
6000h
10000h
Figure 4-13 Lubrication and maintenance diagram
Grease Engine oil Gear oil
Engine oil filter Hydraulic oil filter Hydraulic oil
Engine coolant Fuel filter Air filter
Open type crankcase ventilation

DEF filter DEF injector
(OCV) filter
Note: parts of maintenance are only available to XE750G/XE800GA.

Table 4-3 Lubrication Period Table
Maintenance Time interval (hour)

Item No. Qty
point 8 50 100 250 500 1000 1500 2000
Pin
shaft
for
Wor- buck-
king et and 11 √
1
de- con-
vice nect-
Gre- ing
ase rod
Other 11 √
Slewing
2 3 √
bearing
Slewing
3 2 √
reducer
Oil bath of
4 1 ★√
slewing gear
Engine oil lev-
1 1 √
el inspection
Engine oil
2 1 √
replacement
En-
Engine oil fil-
gine
3 ter 1 √
oil
replacement
OCV filter el-
4 ement 1 ▲√
replacement
Oil
Level
Walk-
In- 2 √
Gear ing
1 spec-
oil re-
tion
ducer
Re-
2 ★★ √
place

Table 4-3 Lubrication Period Table(continued)
Maintenance Time interval (hour)

Item No. Qty
point 8 50 100 250 500 1000 1500 2000
Oil
Level
Slew-
In- 2 √
ing
2 spec-
re-
tion
ducer
Re-
2 ★★ √
place
★ Using a grease containing 5% of molybdenum will extend maintenance period to 2,000 hours,
consult Xugong Mining Machinery dealer.
▲ Only partial machines have. Please contact the dealer of Xugong Mining Machinery Co., Ltd.
★★ Maintenance is only required on the first inspection.
WARNING!
The 500-hour maintenance cycle for engine oil and oil filter of XE750G/XE800GA is only specific
to fuel whose sulphur content percentage is ≤ 0.0015% (15PPM), and for a machine that applies
XCMG special CK-4 engine oil; for other oils, refer to the following table:
Engine oil and oil filter maintenance period

Low quality
Model Oil type Standard Sulphur content
Altitude > 1800m
>15PPM
XE750G CK-4 500hours Prohibited 250hours
XE800GA CJ-4 / CI-4 Prohibited Prohibited Prohibited
WARNING!
The 500-hour maintenance cycle for engine oil and oil filter of XE750D/XE800D is only specific to
fuel whose sulphur content percentage is ≤ 0.05% (500PPM), and for a machine that applies
XCMG special CI-4 engine oil; for other oils, refer to the following table:

Engine oil and oil filter maintenance period

Low quality
Sulphur con-
Model Oil type Standard Sulphur con- Altitude >
tent
tent >500PPM 1800m
>2000PPM
XE750D CI-4 500 hours 250 Prohibited 250 hours
XE800D CH-4 Prohibited Prohibited Prohibited Prohibited
Safety notices and precautions
• Accurately calculate working hours in order to determine the time of lubrication.

• Shutdown the machine before lubrication; when the machine fails to park as required, stop the
lubrication.
• Take fire prevention measures during lubrication.
• Prevent hot oil and harmful matters from injuring working staff.
• Don’t mix lubricants of different brands.
• Clean related parts and vents before lubricating these points; after lubrication, keep the seals as effective
as before.
• Regularly clean and replace filters; mark it after draining engine oil and don’t start the engine without
oil.
• Wipe overflowed lubricant off the machine.
• Engine oil replacement cycle is in relation to diesel quality, use of low quality diesel will shorten oil
change cycle. Please apply high quality diesels up to national standards.

4.3 Maintenance and repair

4.3.1 Safety regulations
Safety maintenance
• In order to prevent accidents:

1. Have knowledge of maintenance
procedure.
2. Keep working area clean and dry.
3. Don’t spray water or steam in the
cab.
4. Don’t lubricate or maintain the ma-
chine when it’s still moving.
5. Don’t touch rotary parts with your Figure4-14
hands, feet or clothes.
• Before maintaining the machine:

1. Park the machine on a level area.
2. Lower the bucket down to ground.
3. Idle the zero-load engine for 5 minutes.
4. Turn engine key switch to position “OFF” and stop the engine.
5. Operate control levers and release residual pressure from hydraulic system.
6. Extract engine key switch.
7. Put a sign on control lever, writing “Forbidding Operation”.
8. Pull the safety lock lever to “Lock” position.
9. Cool down the engine.
• If the maintenance has to be done when

the engine is running, a qualified opera-
tor must stay in the cab.
• If it’s necessary to lift up the machine
for maintenance, the angle between
boom and bucket rod should be kept
within 90°-110°, firmly supporting any
component of the lifted machine.
• It’s forbidden to work under a ma- Figure4-15
chine lifted by the boom.

• Regularly inspect machine components
and repair or replace when necessary.
• Keep all the parts in good working con-
ditions and ensure they’ve been well
installed.
• Replace abraded or cracked parts as soon

as possible and remove deposited grease,
oil or chips.
• Don’t clean parts or surfaces of com-
ponents with highly flammable oils like
fuel and gasoline; instead, incombustible
Figure4-16
washing oil should be used.
• Disconnect negative grounded cable (-)
from storage battery before adjusting
electrical system or welding on the
machine.
• Provide sufficient lighting to working
area. When working under or inside the
machine, remember to use a shielded
working lamp; otherwise, cracked bulb
may light up splashed fuel, engine oil,
antifreeze or washing liquid.
Prevent flying chips
If chips fly into eyes or eject into body, se-

vere injury will be caused.
• To prevent flying metal chips, it’s nec-
essary to wear eye goggles.
• When knocking on objects, other people
should not be admitted in. Figure4-17
Warn the others when maintaining the machine

Unexpected machine move will cause se-

vere damage, so before maintaining the
machine, place a sign on one control lever
writing “Forbidding Operation”.
Figure4-18
Correctly support the machine
Don’t start maintaining the machine before it’s firmly supported.

• Always lower front working device onto ground before maintaining the machine.
• If it’s necessary to lift the machine or its front working device for maintenance, then the machine or
its front working device must be firmly supported. Don’t support the machine with slag bricks, air
core tyres or frames as they may collapse under continuous load; don’t work under the machine jacked
up by only one lifting jack.
Stay away from rotary parts
• You may get injured once caught in a ro-

tary part.
• Take care of your limbs, clothes, jewelry,
long hair when working near a rotary
part in order not to be caught.
Figure4-19

Prevent parts from flying out
• For a tensioning device of crawler, its

grease is under high pressure, failing to
observe following items will cause se-
vere injury, blindness and casualty
accidents:
1. Don’t remove grease nozzle or valve
parts.
2. Keep your body and faces away from Figure4-20
valve blocks as parts may be ejected
out.
• Walking reducer contains pressure:
1. Keep your body and faces away from
air relief bolt as parts may be ejected
out.
2. Overheated gear oil may cause scald,
so be sure to gradually unscrew the air
relief bolt after gear oil cools down.
Safe storage of spare parts
Spare parts, like bucket, hydraulic hammer

and grafter, may fall down during storage
period, and that may cause casualty acci-
dents. Pay attention to storage safety and
keep children and other staff away from
storage area.
Figure4-21

Be alert to high temperature liquids
• Prevent from being scalded by splashed

high temperature liquids. After opera-
tion, engine coolant is still hot and pres-
surized; engine and radiator contains hot
water and steam. If hot water and steam
come in contact with skin, it will cause
serious scald.
1. Don't open radiator cover before en-
gine cools down. To uncover the radi-
ator, the operator should slowly turn Figure4-22
the cover to the end; don’t remove
the cover until pressure is completely
relieved.
2. As hydraulic oil tank is pressurized,
don’t remove the cover before re-
lieving the pressure.
• High pressure liquids and surfaces. En-

gine oil, gear oil and hydraulic oil will
be heated during operation; likewise, en-
gine, hose, pipe and other parts will also
become hot. Don’t check or maintain
them until oil and related parts cool
down.
Figure4-23
Regularly replace rubber hoses
• Due to ageing, fatigue and wear, rubber hoses containing flowing liquids may burst under pressure.
It’s hard to judge how much are rubber hoses deteriorated or abraded, so please regularly replace
them.
• Failing to regularly replace rubber hoses may cause fire accidents, liquid may inject into skin and cause
severe scald as a result, and front working device may injure people for the same reason.
Be alert to high pressure liquids.

• Fuel and hydraulic ejected under high pressure could penetrate skin or enter eyes, causing severe injury,
blindness and casualty.
• To prevent this danger, please release pressure before removing hydraulic pipes or other pipelines.
• Tighten up all the connections before pressurization.
Figure 4-24
• Find the leak with a paper board, and prevent your hands and body from touching high pressure liquids.
Wear face mask and eye goggles.
• If an accident happens to you, please to hospital immediately. If your skin is injured by ejected liquid,
please go to hospital, conduct a surgical operation and remove it; otherwise, it will cause gangrene.
Disposal of accumulator
Given that the pilot control system has an accumulator which contains high-pressure nitrogen gas; there-
fore, be sure to release pressure before maintaining the system; incorrect operation will result in very dan-
gerous consequences.
• Don’t drill the accumulator or get it in contact with flame or heat sources.
• Don’t weld accumulator or attach any object on it.
• To remove or maintain the accumulator, working staff must relieve the gas before dispose of it. Please
contact Xugong Mining Machinery’s authorized dealers.
• Please wear eye goggles and protective gloves when disposing the accumulator; otherwise, high-pres-
sure hydraulic oil will penetrate skin and cause injury.

Safely maintain a/c system
Once splashing onto skin, refrigerant will

cause frostbite.
• When maintaining a/c system, please re-
fer to the description on Freon container
and correctly use it.
• Don’t drain Freon into atmosphere; in-
stead, use recovery or recycling system.
• Don’t let Freon touch skin. Figure4-25
Correctly dispose waste
Improper disposal of waste will harm the environment and ecology. This equipment contains following
harmful matters: hydraulic oil, fuel, engine oil, coolant, filters and storage battery.
• Use an enclosed container to collect

draining liquids. Don’t use food or
drink containers to hold the liquid, be-
cause people may mistakenly swallow it.
• Don’t pour liquid waste on the ground,
in the sewer or into any water source.
• Refrigerant will damage the atmosphere
once leaking into air. According to regu-
lations, a licensed air conditioner service
Figure4-26
center should collect it and re-produce
refrigerant.
• Consult with local environmental protec-
tion agency, recovery center or Xugong
Mining Machinery authorized dealer for
correct handling of waste.

4.3.2 Maintenance
Inspect and maintain hydraulic device
CAUTION!
Hydraulic components will become very hot as operation continues, so be sure to cool it down
before inspecting or maintaining it.
• Park the machine on flat and hard

ground when maintaining hydraulic
devices.
• Lower the bucket on ground and cor- Figure4-27
rectly shut down the engine.
• As there is residual heat in hydraulic system after operation, don’t maintain hydraulic system unless
machine components, hydraulic oil and lubricants completely cool down;
1. Release the pressure by exhausting air from hydraulic pipeline.
2. Cool down the engine. Heated parts may suddenly fly out and hydraulic oil may be abruptly ejected
out and cause personal injury.
3. When removing bolts, don’t face them or turn your body towards them, as hydraulic parts, even
cold, are still pressurized.
4. Don’t maintain or inspect oil lines of walking motor and slewing motor on a slope, as the lines are
pressurized under gravity.
• When connecting hoses or hard tubes, take extreme care to keep sealing surfaces clean and avoid dam-
aging them. Please keep following notices in mind:
1. Wash the interior of hoses, hard tubes and tanks with washing liquid, and dry them before
connection.
2. Use new O-rings instead of damaged or defective ones, and don’t damage them during assembly.
3. When connecting hoses, don’t make high pressure hoses kinked, which will largely shorten their
service life.
4. Tighten up low-pressure hose clips discreetly and don’t exert excessive tightening force.
• Always use oils of the same brand and mix-use is forbidden. Use the oil listed in “Recommended Hy-
draulic Oil Grade and Name”,ensure all hydraulic oil of the entire system has been replaced.
• It’s forbidden to run the engine when hydraulic oil tank is empty.

Exhaust air out of hydraulic system
Before replacing hydraulic oil, replacing or repairing hydraulic pump, replacing or detaching hydraulic oil
suction pipe line, be sure to discharge air out of hydraulic pump, and hydraulic oil cylinder; before replac-
ing or repairing hydraulic oil cylinder, replacing or maintaining control valve, replacing or detaching the
pipeline between control valve and hydraulic oil cylinder, be sure to discharge air out of hydraulic oil cyl-
inder; before replacing or maintaining hydraulic motor, replacing or detaching the line between control
valve and hydraulic motor, be sure to discharge air out of hydraulic motor.
Important: When hydraulic oil pump is empty, starting the engine will damage the pump.
Important: When hydraulic motor is not filled up with oil, starting it will cause damage.
Important: When hydraulic pipeline and oil cylinder has air, starting it will cause damage to hy-
draulic oil cylinder.
1. Exhaust air out of hydraulic main pump
Important: When hydraulic main pump

is empty, starting the engine will damage
the pump.
CAUTION!
• Remove the venting plug from top of hy- Before starting the engine to discharge air, be sure to
draulic main pump. cancel auto-preheating function.
• Fill up hydraulic main pump through
venting plug.
• Install and screw in the venting plug.
• Start and idle the no-load engine. Put on
safety locking lever a sign writing
“Forbidding Operation”, ensuring the
safety locking lever is pulled on locking
position.
• Slowly unscrew venting plug to release
the air accumulated in hydraulic main
pump; when the air exhausts and oil Figure4-28
starts flowing from the plug hole, screw

down the venting plug.
2. Exhaust air out of hydraulic heat dissipation pump

Important: When hydraulic heat dissi-

pation pump is empty, starting the en- CAUTION!
gine will damage the pump.
Before starting the engine to discharge air, be sure to
• Remove the venting plug from top of hy-
cancel auto-preheating function.
draulic main pump.
• Fill up hydraulic main pump through
venting plug.
• Install and screw in the venting plug. Venting plug
• Start and idle the no-load engine. Put on
safety locking lever a sign writing
“Forbidding Operation”, ensuring the
safety locking lever is pulled on locking
position.
• Slowly unscrew venting plug to release Figure4-29
the air accumulated in hydraulic main
pump; when the air exhausts and oil
starts flowing from the plug hole, screw
down the venting plug.

3. Exhaust air out of hydraulic oil cylinder

Important: once engine is started, if you simultaneously operate the oil cylinder in high speed, or
quickly fully telescope it, the accumulated air inside the cylinder will damage seals.
• Start the engine and idle it without load and slowly telescope each cylinder for 4-5 times, be sure to
stop it at 100mm’s distance to the ending point.
• Run the no-load engine in low speed, extend and retract each cylinder for 3-4 times during the full
stroke.
• Run the no-load engine in low speed, extend and retract each cylinder for another 4-5 times during
the full stroke in order to discharge air.
After completing air-discharging operation, stop the engine for 5 minutes in order to remove the
bubbles out of hydraulic oil.
4. Exhaust air out of rotary motor
Important: if air is not discharged out of

rotary motor, there will be a risk of dam-
aging the motor bearing.
CAUTION!
• Before connecting the joint of motor Never make slewing operation when exhausting air
drain hole, fill up the motor casing with out of rotary motor.
hydraulic oil through the drain hole.
• Install motor drain hole and screw down
the hose.
• Run the no-load engine in low speed,
gently smoothly operate control lever,
and slowly slew upper structure to left
and right respectively for 2-3 times.
• Inspect whether there is hydraulic oil
leakage; if there is, wipe the overflowed
hydraulic oil.
Figure4-30

5. Exhaust air out of walking motor

walking motor, there will be a risk of
damaging the motor bearing.
CAUTION!
• Before connecting the joint of motor Never make walking operation when exhausting air
drain hole, fill up the motor casing with out of walking motor.
• Install motor drain hole and screw down Oil drain hole connector
the hose.
• Run the no-load engine, select Low
Speed for walking operation; pull the
control lever to “Forward” and “Re-
verse” for 4-5 times, each lasts over 2
minutes.
hydraulic oil.
• Install walking motor head cover.
Figure4-31
6. Exhaust air out of heat dissipation motor


heat dissipation motor, there will be a CAUTION!
risk of damaging the motor bearing.
Never start engine when exhausting air out of heat
• Before connecting the joint of motor
dissipation motor.
drain hole, fill up the motor casing with
Oil drain hole connector
• Install motor drain hole and screw down
the hose.
• Start and idle the no-load engine for 2-3
times.
hydraulic oil. Figure4-32
Inspect hydraulic oil level

Important: It’s forbidden to run the

engine when hydraulic oil tank is empty
• Inspect hydraulic oil level each day.
• Reposition the machine by fully re- Liquidomete
tracting bucket-rod hydraulic cylinder
and fully extending bucket hydraulic
cylinder.
• Stop the engine according to standard
shutdown procedure.
dure is incorrect, turbo charger may
be damaged.
• Pull safety locking lever to locking
position.
• Open the access door near hydraulic Figure4-33
pump, and check the level gauge, ensur-
ing that the oil level should be between
the Up mark and Low mark. If not so,
CAUTION!
please add hydraulic oil.
Hydraulic oil tank is pressurized. Release the
• Add hydraulic oil, and then re-check lev- pressure before slowly uncovering the tank.
el gauge.
• Recover the tank and ensure filter and
hanging stick assembly are correctly
located.

Drain dirt storage tank of hydraulic oil tank
Important: It’s forbidden to run the engine when hydraulic oil tank is empty.
• Drain dirt storage tank of hydraulic oil

tank every 250 hours. Quick filling connector
• To easily access, turn upper structure

90°, and then place the machine on flat
ground.
shutdown procedure.
be damaged.
• Pull safety lock lever to LOCK position.
• Drain water and sediments out of hy-
Figure4-34
draulic oil tank from the bottom quick
filling connector.
• Before oil cools down, drain water and CAUTION!
sediments out of hydraulic oil tank from
the bottom quick filling connector. Hydraulic oil tank is pressurized. Firstly, release
• Don’t remove but loosen the quick fill- pressure; before oil cools down, never loosen the
ing connector, as long as water and sedi- quick filling connector; the oil might be hot, may
ments comes off. cause severe scald.
• After draining water and sediments, re-

tighten quick filling connector.
Replace hydraulic oil and clean oil suction filter
CAUTION!
Hydraulic oil may be hot, please wait till it cools down before work.

• Replace hydraulic oil every 3,000 hours

and clean oil suction filter.
• For convenient oil replacement opera-
tion, turn upper structure 90°, and then
place the machine on flat ground.
• Reposition the machine by fully re- 3
tracting bucket-rod hydraulic cylinder
and fully extending bucket hydraulic
cylinder.
shutdown procedure.
3-Oil suction filter and
hanging stick assembly
be damaged.
Figure4-35
position.
• Clean top of hydraulic oil tank and pre- CAUTION!
vent pollutant from invading the tank.
Hydraulic oil tank contains pressure, so release the
• Remove the tank cover of oil suction
pressure before slowly uncovering the tank.
filter.
• Use a pump to draw hydraulic oil. The
amount of hydraulic oil in the tank and
hydraulic system is about: 660L.
• Take out oil suction filter and hanging
stick assembly.
• Wash filter and interior of fuel tank; to
replace the filter, you may install a new
filter on hanging stick assembly, refer to
the right figure.
• Install filter and hanging stick assembly, Figure4-36
ensuring the filter is correctly located on
the outlet.
• Replace return oil filter of hydraulic oil CAUTION!
tank (refer to “Maintenance Interval
If equipped with a quick filling accessory, it’ll be
Chart”).
convenient to extract or inject oil through it.

• Add hydraulic oil till the surface rises to

required level within the Up mark and
Low mark.
• Recap the tank and ensure filter and
hanging stick assembly are on correct
positions.
• Exhaust the air inside of hydraulic pump
and hydraulic oil cylinder.
• Inspect hydraulic oil level gauge. Open
tank cover and add oil if necessary.
Note: Be sure to dispose waste oil ac-
cording to local laws and regulations.
Replace breather valve of hydraulic oil tank

• Replace breather valve element of hy-

draulic oil tank every 500 hours.
CAUTION!
• Park the machine on flat and solid Replace breather valve of hydraulic oil tank
ground, and slowly lower the front work-
ing device onto ground
• Shut down the engine.
• Pull the left and right control levers for
several times in order to release residual
pressure out of hydraulic system.
• Use a socket head wrench (4mm) to turn
the breather valve cover 30° to release
residual pressure out of hydraulic oil
tank.
Figure4-37
CAUTION!
Hydraulic oil tank is pressurized. Firstly, release
pressure; before oil cools down, never loosen the
breather valve cover; the hydraulic oil may be hot,
and may cause severe scald.
Replace return oil filter of hydraulic oil tank.
CAUTION!
• Replace hydraulic oil return oil filter every 500 hours.

• For convenient oil replacement operation, turn upper structure 90°, and then place the machine on flat
ground.
• Reposition the machine by fully retracting bucket-rod hydraulic cylinder and fully extending
bucket hydraulic cylinder.
• Stop the engine according to standard shutdown procedure.
Important: If engine shutdown procedure is incorrect, turbo charger may be damaged.

• Clean top of hydraulic oil tank and prevent pollutant from invading the tank.
CAUTION!
Hydraulic oil tank contains pressure, so release the pressure before slowly uncovering the tank.
• Remove the tank cover of return oil filter.
CAUTION!
There is spring tension existing at filter bottom. When removing the last two bolts, be sure to
hold filter cover.
• Take out the return oil filter.

• After installing a new return oil filter, recap the filter tank.
• Dispose return oil filter according to local laws and regulations.
Replace hydraulic oil pilot filter and drain filter
CAUTION!
• Replace hydraulic oil pilot filter every 1,000 hours.

• Replace hydraulic oil drain filter every 500 hours.
• For convenient oil replacement operation, turn upper structure 90°, and then place the machine on flat
ground.
• Reposition the machine by fully retracting bucket-rod hydraulic cylinder and fully extending
bucket hydraulic cylinder.
Important: If engine shutdown procedure is incorrect, turbo charger may be damaged.
• Take out pilot filter and drain filter.
• Install a new pilot filter and drain filter.
• Dispose pilot filter and drain filter according to local laws and regulations.
Drain dirt storage tank out of fuel tank

• Remember to drain dirt storage tank out

of fuel tank every day.
• For convenient dirt removing operation,
turn upper structure 90°, and then place
the machine on flat ground.
shutdown procedure.
dure is incorrect, turbo charger may Figure4-38
be damaged.
position.
• Open the global drain valve on turntable
edge at fuel tank lower part, drain water
and deposit for several seconds and then
close it.
Replace breather valve element of fuel tank
• Replace breather valve element of fuel tank every 2,000 hours.

Refuel the machine
• Remove the top cover of fuel tank

• Keep close attention to liquid level when refueling the tank; adding amount shall not exceed the upper
limit of level gauge. Fuel tank capacity is about 925L
• After filling fuel tank, be sure to lock up the tank.
• If the machine equipped with a quick filling accessory, it’ll be convenient to fill the tank through
it.

Oil-water separator - drain water
Before operation, check oil-water separator every day. Oil-water separator can separate the water from
fuel. Too much moisture in fuel will cause insufficient engine power and increase emission.
Important: If fuel contains excessive amount of moisture, please reduce inspection interval.
Draining procedure:
• Oil water separator is located in fuel fil-
ter element chamber which is above the
pump chamber.
• Close the global fuel valve at the inlet of
oil water separator and stop fuel supply.
• Turn the drain plug on the bottom of oil
water separator and drain the clogged
water.
caution：After draining water, ensure
to release air from fuel system.
• After drainage, tighten up the drain
valve. Reposition the global fuel valve.
• Start the engine. Inspect the drain valve
for oil leak. Increase rotation speed and
Figure4-39
maintain that speed for 1 minute to ex-
haust system air.
caution：Exhaust water, and drain sediments into a

proper container. Dispose water and sediments
according to local laws and regulations

Replace oil-water-separator filter element
At a 500-hour interval or every time fuel level reaches the top black strip of filter element, replace the fil-
ter element for oil water separator.
WARNING!
A fire accident may take place if fuel leaks or sprinkles on hot surfaces or electric components. To
prevent potential dangers, be sure to turn off power master switch before replacing oil water
separator or its filter element. Immediately clean the oil leak if it happens.
Oil-water-separator filter element replacement procedure:

• Close the global fuel valve at the inlet of oil water separator and stop fuel supply.
• Turn the drain plug on the bottom of oil water separator and drain the clogged water.
Notice: exhaust water, and drain sediments into a proper container. Dispose water and sediments
according to local laws and regulations.
• After drainage, tighten up the drain valve.
• Use a filter spanner to remove the outer casing (1) of filter element from the base seat of oil water sepa-
rator, extract the element (2) and scrap it.
Notice: The outer casing (1) of filter element is reusable, do not discard it.
2 2
5
5 1
3
4 1
Figure 4-40
• Remove the cover (4) from the bottom of new filter element (2). Remove the seal ring (5) from cover
(4) and inspect if the ring has been damaged. If it has, install a new seal ring.
• Clean the internal face of filter element outer casing (1) as well as the seal ring (5) with clear fuel. Place
the cleaned seal ring (5) and new filter element (2) into the slot of outer casing (1).
• Manually install filter element outer casing (1) onto oil-water separator base seat.
Please do it manually, do not use filter wrench.
• Dispose oil-water separator filter element according to local laws and regulations.

Replace the fuel filter element.
• Replace the two-stage fuel fine filter elements every 500 hours.
WARNING!
A fire accident may take place if fuel leaks or sprinkles on hot surfaces or electric components.
To prevent potential dangers, be sure to turn off power master switch before replacing fuel filter
or its element. Immediately clean the oil leak if it happens.
• To protect the environment and for safety concern, always use a proper container to collect the drained
fuel. Don’t pour the waste fuel on the ground, in ditches, rivers, ponds and lakes; instead, dispose it
according to local regulations.
• Remove the filter with a filter wrench.

• Apply a thin layer of fuel coating on a
new filter gasket.
• Manually tighten up filter till the gasket
touches the sealing surface.
• Use a filter wrench to tighten the filter
by turning the wrench by 3/4 circles and
don’t excessively tighten it.
• After replacing the filter, ensure to re-
lease air from fuel system.
• Dispose fuel filter element according Figure4-41
to local laws and regulations.
Exhaust air out of fuel system
Important: Air coming in fuel system will cause it hard to start the engine or make it run abnor-
mally. After draining water and deposit from oil-water separator, replacing fuel filter or drying fuel
tank, it’s also important to release air out of fuel system.
• Ensure drain plug of oil-water separator has been tightened up.
• Ensure that the global fuel valve at the inlet of oil water separator is open.
• Start the engine, and idle it for 1 minute.
• Pull a sign on control lever writing “Forbidding Operation”.
• Pull safety lock lever to LOCK position.
• Inspect fuel system for leakage.


Inspect engine oil level
Important: to obtain correct readings,

be sure to inspect engine oil level each
day before starting the engine.
• Park the machine on a level area.
• Wait for 10-20 minutes, re-inspect oil
level; if necessary, and refill it.
• Take out oil dipstick. Wipe oil dipstick
with clean cloth and insert it back again.
• Keep it still for 3s, take it out and read
the level. Oil level should be at the cen-
ADD FULL
ter of the FULL and ADD scales.
Filling scope
• If oil level is below ADD, fill up oil till
Figure4-42
the level reaches the center between
FULL and ADD scales. Be sure to use
up-to-standard engine oil.
Note: If you attempt to take the reading the moment

you shut down the engine, you may get an incorrect
reading; before check, wait at least 10 minutes for
oil to come still.
Replace engine oil filter
• Replace engine oil and oil filter every

500 hours. Oil Filling
• Run the engine and raise oil temperature

for it to flow. Don't over run the engine
Filter
in case of overheating the engine.
• Shut down engine automatic idle Global
function.
Important: If engine shutdown proce- Figure4-43
be damaged.

• Idle the no-load engine for about 5
minutes.
• Stop the engine and extract the key.
• Pull pilot control cut-off lever to locking
position.
WARNING!
Engine oil can be very hot when it stops. Be cautious and do not get scalded by hot oil.
• Prepare a 67L or larger container to drain oil.

• Open the global valve on engine oil pan, and drain engine oil.
• Use a clean cloth to filter the drained oil, and check if there is metal scrap or foreign matter mixed in
the oil.
• Close the global valve.
• Remove the filter with a filter wrench.
• Fill the new filter in order to prevent crankshaft or bearing from being damaged. Apply a thin layer of
lubricating oil on sealing washer before installing the filter.
• Put filter cartridge on filter head cover, and then tighten it manually till the seal touches filter head
cover.
• Use a filter wrench to further tighten the cartridge for 3/4 round.
• Take out engine oil cover and refill it.
• Confirm oil level, be sure that oil dipstick is at the center between FULL and ADD. Idle the engine for
5 minutes at idle speed. After confirming that engine oil pressure can increase, stop the engine. Wait for
10-20 minutes, re-inspect oil level; if necessary, refill it.
• Dispose engine oil filter according to local laws and regulations.
Clean the filling port of Diesel Exhaust Fluid (DEF) system
WARNING!
DEF is corrosive to both the machine and human body. Immediately clean the oil leak if it leaks.
When filling DEF tank, in order to avoid polluting the tank, clean or replace the far-placed filler pipe of
DEF tank filter.

• Open the far-placed blue filler cap on

top of DEF tank. 1
2
• Press down the bayonet (1) with 3
screwdriver.
• Pull up the assembly (2) from both sides,
and remove it from far-placed filler pipe.
• Remove impurities out of the filter
screen (3) with water or compressed air.
• If it’s impossible to clean the filter
screen (3), or if it is damaged, you may Figure4-44
replace it (3).
Fill Diesel Exhaust Fluid (DEF).
WARNING!
• Remove the far-placed blue filler cap

from top of DEF tank. DEF tank is lo-
cated inside tool box.
• DEF adding amount shall not exceed the DEF filler
upper limit. DEF tank capacity is about

47.2L.
• Clean far-placed filler cover and the ad-
jacent zone.
• Remove the far-placed filler cover.
• Fill DEP.
• After filling up DEF tank, recap the far- Figure4-45
placed cover.
• Close tool-box upper cover.
WARNING!
Excessive DEF may possibly cause pipeline to be freezed. To avoid this, stop filling the tank when
DEF level reaches the top of far-placed filler pipe. DEF inside the remote pipe will flow into DEF
tank.


Replace the fine filter element of Diesel Exhaust Fluid (DEF).
• Replace DEF fine filter element every 5,000 hours.
WARNING!

• Remove the covering plate from the bot-
tom closure plate of the right front side
of turntable.
Figure4-46
Figure4-47

• Remove DEF end cover (3) with a

27mm wrench.
1
• Take out the rubber cone (2) from DEF
fine filter element (1).
• Insert DEF tool (4) into fine filter ele-
ment (1), and remove the element (1). 2
Note: Try to avoid twisting DEF fine
filter element (1) during detachment.
Twist may involve into a fracture. 3
• Clean the area around filter outer casing.
• Lubricate the seal of the new DEF fine Figure4-48
filter element with DEF or distilled
water.
• Install a new DEF fine filter element (1)
and rubber cone (2) with the tool (4). 1
Torque value: 20±5N·m
Note: Try to avoid twisting DEF fine
filter element (1) during installation.
Twist may involve into a fracture. 4
• Dispose DEF fine filter element ac-
cording to local laws and regulations.
Figure4-49

Replace the fine filter element of Diesel Exhaust Fluid (DEF)
• Replace DEF coarse filter element and suction filter element every 10,000 hours.
WARNING!

• Open tool box upper plate and you’ll see DEF tank is located inside.
1. Clamp the hose (1);
1 2
2. Remove hose clip (2) and (3). Discon-
nect wire harness (4) connection. Re- 5
move hose component (1) and (5).
Figure4-50
3. Remove bolt (6), plate (7), DEF tank

6
manifold (8) and washer (not indicated). 7
Figure4-51

4. Detach the hose clamp (9) and remove it

from filter base seat (10).
10
9
Figure4-52
5. Remove filter element (11) from the base

seat.
11
Figure4-53

6. Remove the suction filter element (12)

from spiral pipe bottom by dragging the 12
pull ring (13). Install a new suction filter
element.
7. Install the suction filter element by pull-

ing it from the spiral pipe to the bottom
of the already installed filter base seat.
13
Figure4-54
8. Tighten up band clamp (4.5 ±0.7 N•m)

and ensure the clip is in alignment,
shown as below. Ensure the filter will be
deformed during tightening process.
9. Follow step 3 to step 5, use a new wash-

er to install DEF tank manifold in re-
verse order.
10.Tighten up bolt (6) (5±1N· m) diago-

nally. Apply rubber lubricant on the in-
ner O ring of hose assembly (1).
Figure4-55

Replace the injector of Diesel Exhaust Fluid (DEF).
• Replace DEF injector every 5,000 hours.

• DEF injector (4) must be removed from the after-treatment main body and a new injector must be
installed.
1. Take out DEF pipe (1) from injector (4).

4 3 2
2. Take out coolant pipe (2) from injector
(4).
3. Take out electrical connector (3) from

injector (4).
4. Remove bolts first, and then the injector.
5. Replace the washer. Orientate the steel

edge of washer towards DEF outlet.
6. Replace the injector

1
7. Apply anti-seizure agent on bolts. Figure4-56
8. Re-tighten all bolts to 5N·m, and then

turn 90°.
9. Re-connect electrical connector (3).
10.Re-connect coolant pipe (2).
11.Re-connect DEF pipe (1).
Clean Diesel Particulate Filter (DPF)
• Clean DPF every 5,000 hours.
WARNING!
Before you attempt to clean DPF, please contact the dealer of Xugong Mining Machinery Co.,
Ltd. for detailed information. Xugong Mining Machinery bears no responsibility for any failure
or damage caused by privately cleaning DPF.
• According to approved Xugong Mining Machinery DPF maintenance procedure, one of following oper-
ations is required to take in order to clean DPF:
1. The machine DPF can be replaced with a new one.

2. The machine DPF can be replaced with a re-manufactured DPF.

3. The machine DPF can be cleaned and then re-installed by Xugong Mining Machinery authorized
dealer or approved DPF washing machine.
WARNING!
To stick to disposal regulations, after cleaning DPF, install it onto the original machine.
CAUTION!
It’s required to firstly execute particular re-generation function before removing the DPF to
wash. After executing any of the above-stated three occasions, it is required to reset the dust
monitoring system of engine ECM.
Clean ignition plug for After-treatment Regeneration Device (ARD)
• Clean ARD ignition plug every 5,000 hours (referred to as ARD below).
WARNING!
Engine must be shut down before cleaning ARD ignition plug. After engine stops, engine hood
and after-treatment components may still be hot, which may cause scald. Do not touch these hot
parts with your skin. Please wear protective clothes or devices to guard your skin.
WARNING!
When engine is running or key switch is at position ON, ARD ignition plug is at energized state,
please continue with ignition. For this reason, please turn key switch to position OFF before
repairing or cleaning ARD ignition plug.
• Clean ARD ignition plug as below:

1. Place the machine on a flat zone and
lower down the bucket onto ground.
2. Pull pilot control cut-off lever to lock-

ing position. Shut down the engine.
3. Try to let exhaust system cool down

before executing this process.

4. Open the engine hood.
5. Remove any dirt or chippings out of

the area surrounding ignition plug. If
you choose compressed air, ensure the
maximum air pressure is below
205kPa.
6. Remove wire harness (2) out of igni-

tion plug (1).
7. Use a lengthened socket (22mm) and

ratchet to loosen the ignition plug.
After the plug becomes loose, use the
socket to remove it; test if the ignition
works well.
8. After removal of the ignition plug, use

a plug brush to pass through the hole
of ARD ignition head and clean the
1
probe inside of ARD. Brush it 2
repeatedly. Figure4-57
9. Use a non-metal cleaning detergent to

carefully clean the ignition plug. If the
probe is bent, replace it with a new
WARNING!
one. The ignition plug may be damaged. If the ignition
plug sinks, replace it.
10.Install the ignition plug with hands

till it reaches ARD. The tightening WARNING!
torque for ignition plug is 43.4～51.5
N•m. Don’t over-tighten the ignition plug. Outer casing
may crack and washer may deform. Engine may be
11.Connect wire harness (2).
severely damaged. Please apply proper torque.
12.Close the engine hood.
Replace open type crankcase ventilation (OCV) filter element (if equipped)

Replace OCV filter element at a 2,000-hour interval or when OCV (Open Crankcase Ventilation, referred
to as OCV below) filter has a blocking warning,
Please contact the dealer of Xugong Mining Machineryfor detailed information.

Air filter external element
Clean the external element of air filter every 250 hours or when air filter element warning lamp turns on.
• When using compressed air to clean it, dirt may fly out and hurt people. Be sure to wear protective
glasses, dust cover or other protective devices.
• When removing the external filter element out of air filter, be sure to do it gently; it is dangerous to drag
it out with excessive force. When working high or not standing firm, you may fall under the counterac-
tion of pulling force.
CAUTION!
Don’t clean air filter element until air filter blockage warning appears on the monitor. If you
frequently wash filter element before the blockage warning appears, you will not only fail to be
convinced of air filter performance, your cleaning effect may also decrease. Additionally, dirt that
is stuck on filter element may fall into the element during cleaning, and may eventually enter the
engine, causing early wear of engine.
Clean external filter element:
• When cleaning filter element, do not

knock or impact any object. Use dry
compressed air (below 200 kPa) to blow
from fold layers towards the external fil-
ter element, and then directly blow from
exterior along fold layers; after that, do
Figure4-58
it again from interior.
• Replace any filter element who has been
repeatedly cleaned for 6 times or used
for one good year; the internal filter ele-
ment must also be replaced at the same
time
• After installation of the cleaned external
filter element, if system gives an air fil-
ter blockage warning, even if it has not
been cleaned for 6 times, the internal
and external filter elements must be
replaced.

• After clean, use a lamp to inspect

whether orifices or thin sections appear
on the element; if any is found, replace
the filter element.
Replace external and internal elements of air filter
Replace external and internal elements of air filter.

After air filter has been cleaned 6 times or after being used for a year, replace the internal and external air
filter elements.

• Stop the engine according to standard Air plug switch 1 2
shutdown procedure.
Important: If engine switch off proce-
dure is incorrect, turbocharger might
Shroud
be damaged.
position.
• Loosen the fixation clamp and remove 3 Valve
the end cover.
• Remove external filter element. 1－External filter element2－ Fixation clamp
• Softly tap filter external element and 3－ Internal filter element
don’t knock on hard positions. Figure4-59

• When using compressed air to clean ex-
ternal filter element, remember to blow
from inside the element towards
CAUTION!
outward. Before cleaning with low-pressure air (below
• Install external filter element. 0.2MPa), be sure to inform surrounding people to
• Install the end cover and tighten up the stay away for prevention of flying chips. Cleaning
fixation clamp. staff should wear personal protective articles,
• Start and idle the no-load engine. including eye goggles or safety glasses.
• Inspect the indicator of filter element
alarm lamp on the monitor. If the indica-
tor turns on, immediately shut off the en-
gine and replace external filter element.

• When replace an air filter element, remember to replace both the external and internal elements. Take
down the external filter element; clean filter interior before taking down the internal filter element; re-
move the internal filter element; install the internal filter element first and then the external one.
WARNING!
When removing the external filter element out of air filter, be sure to do it gently; it is dangerous to
drag it out with excessive force. When working high or not standing firm, you may fall under the
counteraction of pulling force.
CAUTION!
Don’t clean air filter element until air filter blockage warning appears on the monitor. If you
frequently wash filter element before the blockage warning appears, air filter won’t play its full
performance, and the cleaning effect may also decrease. Additionally, dirt that is stuck on filter
element may fall into the element during cleaning, and may eventually enter the engine, causing
early wear of engine.
CAUTION!
Clean external filter element:
• When cleaning filter element, do not knock or impact any object. Use dry compressed air (below
0.2 MPa) to blow from fold layers towards the external filter element, and then directly blow
from exterior along fold layers; after that, do it again from interior.
• Replace any filter element who has been repeatedly cleaned for 6 times or used for one good year;
the internal filter element must also be replaced at the same time
• After installation of the cleaned external filter element, if system gives an air filter blockage
warning, even if it has not been cleaned for 6 times, the internal and external filter elements must
be replaced.
• After clean, use a lamp to inspect whether orifices or thin sections appear on the element; if any
is found, replace the filter element.

Maintain oil-bath type air filter (if equipped)
See the figure below for oil-bath filter:
Housing assembly
Middle pipe
Detachable filter element
Internal oil cup
External oil cup

Detachable component
Figure 4-60
Inspection
Daily inspect the internal and external oil cup for accumulated dust; if the accumulated dust of either oil
cup has increased to 1/2 inches (12mm), it is time to maintain oil cup and the detachable filter element.
Check dust more than once everyday if there working area is dusty. Failing to inspect and maintain oil
cup, impurities may cause engine early abrasion.

Maintenance
The procedure is as follows:
1. Unlock upward the buckles from both

sides, take out the lower part, and then
extract the detachable filter element as-
sembly from oil cup. (See the following
figure)
Figure4-61
Figure4-62
2. Pour the oil, take out the internal cup

from the external cup, clean the cups and
then wipe them. (See the following
figure)
Figure4-63

3. Put the internal cup into the external

cup, and then fill up the cups. Use the
engine oil as designated. (See the follow-
ing figure)
油标线
OIL LEVEL
Figure4-64
CAUTION!
Don’t let engine oil exceed or below oil level line.
Excessive oil will shortenlife cycle; deficient oil will
cause insufficient filtration.
4. Place the detachable filter element under

strong sunlight for inspection (see the
figure below); if there is even and bright
light penetrating the net-like filter ele-
ment, it means the filter element is clean.
Figure4-65

5. If the filter element is partially blocked

by dust, cloth or chaff, use detergent to
clean it and blow it with compressed air.
(See the following figure)
Figure4-66
Figure4-67
6. Besides, every time you maintain the oil

cup, don’t forget to inspect the pipes at
the lower part and middle of housing
component. (See the following figure)
Figure4-68
7. Re-assemble the detachable component,

inspect oil cup and filter housing compo-
nent. Ensure oil cup has been fixed on
air filter housing. (See the following
figure)
Figure4-69

Check and repair

1. Remove the oil cup and detachable filter element.
2. Inspect and clean the middle pipe.
3. Wash the oil-bath filter by scouring through the air outlet with a high-pressure pump which contains
cleaning detergent, the scouring must have sufficient and even force. Repeat the scouring step till all im-
purities are removed.
4. Re-install the detachable filter element into the cup, and fix the oil cup in place. Ensure oil cup has been
correctly fixed onto the housing.
Check coolant level
• Check coolant level every day.

• Coolant level must be flush with the CAUTION!
viewing port of coolant tank, which is on
the radiator. If coolant level is low, Unless the system has cooled down, otherwise,
please refill the tank. If water tank is don’t straight unscrew radiator cap; instead,
empty, please first add coolant to radia- loosen the cap so as to release the pressure before
taking the cap down.
tor and then to water tank.
1-Cooling water filler cap

Figure4-70

Clean radiator interior
• Clean radiator interior before replacing

coolant liquid. CAUTION!
• Remove radiator cover, and open the
drain valves of radiator and engine to Unless the engine has cooled down, otherwise,
drain the coolant. don’t straight unscrew radiator cap; instead,
• Close drain valves and add running loosen the cap so as to release the pressure before
taking the cap down.
water and washing agent into radiator;
start the engine and run it in low speed
(slightly higher than idling speed); when
cooling water temperature indicator
points to green area, continue to run the
engine for about 10 minutes.
• Turn off the engine, open drain valve so
as to drain the system. Stop it when
draining water becomes clear, so as to
remove rust and deposit.
• Close drain valves and add coolant into
radiator. Adding speed should be slow so Figure4-71
as to avoid bubble entering into the
system.
• Run the engine and completely exhaust
air out of the system.
• After adding coolant, keep engine run-
ning for several minutes. And then re-
check coolant level; add a bit if
necessary.
Electric control system
Important: Improper installation of wireless communication device and attachment will influence
in-car electronic components and cause accident movement. Improper installation of electric devices
may likewise cause machine failure or fire accident. When you are about to install wireless commu-
nication devices or accessory electric components, or replace electric components, consult a Xugong

Mining Machinery Company authorized dealer. Never attempt to decompose or modify electric and
electronic components. Before changing or modifying these components, please contact Xugong
Mining Machinery Company authorized dealers.
Battery
CAUTION!
Storage battery gas may cause explosion, therefore, please forbid flame and spark from
approaching the battery.
1. This machine has maintenance-free battery, so it doesn’t need to frequently fill water.
2. Frequently inspect remaining electric quantity of battery, so as to lengthen its service life.
• Inspect storage battery
1. Inspect the storage battery for remaining quantity of electricity at least once a month.
2. Frequently inspect remaining electric quantity of battery, so as to lengthen its service life.
3. Stop the engine according to standard shutdown procedure.
4. Inspect storage battery power.
Inspect densitometer from top of

battery, if you see:
Green circle ── Battery is in

normal state
Black circle ── Battery is low

and needs charging.
White circle ── Battery is

spoiled, please change.
Densitometer Observation
Figure4-72
5. Always keep terminals clean so as to prevent the battery from discharging. Inspect if terminals are
loose or rusted. Apply grease or mineral fat on terminals in case it gets eroded.
• Battery

There are four 12V batteries in the machine whose negative poles (一) are grounded. If one battery of 24V
system loses function while the others can still work, please install a new battery of the same type. Charg-
ing speed of different types of batteries may vary which may overload one of these batteries and spoil it.
Replace fuse
XE750D uses standard resettable fuse.

If the electric device or hydraulic system stops working, please first inspect the fuse. Open the fuse boxlo-
cated in the front of electrical control box, and you will see the fuse is inside the box.
Important: prevent damaging electric devices from overloading them, and be sure to install fuses
with correct amperes.
Replace bucket
CAUTION!
When knocking in the connecting pin, wear eye goggles or safety glasses and other protective
articles to prevent being hit by ejected metal chips or pieces.
• Place the machine on flat ground. Lower

bucket on the ground, locate its plane Move the O-ring
part on ground surface and ensure the
bucket won't roll after pins are removed.
• Follow the figure to remove the O-ring
• Remove pin A and pin B from bucket
and separate bucket and bucket rod.
Clean the pins and pin holes, apply suffi-
cient lubricant on the pins and holes.
• Align bucket rod and new bucket, ensur-
ing the bucket won’t roll.
Bucket rod sleeve
Figure4-73

• Install bucket pin A and pin B.

Connectin
• Install lock pins and buckles on pin A
and pin B. B
• Adjust bucket joint gap of pin A (refer to
“Adjust Bucket Joint Gap”). A
• Apply grease on pin A and pin B.
• Start the engine and idle it in low speed.
Slowly rotate the bucket backward and
forward, checking if the movement is
Figure4-74
disturbed. If it is, immediately handle it.
Adjust bucket joint gap
1 2 4
3 5
6
7
8
9
12 11 10
13
Figure 4-75
No. Name No. Name No. Name

1 No clearance 2 Bucket rod head 3 Bucket clearance
4 Adjusting piece 5 Blind flange 6 Link stopper
7 Bolt 8 Washer 9 Bolt
10 Washer 11 Position 12 T-sleeve
13 Bucket
The machine has a bucket joint gap adjusting system designed to eliminate sway phenomenon. If there is
excessive clearance between bucket and bucket rod, please adjust bucket clearance (3) to 0.5 ～ 1mm.
When the sway accelerates, remove or install adjusting shims as below.
1. Park the machine on flat ground and lower bucket on ground surface.
2. Slowly swing control lever till bucket head (2) and bucket (13) are in touch at the no-clearance (1) part.
This operation will help determine the total clearance between bucket and bucket rod.
3. Shut off the engine. Pull safety locking lever to locking position.
4. Measure bucket clearance (3).

5. Remove a proper amount of adjusting pieces at position (11) so as to make the clearance between
0.5mm and 1mm. In order to remove the washer, you need to remove bolt (7), washer (8), block (6),
bolt (9), washer (10) and blind flange (5).
6. After removing a proper amount of adjusting pieces, install blind flange (5), washer (10), bolt (9), block
(6), and washer(8) and bolt (7).
7. After installation ensure bucket clearance (3) is still correct.
Remove walk control lever
If necessary, walk control levers can be removed.

• Remove bolt 1 and bolt 2, and remove walk control lever 3 and 4 from control valve.
Lock catch
3 4
Walk control lever

Safety belt
Bolt
2 Connecting
1
Bolt
Figure 4-76
Check or replace the safety belt
• Inspect the safety belt everyday; replace it every 3 years.

• Keep safety belt in good condition; to ensure good performance, replace it as required.
• Inspect safety belt, latch and connectors before operating the machine. If safety belt or its parts are dam-
aged or abraded, replace them before operation.
Adjust crawler
Inspect crawler tension

• Operate the machine towards marching direction.
• Stop track pin above the first carrier roller. Park the machine and shut off the engine.

Figure 4-77
• Place a straight rule above the crawler between the first and second carrier roller. The straight ruler
should be long enough, longer than the distance between the two carrier rollers.
CAUTION!
If the machine has three carrier rollers, then, the straight ruler should be longer than the
distance between any of two adjacent carrier rollers.
• Measure the maximum amount of crawler sag. Sag is the height between the lowest point of crawler
and the straight ruler. Normal sag is between 40mm and 55mm.
• If the crawler is too tight or too loose, please adjust crawler tension.
Adjust crawler tension
• Crawler tension adjuster is located on the longitudinal beam of chassis.
1
2
Grease export
Figure 4-78
• Tighten up the crawler

Wipe the fittings before applying lubricating grease.
1. Add grease through grease nozzle (2) till crawler tension is up to standard.
2. Walk the machine back and forth for several times.
3. Measure whether the maximum amount of crawler sag is within a proper range. Adjust crawler ten-
sion as required.
• Slacken the crawler:
1. Carefully loosen the safety valve (1) in order to release grease till the crawler begins to loosen.

2. When crawler tension reaches the standard, tighten the safety valve (1).
3. Walk the machine back and forth for several times.
4. Measure whether the maximum amount of crawler sag is within a proper range. Adjust crawler ten-
sion as required.
WARNING!
• Don’t loosen the valve too fast or excessively; otherwise, grease may eject out of the tensioning
device. Loosen the valve discreetly and don’t stand in front it face to face.
• Never loosen the grease nozzle.
Inspect air conditioner
• Inspect air conditioner every day.

• Check if refrigerant gas is escaping from pipe connection. If the there is oil oozing from the connection,
it may also leak air.
• Inspect refrigerant amount: run the engine with rotating speed of 1500r/min for 1-3 minutes and check
refrigerant amount through the viewing port on liquid storage tank.
• Inspect condenser: if condenser propellers are stained or blocked by bugs, refrigerant effect will be af-
fected. For this reason, always keep them clean.
• Inspect compressor: run the air conditioner for 5-10 minutes, reach out hands and touch the pipes at
low-pressure side and high-pressure side. If it works well, the pipe at high-pressure side should be hot
while the one at low pressure side should be cold.
• Inspect mounting bolts: ensure that all the mounting bolts of the compressor and other mounting/tight-
ening bolts are tightened up.
Inspect tightening torque of bolts and nuts
Inspect tightening torque of bolts and nuts every 250 hours.

Inspect all the bolts and nuts after the initial 50-hour running in period; after that, do it again after every
250 hours. If loose bolts are found, tighten them up in accordance with required tightening torque; if it’s
time to replace them, new bolts and buts should be of the same level or higher. Refer to “Tightening Tor-
que Table” for bolts and nuts excluded from this table.
Important: Use a torque wrench to inspect or tighten up bolts and nuts.

• Tightening Torque Table

Table 4-4 Tightening Torque Table
Bolt Socket
Torque
No. Item diameter Qty diameter
N•m
mm mm
Fixing bolts for engine
1 vibration-isolation rubber 30 6 46 1850
cushion
Engine base fixing bolt (at pump
5/8" 12 24 255
side)
2
Engine base fixing bolt (at
20 4 30 600
radiator side)
Main pump connection plate
3 7/16" 12 18 90
fixing bolt
4 Radiator fixing bolt 24 9 36 1000

5 Hydraulic cylinder fixing bolt 20 6 30 600
6 Diesel tank fixing bolt 20 6 30 600
7 Hydraulic pump fixing bolt 24 4 36 1000
8 Multi-way valve fixing bolt 20 3 30 600
Multi-way valve frame fixing
9 16 4 24 300
bolt
10 Slewing reducer fixing bolt 24 28 36 1000
11 Battery fixing nut 10 4 16 70
12 Cab fixing nut 16 8 24 300
Slewing bearing fixing bolts
30 48 46 1850
(superstructure)
13
Slewing bearing fixing bolts
30 60 46 1850
(lower structure)
14 Walk reduction gear fixing bolt 24 64 36 1000

15 Frame connecting bolts 36 56 55 3000
16 Drive wheel fixing bolt 24 64 36 1000
17 Track idler fixing bolt 20 24 30 600
18 Track roller fixing bolt 27 64 41 1500
19 Rail clamp fixing bolt 24 28 36 1000

Table 4-4 Tightening Torque Table(continued)
Bolt Socket
Torque
No. Item diameter Qty diameter
N•m
mm mm
Working-device pin pressure-
20 18 30 600
plate fixing bolt
20
Working-device pin pressure-
24 21 36 1000
plate fixing bolt
21 Counterweight mounting bolt 42 6 65 3800

10 - 16 70
22 Fixing bolt for various clamps
8 - 13 30

• Tightening torque table

Table 4-5 Tightening Torque Table
Socket wrench Inner-hexagon Torque

Bolt
size wrench N•m
specification
mm mm 10.9 level 8.8 level
M8 13 6 30 20
M10 16 8 70 50
M12 18 10 120 90
M14 21 12 195 140
M16 24 14 300 210
M18 27 - 410 300
M20 30 17 600 400
M22 34 - 800 550
M24 36 19 1000 700
M27 41 - 1500 1050
M30 46 22 1850 1450
M36 55 27 3000 2450
M42 65 32 3800 3200
Tightening torque is expressed in N•m. For example, when a one-meter long wrench is used to
tighten the bolt or nut, rotate the wrench tail with a force of 120N to produce the following torque:
1m ×120 N=120 N•m
For a 0.25M long wrench: 0.25m× =120N•m
The force required is: 120 /0.25=480 N

Maintenance under special environment conditions
Table 4-6 Maintenance table under special environment conditions
Operation conditions Maintenance notices

Before operation: inspect and ensure the screw plug and all drain valves are
tightened.
Muddy road, rainy or
After operation: clean the machine and check for fracture, damage, loose or
snowy weather
lost of bolts and nuts, and immediately lubricate related components if
required.
Before operation: inspect and ensure the screw plug and all drain valves are
tightened.
Seaside
After operation: thoroughly clean the machine and wash away salt;
frequently maintain electric devices for prevention of corrosion.
Air filter: regularly clean filter element at short intervals.
Radiator: clean screen net of the cooler, in case cooler core is blocked.
Dusty air Fuel system: regularly clean filter element and filter screen at short intervals.
Electrical devices: regularly clean wiring terminals of especially AC
alternator and start motor.
Fuel: use high-quality fuel designed for cold weather.
Lubricant: use high-quality low-viscosity hydraulic oil and engine oil.
Engine coolant: be sure to use antifreeze.
Cold weather Battery: maintain and charge storage battery at short intervals; if battery is
low, battery liquid may be frozen.
Crawler: keep crawler clean; park it on solid ground for prevention of being
frozen to the ground.
Crawler: operate the machine discreetly. Frequently inspect the crawler and
check for fracture, damage and loss of bolts and nuts; slacken the crawler a
little bit looser than usual.
Rocky road
Working device: when digging rocky ground, the standard equipment may
get damaged; before operation, reinforce the bucket or use a heavy duty
bucket.
Cab: when necessary, install a protective cover for the cab in case of being
Falling rocks
damaged by falling rocks.

Air conditioner maintenance
Air conditioner cools, heats and filters air and also dehumidifies air; it repeatedly sends the air processed
in this way into the room to meet our needs.
Cooling principle: air conditioner cools down indoor temperature by absorbing in-cab heat released during
liquid evaporation, and exhausts vaporized materials out of the cab, heat is dissipated in the form of lique-
fied cooling process, this recirculation results in cooling effect.
Heating principle: coolant is heated up engine residual heat. The heated coolant is pumped into heater
core, heating up in-car temperature in return.
Cooling recirculation diagram
See the figure below for cooling recirculation diagram:
Evaporator Cold air
Expansion
Fluid
Compressor reservoir
Condenser
Figure 4-79
See the table below for component function and refrigerant status:
Name Function and refrigerant status

Compressor takes in, compresses evaporated refrigerant, and pressurizes it for it
Compressor to be easily liquidized. Compressed refrigerant is in “high-temperature/highly
pressurized state”.
Cools and liquidizes compressed “high-temperature/highly pressurized
Condenser refrigerant”. Temporarily stores liquidized refrigerant or further cools it into
super-cooling liquid.
Temporarily stores high-temperature/highly pressured refrigerant the came out
Fluid reservoir
of condenser, removes moisture and filters dust.

Name Function and refrigerant status

Expansion valve is a throttle valve that helps to form a low-pressure chamber
Expansion valve
inside of evaporator. By ejecting high-temperature/highly pressured refrigerant
(Conditioning unit
out of an orifice, turn it into low-temperature/low-pressure thin fog that easily
interior)
evaporates (vaporizes).
Evaporator takes in heat from surroundings in order to evaporate refrigerant. As
Evaporator a result, the cab is cooled down as surrounding air temperature reduces. By
(Conditioning unit absorbing in-cab heat, the low-temperature/low-pressure thin fog inside of
interior) evaporator quickly evaporates. The refrigerant at evaporator outlet becomes
low-temperature/low-pressure gas.
Refill compressor oil
Add a certain amount of oil that serves as lubricant into air conditioner system, compressor oil will be dis-
solved into refrigerant and then circulates in the entire system. When air conditioning system turns off,
compressor oil will become stagnant in each component; during replacement of main components, lacking
in oil supply will cause deficient lubrication. Add sufficient oil when replacing main components, see the
table below:
Replacement Compressor Condenser Evaporator

Refer to the note below
Oil amount (CC) 40 40
for details
Compressor oil type ND8# oil (10P, 10PA, 10S series compressor)
Cautions
1. A new compressor has contained sufficient amount of circulating oil, which should be drained during
replacement of compressor.
2. Improper amount of oil: if air conditioning system has excessive compressor oil, cooling performance
will be impaired; if the system lacks oil, compressor will be abnormally abraded and stuck.

New compressor Replaced compressor
Remove excessive oil

A B
A B
Figure 4-80
CAUTION!
When removing compressor, please protect pipe joint and keep O ring clean.
Compressor trial run
CAUTION!
After replacement, trial-run the new compressor.
Trial running time: idle air conditioner for over 10 minutes.

Compressor trial run notices:
1. During trial run, it is strictly forbidden to increase speed; instead, the trial run must be maintained and
completed in idle state.
2. During trial run, temperature of the air to be taken in air conditioning system is normally maintained
above 18℃, which should last for over 10 minutes.
CAUTION!
When in cold winter or when the air conditioner wont’ be used for a long term (over 1 week),
regularly run the air conditioner for over 10 minutes to prevent from being stuck due to lack of oil.
Pipeline installation

During pipeline installation, correctly connect each pipe (see the figure) and bolt must be tightened to
specified torque with a torque wrench.
OK NG
Figure 4-81
CAUTION!
1. Do not re-use an O ring that has been used.
2. Apply ND-8# oil on O ring.
Connection Pipe size or thread size Tightening torque (N•m)

Φ8 pipe (liquid pipe) 12～15
Nut specification D1/2 pipe (air exhaust pipe) 20～25
D5/8 pipe (air intake pipe) 30～35
liquid reservoir M6 nut (4T) 4.0～7.0
Connector M6 bolts except the above contents
8.0～12
(6T or 8T)
Condenser fin inspection
For a vehicle that has been used for a while, it is necessary to regularly inspect condenser fin for dust,
mud or leaves; if there are such impurities on the fin, blow or wash them with compressed air, vapor or
water.

CAUTION!
1. If compressed air, vapor or water hits body directly, it may result body injury. Be sure to wear
protective glasses, face mask and safety boot.
2. To avoid damaging cooling fin, keep a distance between compressed air nozzle and cooling fin.
Once damaged, the cooling fin may cause leakage or overheat phenomenon. When the machine
works in a dusty environment, be sure to daily inspect the cooling fin, and do not be confined to
the inspection intervals specified in the maintenance manual.
3. Prohibit washing condenser with high pressure water: besides, during car wash, avoid sprinkling
water into compressor clutch clearance, and prevent clutch from slipping and burning during
engagement.
Air filter maintenance
The internal and external air filter net is located at the inlet of internal and external recirculation air chan-
nel of air conditioner cooling unit; if the net is blocked or loses efficacy, dust will enter evaporator surface
and cause dust blockage, which will influence air blowing amount or block air, and directly reduce air con-
ditioner working performance.
Use compressed air to clean air filter; if the filter is stained with oil or is very dirty, neutralized washing
liquid may work.
Wait till it completely dries before use. If the blocked air filter net cannot be washed with compressed air
or water, you may consider changing the filter net.
CAUTION!
The washing time interval is normally 500 hours, but if the vehicle works in a dusty environment,
be sure to shorten the washing interval and spot check the filter net daily if necessary.
R5
Internal air filter net External air filter net
Figure 4-82

Use of antifreeze
Heating principle of air conditioning system is to heat up the cab by passing engine coolant through pipe
lines and heat radiator that compose a warm air recirculation system; as the heat radiator is made of alumi-
num, so do not add antifreeze that contains corrosive element.
Antifreeze type for use: do not use the one that contains amine phosphoric acid.
CAUTION!
Antifreeze that contains amine phosphoric acid will corrode heat radiator, do not use it.
CAUTION!
1. When engine shows lack of coolant, be sure to add antifreeze of the same brand.
2. It is absolutely forbidden to use mineral water like running water, river water or sea water.
Vacuum operation
The prior concern for air conditioner installation is that there shall be no moisture mixed inside the device.
The refrigerant (R134a) used in an air conditioner is soluble in water, if there is a tiny little amount of
water left in the device, when the air conditioner runs, the tiny amount of water will cause expansion valve
orifice to be frozen, or compressor valve to rust; therefore, before refilling refrigerant, try as much as pos-
sible to purge the system of water. To minimize the residual water, the best way is to vacuum the system
by gasifying the residual water.
1. Manifold pressure gauge connection
1) Close manifold pressure gauge high-pressure valve (HI) and low-pressure valve (LO)
2) Connect inflation pipes (red and blue) with compressor auxiliary valve.
Red hose …… high pressure side (mark D)
Blue hose …… low pressure side (mark S)
CAUTION!
The L-shape bending part at front end of inflation pipe presses compressor auxiliary valve; if
it is reversely connected, the compressor internal valve won’t open. Except that, pay
attention to not connect high/low pressure reversely. The one with a quick coupling is free of L
limitation.
3) Connect the inflation pipe (green) at the middle of manifold pressure gauge with the vacuum pump.

Valve section
LO HI
Low pressure 关关 High pressure Connect L-shape
valve valve
Inflation
pipe
Green Mark D - side

Red
Mark S - side
Blue
Compressor
Vacuum pump (stop)
Figure 4-83
2. Vacuum
1) Open manifold pressure gauge high-pressure valve (HI) and low-pressure valve.
2) Turn on vacuum valve and run it for about 15 minutes.
3) When pressure gauge negative pressure scale (that's vacuum degree) reaches 750mm Hg, cut off the
switch, close the high pressure valve and low pressure valve.
Valve section Low pressure gauge

LO HI Over 750mmHg LO HI
Low pressure 开开关关
gauge High pressure
Low pressure
valve High pressure valve
Green
Red D
Blue
S
Compressor
Vacuum pump
Figure 4-84
3. Sealing inspection
1) Place the manifold pressure gauge for over 5 minutes with high and low pressure valve closed, ensure
the reading won't return to zero point.
2) It indicates a leak if pressure pointer returns to around 0 point; on this occasion, repair pipe connec-
tions; after repair, tighten it and re-do the vacuum till there is no leak in the system.

Valve section
Place it for
LO HI over 5 minutes
关关
Low pressure pointer
returns to zero
Low pressure gauge
Pointer returns
to zero Tighten up
pipe connection
Figure 4-85
4. Air leakage inspection
1) Connect the inflation hose (green), which was connected to vacuum pump, to Freon tank.
2) Connect inflation hose (green) to the manifold pressure gauge firstly, open the valve used for Freon
tank, press pressure gauge deflation valve secondly (don’t press the valve with bare hands in case
of ejecting refrigerant freezes you), and then exhaust the inflation hose by pressurized refrigerant (re-
lease inflation valve when a sound will give out)
Valve section
LO HI
关关
Deflation
valve
Release air Open refrigerant

tank valve
Blue
Inflation
R134a
Red hose (green)
Connect compressor Freon tank
Figure 4-86
3) Replenish refrigerant till low pressure gauge reading is 0.1 MPa (1 kgf/cm2); at this time, the gauge
high valve is open, after replenish, close the high pressure valve.
4) For safety concerns, use a leakage detector to inspect whether there is air leakage in cooling system.
Repair (tighten up) it if there is.

Valve section Low pressure gauge reading 1kg

2
LO HI 1kg/cm LO HI
关开关关
Low pressure
gauge reading
1kg/cm2
Low pressure
valve (close) Open high
pressure valve
Valve used for
Freon tank (open)
S
R134a Freon tank Compressor
Figure 4-87
Refrigerant refilling
1. Refilling method and amount:

The correct refrigerant is HFC-134a.
Refrigerant refilling method: it’s strictly forbidden to refill liquid refrigerant from low pressure side,
try to prevent compressor from taking in liquid refrigerant, as liquid impact may damage the compres-
sor. If the refilling fails, to re-do this, be sure to drain the already filled refrigerant before re-filling it
again.
Refrigerant refilling amount: 820g±50g
2. Inspect refrigerant flowing state through observation window: the observation window is located on the
connection pipe on liquid reservoir.
Refill a proper amount: you can barely see bubbles when refrigerant flows. When gradually increasing
speed of the idling engine to 1500 rpm, bubbles disappear and refrigerant becomes transparent.
Refill excessive amount: you see no bubbles when refrigerant flows.
Refill deficient amount: you see bubbles when refrigerant flows.

Observation window
Refill a proper amount
Refill deficient amount
Figure 4-88
Refrigerant refilling operation
CAUTION!
Before refilling refrigerant, vacuum air conditioner system first (refer to Vacuum Operation)
1. Refill from high pressure side
1) Remove the inflation hose (green) of manifold pressure gauge from vacuum pump and then connect
to Freon tank.
2) Open Freon tank valve, press the deflation valve to discharge air out of inflation hose by use of refrig-
erant pressure. A sound will give out; indicating refrigerant has come out; after hearing the sound, re-
lease deflation valve. Prohibit pressing the deflation valve with bare hands in case of causing
frostbite.

Valve section
(Note) a sound gives out
and refrigerant comes out
Deflation valve
releases air
Open refrigerant
tank valve
Loosen the
horn-opening-like nut
Blue
Inflation
Red hose (green)
Connect compressor Freon tank
Figure 4-89
3) When engine is in stop state, open the high pressure valve of manifold pressure gauge as well as the
valve used for Freon tank, so as to refill the tank.
Valve section Refill one tank (about 600g)

LO HI LO HI
关开关关
(Prohibited)
Do not run compressor
Do not open the low
Low pressure pressure valve
valve (close)
Open high
Valve used for pressure valve
Freon tank (open)
D
S
R134a
Figure 4-90
If failing to fill it to specified amount, close the high pressure valve and Freon tank valve, and then
follow step 2 to refill refrigerant from low pressure side.
CAUTION!
At this moment, never run the compressor; once it runs, refrigerant flow may return, causing
Freon tank and hose to burst; besides, when the compressor runs without refrigerant, it will
be damaged; and remember never to open the low pressure valve of manifold pressure gauge
(liquid compression will happen and damage compressor).

2. Refill from low pressure side
1) First make sure that the high pressure valve of manifold pressure gauge is close.
High pressure
valve (close)
Manifold
pressure gauge
(Notice)
Opening high pressure valve
will cause Freon tank to burst,
resulting in major injury.
Figure 4-91
2) Start the engine and open all doors.
3) Turn on air conditioner switch. Set temperature to “18℃”.
4) Set engine rotation speed to 1300-1500rpm
ON (Open)
Start engine
1300-1500rpm
Figure 4-92
5) To refill refrigerant, open low pressure valve of manifold pressure gauge and the valve used for re-
frigerant till no bubble can be seen from liquid reservoir.

Refill the tank till no

bubble can be seen
Valve section from observation glass
Low pressure gauge
High pressure
gauge
Open low
pressure valve High pressure valve
(close) (absolutely not open)
Valve used for
Freon tank (open)
Freon tank Compressor

(no “upside down”) running
Figure 4-93
6) After refilling refrigerant, close low pressure valve of manifold pressure gauge and the valve used for
refrigerant.
7) Inspect the system with leakage detector for any gas leak.
CAUTION!
By no means open manifold pressure gauge high-pressure valve (HI). If high pressure valve is
open, high pressure gas flow will reverse, and refrigerant tank and inflation hose will burst
(causing major injury); besides, do not upside down the refrigerant tank. (When engine is on
and refrigerant is being refilled), if refrigerant tank is upside down, liquid refrigerant will be
directly taken into compressor, causing liquid compaction, which will damage compressor
valve and gasket. You’re required to place the refrigerant tank vertically, as refrigerant is
under gasified refilling process.
CAUTION!
If outdoor temperature is low and it’s impossible to refill refrigerant, then place the
refrigerant tank in warm water (below 40℃), so as to increase refrigerant pressure.

Refill the tank till no
Valve section bubble can be seen
LO HI from observation LO HI
开关关关
Low pressure
valve (open) High pressure
Valve used for valve (close)
Freon tank (open)
Warm water
(below 40℃) Compressor
(prohibit heating it running
up with hot water)
Figure 4-94
WARNING!
Prohibit heating up refrigerant tank in hot water or with direct fire; otherwise, refrigerant tank
will crack. The water must be below 40℃.
CAUTION!
When outdoor temperature is high: use an electric fan to cool compressor.
3. Replace refrigerant tank

During refilling operation, if the refrigerant tank is exhausted, you may replace it according to following
tips.
1) Close manifold pressure gauge high-pressure valve and low-pressure valve.
2) Lift the pointed pin and round plate of valve used for refrigerant tank, and then remove the empty re-
frigerant tank.

Hand wheel
Inflation hose joint
Pin valve
Pad
Concave plate
Refrigerant tank
Figure 4-95
3) Install the new refrigerant tank on the valve used for refrigerant tank.
4) Discharge inflation hose air in following way: first, screw down the valve used for refrigerant tank
and then loosen it a little; second, open manifold pressure gauge low pressure valve a little bit; third,
press deflation valve and the refrigerant will be released; at this time, immediately close the valve
used for refrigerant tank and low pressure valve of manifold pressure gauge.
CAUTION!
Prohibit pressing the deflation valve with bare hands in case of causing frostbite.
Valve section
LO HI
稍开关 Hearing a sound means the
refrigerant is being released.
Low pressure
valve Loosen the tank
valve a little bit
Green
Blue
R134a Refrigerant
Red
tank
Connect compressor
Figure 4-96
5) Turn valve handle used for refrigerant tank, open it and continue with refilling operation.


Detect fault with manifold pressure gauge.
After pre-heating engine, take the reading of manifold pressure gauge under specified conditions:
1. Refrigeration system in normal state
Low pressure end: 0.15-0.25MPa (1.5-2.5kgf/cm²)
High pressure end: 1.37-1.57 MPa (14-16 kgf/cm²)
0.4 1.5 2
0.3 0.5
4 1 20
3 5
1
0.2 0.6 2.5
2 6 10 25
1 0.7 5 30
0.1 (CMHg kgf/cm 0.5 2
(CMHg kgf/cm)
0 8.5 3
-50 0
0 0.8 -76 35
-76
0.85 0 - 0.1 3.5
- 0.1 1.5
MPa MPa
LO
R134a HI
Figure 4-97
2. Moisture appears in refrigeration system: refrigeration works intermittently and then stops.
0.4 1.5 2
0.3 0.5
4 1 20
3 5 1
0.2 0.6 2.5
6 10 25
2
7
1 5
0.1 0.7 2 30
2 (CMHg kgf/cm)
(CMHg kgf/cm) 0.5
8 3
0
-50 8.5 0
0 0.8
-76 -76 35
0.85 0 - 0.1 3.5
- 0.1 1.5
MPa
MPa
Figure 4-98
Symptoms of Refriger-
Possible cause Diagnosis Troubleshooting
ation System
Moisture enters 1.Drier is in over-

refrigeration system saturated state. 1.Replace the receiver/
and getsfrozen at 2.Moisture enters drier.
When system is running,
expansion valve, refrigeration system 2.Remove system
low-pressure end is
causing the circulation and getsfrozen at moisture by exhausting
sometimes normal and
to temporarily stop; expansion valve, air nonstop.
sometimes vacuum.
when the ice melts, preventing 3.Refill a proper amount
system resumes to refrigeration system of new refrigerant.
normal. from circulating.

3. Insufficient refrigeration.
0.4 1.5
2
0.3 0.5
4 15 20
3 5 1
0.2 0.6
6 10 25 2.5
2
1 7
0.1 2
0.7 5 2
30
(CMHg kgf/cm) 0.5 (CMHg kgf/cm)
0 8
8.5 3
-50 0
0 0.8
-76 -76 35
0.85 0 - 0.1 3.5
- 0.1 1.5
MPa MPa
Figure 4-99
Symptoms of Refrig- Possible Diagnosis Troubleshooting

eration System cause
1.Low pressure at both Air leaks in 1.System has 1.Use a leakage detector to inspect if
high and low pressure refrigeration deficient amount there is system gas leakage; if there
ends. system. of refrigerant. is, repair it.
2.Continuously see 2.Refrigerant 2.Refill a proper amount of
bubbles through leakage. refrigerant.
observation glass. 3.When connecting with testing
3.Insufficient device, if the pressure is around 0,
refrigeration. after inspection and repair, place the
system in vacuum state.
4. Refrigerant is in poor circulation: insufficient refrigeration.
0.4 1.5 2
0.3 0.5
4 15 20
3 5
1
0.2 0.6
6 10 25 2.5
2
7
1 0.7
0.1 5 30
2
0.5 2
(CMHg kgf/cm)
(CMHg kgf/cm) 8
0 3
-50 8.5 0
0 0.8 -76 35
-76
0.85 0 - 0.1 3.5
- 0.1 1.5
MPa MPa
Figure 4-100

Symptoms of Refrigera-
Possible cause Diagnosis Troubleshooting
tion System
1.Low pressure at both
high and low pressure
Reservoir dirt
ends. Liquid reservoir
inhibits refrigerant Replace the liquid reservoir.
2.Frost grows on both is blocked
from flowing.
components and liquid
reservoir pipe.
5. Refrigerant doesn't circulate: no refrigeration
0.4 1.5 2
0.3 0.5
4 15 20
3 5
1
0.2 0.6
6 10 25 2.5
2
7
1 0.7
0.1 5 30
2
0.5 2
(CMHg kgf/cm)
(CMHg kgf/cm) 8
0 3
-50 8.5 0
0 0.8 -76 35
-76
0.85 0 - 0.1 3.5
- 0.1 1.5
MPa MPa
Figure 4-101
Symptoms of Refrig- Possible cause Diagno- Troubleshooting

eration System sis
1.Vacuum appears at 1.Moisture and dirt that Refriger 1.Inspect expansion valve and
low-pressure end and exist in refrigerant inhibit ant EPR.
very low pressure at flowing movement. doesn't 2.Clean dirt contained in
high pressure end. 2.The gas leakage at hot- circulate expansion valve by blowing air; if
2.Frost or dew grows sensitive pipe of expansion this method doesn't work, replace
on the pipes before or valve inhibits refrigerant the expansion valve.
after expansion valve from flowing. 3. Replace the liquid reservoir.
or liquid reservoir 4.Exhaust air and refill a proper
drier. amount of refrigerant; if air leaks
at hot-sensitive pipe, replace the
expansion valve.
6. Excessive amount of refrigerant or condenser fails to sufficiently refrigerate: deficient refrigeration.

0.4
1.5 2
0.3 0.5
4 20
5 15
3 1
0.2 0.6
6 10 25 2.5
2
7
1 0.7
0.1 5 30
(CMHg kgf/cm)
2 0.5 (CMHg kgf/cm)
2
0 8
8.5 3
-50 0
0.8
0 -76 35
-76
0.85 0 - 0.1
- 0.1 1.5 3.5
MPa MPa
Figure 4-102
Symptoms of Refrig- Possible cause Diagnosis Troubleshooting

eration System
1.High pressure at 1.System has excessive 1.System has 1.Clean condenser.
both high and low amount of refrigerant, excessive amount 2.Inspect fan motor
pressure ends. failing to sufficiently of refrigerant: working state.
2.Even engine rotation play refrigerating role. filling excess of 3.If item 1 and 2 are in
speed reduces, there is 2.Insufficient refrigerant. good conditions, inspect the
no bubbles can be refrigeration. 2.Condenser amount of refrigerant. Fill a
seen from observation refrigerates proper amount of
glass. insufficiently: refrigerant.
condenser cooling
fan is blocked or
fan motor is
faulty.
7. Air exists in refrigeration system: poor refrigeration effect.
0.4
1.5 2
0.3 0.5
4
5 15 20
3
0.6 1
0.2
6 10 2.5
2 25
7
1 0.7
0.1 5 30
(CMHg kgf/cm)
2 0.5 (CMHg kgf/cm)
2
0 8
8.5 3
-50 0
0 0.8
-76 -76 35
0.85
- 0.1 1.5 0 - 0.1 3.5
MPa MPa
Figure 4-103

Symptoms of Refrigera- Possible cause Diagnosis Troubleshooting

tion System
1.High pressure at both Air enters 1.Air enters 1.Inspect whether compressor
high and low pressure ends. refrigeration refrigeration oil is unclear or deficient.
2. Low pressure pipe is hot system system. 2.Exhaust air and fill new
by touch. 2.Insufficient refrigerant.
3.Bubbles can be seen vacuuming
through observation glass.
8. Expansion valve installation is incorrect/defective hot-sensitive pipe: deficient refrigeration.
0.4
1.5 2
0.3 0.5
4
5 15 20
3
0.6 1
0.2
6 10 25 2.5
2
7
1
0.1 0.7 5 30
(CMHg kgf/cm)
2 0.5 (CMHg kgf/cm)
2
0 8
8.5 3
-50 0
0 0.8
-76 -76 35
0.85
- 0.1 1.5 0 - 0.1 3.5
MPa MPa
Figure 4-104

eration System
1.High pressure at both Expansion valve 1.Low pressure pipe 1.Inspect the installation of hot
high and low pressure is faulty or contains excessive sensitive pipe.
ends. improper amount of refrigerant 2.If the item above is normal,
2.Frost grows on low- installation of 2.Expansion valve then inspect expansion valve;
pressure pipe or a large hot sensitive opening is too wide. if it is defective, replace it.
amount of dew appears pipe
9. Compressor has a compression fault: doesn’t refrigerate.
0.4 1.5
0.5 2
0.3
4
5 15 20
3 1
0.2 0.6
6 10 2.5
2 25
7
1 0.7
0.1 5 30
(CMHg kgf/cm)
2 0.5 (CMHg kgf/cm)
2
0 8 3
8.5 0
-50
0 0.8
-76 -76 35
0.85 0 - 0.1
- 0.1 1.5 3.5
MPa MPa
Figure 4-105


eration System
1.Too high pressure at Compressor 1.Compressor fault Repair or replace compressor
low pressure end. internal leakage 2.Valve leakage or
2.Too low pressure at damage, parts fall
high pressure end.
Fault code
Air conditioner system has an electrical fault, find the corresponding fault code in following steps:
1. Press OFF switch on control panel, temperature and air volume indications on LCD are off, and opera-
tion stops;
2. Simultaneously press temperature setting switch “<” and “>” for 3s, LCD shows fault self-diag-
nosing mode;
3. Fault code and corresponding fault mode shown on the monitor are as below:
Indica- Fault mode Indica- Fault mode

tion tion
E– No fault E18 Solar sensor short circuit
E11 Internal air sensor break circuit E43 Outlet air baffle is abnormal
E12 Internal air sensor short circuit E44 Air mixed wind baffle is abnormal
E15 Water temperature sensor is E45 Internal and external air door are
disconnected abnormal
E16 Short circuit to water
temperature sensor
4. When detecting more than one fault, you may press temperature setting switches “<” and “>” to
show these faults one by one;
5. After fault diagnosis is completed, press internal and external circulation button to erase fault codes.
CAUTION!
The above-said fault code self-diagnosis function only applies to general instruments, please
inquire air conditioner fault code of a touch screen instrument in system fault inquiry interface.
Engine maintenance
―― Refer to the Engine Operation and Maintenance Manual for details.

Table 4-7 Maintenance Interval
Q- Time interval (hour)

Item No. Maintenance point
ty 8 50 250 500 1000 2000 3000 4000 5000 6000 10000
1 Inspect hydraulic oil level 1 √
2 Drain oil reservoir of tank 1 √
3 Replace hydraulic oil √
4 Clean oil suction filter 1 √
Hydraulic 5 Replace return oil filter 2 √

system 6 Replace pilot oil filter 1 √
7 Replace drain oil filter 2 √
8 Replace breather valve of hydraulic oil tank 1 √
Inspect hose Oil leakage √

9
and pipeline Crack and bending, etc √
1 Drain dirt storage tank out of fuel tank 1 √
2 Check oil-water separator 2 √

3 Replace fuel filter (3-stage) 4 √
Fuel system
4 Replace breather valve element of fuel tank 1 √
Inspect fuel Leak and crack √
5
hose Crack and bending, etc √
1 Replace DEF coarse filter element 1 √
After- 2 Replace DEF suction filter element 1 √
treatment 3 Replace DEF fine filter element 1 √

Lubrication, Maintenance and Repair

system 4 Replace DEF injector 1 √
5 Clean DPF 1 √
4-93
Table 4-7 Maintenance Interval(continued)
4-94
ty 8 50 250 500 1000 2000 3000 4000 5000 6000 10000
6 Clean ARD ignition plug 1 √

indicator
External filter element of air Clean 1 √
1 lamp
Air intake filter
Replace 1 Wash 6 times or after a year
system
nner filter element of air
2 Replace 1 When replacing the external filter element
filter
1 Check coolant level 1 √

Inspect and adjust fan belt tension 1 √
2

Replace engine belt 1 √
Cooling 3 Replace coolant (antifreeze) or 2 years √
system Exterior 1 When needed
4 Clean radiator
Interior 1 When replacing coolant
5 Clean radiator front mesh enclosure 1 When needed
6 Clean air-conditioner condenser 1 When needed
Inspect bucket tooth for abrasion and
1 √
looseness
2 Adjust bucket connection 1 When needed

Others 3 Check and replace safety belt 1 √ Every 3 years (replace)
Inspect front window glass washer liquid
4 1 When needed
level
5 Inspect crawler slag 2 When needed

Table 4-7 Maintenance Interval(continued)

ty 8 50 250 500 1000 2000 3000 4000 5000 6000 10000
Circulation Clean 1 √
Inspect air-
air filter Replace 1 Clean 6 times or more
6 conditioner
Fresh air Clean 1 √
filter
filter Replace 1 Clean 6 times or more
7 Inspect air conditioner √
8 Tighten engine cylinder head bolts When needed
9 Inspect and adjust valve clearance √
10 Inspect fuel injection timing When needed
11 Inspect starter and alternator √
12 nspect tightening torque of bolts and nuts ★ √

4-95
★Only required on the first inspection.

4.4 Troubleshooting
Correct maintenance and inspection procedure
To correctly maintain and inspect this machine, please follow the correct procedure specified in this
manual.
• Daily inspect the machine before start:
1. Inspect controller and instruments.
2. Inspect liquid level: coolant, fuel and hydraulic oil.
3. Inspect hoses and pipes for leak, kink, abrasion or damage
4. Take a walk-around check for general phenomenon, like noise and heat amount, etc
5. Inspect if there are loose or lost parts.
6. Repair the machine before operation or contact Xugong Mining Machineryfor any machine problem.
• Frequently inspect hour meter:
1. Determine when to inspect and maintain the machine according to the working hours displayed on
engine hour meter.
2. The time interval in Maintenance Interval Chart is made according to operation conducted under gen-
eral conditions; place shorten the time interval if the machine works in harsh environment conditions.
3. Regularly lubricate, inspect, maintain and adjust the machine according to the Regular Maintenance
Table affixed on the right-side glass of the cab.
When the digits that displayed on hour-meter reaches the recommended replacement interval of lubricant
and filter element, or when conducting regular (daily or monthly) inspections, replace the lubricant and fil-
ter element.
CAUTION!
1. Use correct oil, lubricating grease and antifreeze.
2. Using incorrect oil, lubricant or non-original parts will cause disqualification of warranty.
3. Don't attempt to adjust engine speed limiter or hydraulic system safety valve.
4. Avoid electrical assembly touching water or water vapor.
5. Don't decompose key electrical components like main controller and sensors.

Trouble shooting
Engine
Table 4-8 Engine Fault Code Table
Flash
CDL Fault diagnosis and
SPN FMI indica- Fault description
code troubleshooting
tion
Accelerator pedal Fault diagnosis and
29 2 774-2 1 position 2: not stable, troubleshooting, “speed
intermittent or incorrect control - test”
29 3 774-3 1 position 2: voltage is troubleshooting, “speed
higher than normal control - test”
Accelerator position 2: Fault diagnosis and
29 4 774-4 1 voltage is lower than troubleshooting, “speed
normal control - test”
Accelerator pedal
Fault diagnosis and
position 2: abnormal
29 8 774-8 1 troubleshooting, “speed
frequency, pulse width or
control - test”
period
91 2 91-2 1 position 1: not stable, troubleshooting, “speed
intermittent or incorrect control - test”
91 3 91-3 1 voltage is higher than troubleshooting, “speed
91 4 91-4 1 voltage is lower than troubleshooting, “speed
position 1: abnormal troubleshooting, “speed
91 8 91-8 1
frequency, pulse width or control - test”
period
Fuel pressure: higher Fault diagnosis and
94 3 1 than normal troubleshooting, “High
fuel pressure”

Table 4-8 Engine Fault Code Table(continued)
Flash
tion
Fuel pressure: lower than Fault diagnosis and
94 4 1 normal troubleshooting, “low fuel
pressure”
Fuel pressure: exceeding Fault diagnosis and
94 13 1 detection range troubleshooting, “fuel
supply - test”
Moisture-in-fuel It has been detected that
indicator lamp: voltage is moisture-in-fuel sensor is
higher than normal open circuit. Fault
97 3 3547-3 1
diagnosis and
troubleshooting,
“moisture-in-fuel - test”
Moisture-in-fuel Fault diagnosis and
indicator lamp: High - troubleshooting, “water
97 15 3547-15 1
lowest severity level contained in water-oil
separator”
Moisture-in-fuel Fault diagnosis and
indicator lamp: High - troubleshooting, “water
97 16 3547-16 2
moderate severity level contained in water-oil
separator”
Engine oil pressure: low Fault diagnosis and
100 1 100-1 3 - highest severity level troubleshooting, “low
engine oil pressure”
Engine oil pressure: Fault diagnosis and
voltage is higher than troubleshooting, “sensor
100 3 100-3 1
normal signal (simulation, active) -
test”
voltage is lower than troubleshooting, “sensor
100 4 100-4 1
test”
100 10 100-10 1
updating speed anomaly troubleshooting, “sensor

Flash
tion
signal (simulation, active) -
test”
exceeding detection troubleshooting, “sensor
100 13 100-13 2
range signal (simulation, active) -
test”
100 17 100-17 1 - lowest severity level troubleshooting, “low
100 18 100-18 1 - moderate severity level troubleshooting, “low
Engine crankcase Fault diagnosis and
pressure: voltage is troubleshooting, “sensor
101 3 101-3 1
higher than normal signal (simulation, active) -
test”
pressure: voltage is lower troubleshooting, “sensor
101 4 101-4 1
than normal signal (simulation, active) -
test”
pressure: calibration troubleshooting, “sensor
101 13 101-13 2
required signal (simulation, active) -
test”
Engine crankcase Troubleshooting, “high
101 15 101-15 1 pressure: high - lowest crankcase pressure”
severity level
Engine crankcase Troubleshooting, “high
101 16 101-16 1 pressure: high - moderate crankcase pressure”
severity level
Engine intake air Troubleshooting, “intake
E1045
102 1 3 manifold #1 low pressure manifold air pressure is
（3）
- highest severity level low”

Flash
tion
Engine intake manifold Fault diagnosis and
1: pressure updating troubleshooting, “sensor
102 10 1
speed anomaly signal (simulation, active) -
test”
Engine intake manifold Troubleshooting, “intake
E1045
102 18 2 #1 pressure: low - manifold air pressure is
（2）
moderate severity level low”
E539
105 0 3 #1 temperature: high - manifold air temperature is
（3）
highest severity level high”
#1 temperature: voltage troubleshooting, “sensor
105 3 1
is higher than normal signal (simulation, active) -
test”
#1 temperature: voltage troubleshooting, “sensor
105 4 1
is lower than normal signal (simulation, active) -
test”
E539
（1）
lowest severity level high”
E539
（2）
moderate severity level high”
Engine air filter #1 Fault diagnosis and
pressure difference: troubleshooting, “sensor
107 3 582-3 1
voltage is higher than signal (simulation, active) -
normal test”
Engine air filter #1 Fault diagnosis and
pressure difference: troubleshooting, “sensor
107 4 582-4 1
voltage is lower than signal (simulation, active) -
normal test”

Flash
tion
Engine air filter #1 Troubleshooting, “inlet air
E583
107 15 1 pressure difference: high prevented”
（1）
- lowest severity level
Engine air filter #1 Troubleshooting, “inlet air
E583
（2）
- moderate severity level
Barometric pressure Fault diagnosis and
sensor: voltage is higher troubleshooting, “sensor
108 3 3528-3 1
test”
sensor: voltage is lower troubleshooting, “sensor
108 4 3528-4 1
test”
108 21 3528-21 1 sensor: low data drift troubleshooting, “sensor
power - test”
Engine coolant pressure: Fault diagnosis and
109 3 2302-3 1
test”
Engine coolant pressure: Fault diagnosis and
109 4 2302-4 1
test”
Engine coolant Fault diagnosis and
temperature: voltage is troubleshooting, “sensor
110 3 110-3 1
test”
Engine coolant Fault diagnosis and
110 4 110-4 1
lower than normal signal (simulation, active) -
test”

Flash
tion
Engine fuel injector Fault diagnosis and
metering rail #1 voltage: troubleshooting, “sensor
157 3 1797-3 1
normal test”
Engine fuel injector Fault diagnosis and
metering rail #1 voltage: troubleshooting, “sensor
157 4 1797-4 1
normal test”
Battery level/power input Fault diagnosis and
168 0 2 #1: high - highest troubleshooting, “power -
severity level test”
168 1 2 #1: low - highest severity troubleshooting, “power -
level test”
168 2 1 #1: unstable, intermittent troubleshooting, “power -
or incorrect test”
168 3 168-3 1 #1: voltage is higher than troubleshooting, “power -
normal test”
168 4 168-4 1 #1: voltage is lower than troubleshooting, “power -
normal test”
Environment air Fault diagnosis and
171 3 171-3 1
higher than normal signal (simulation, passive)
- test”
Environment air Fault diagnosis and
171 4 171-4 1
lower than normal signal (simulation, passive)
- test”
Engine inlet air Fault diagnosis and
172 3 2526-3 1
higher than normal signal (simulation, passive)
- test”

Flash
tion
Engine inlet air Fault diagnosis and
172 4 2526-4 1
lower than normal signal (simulation, passive)
- test”
Engine fuel temperature Fault diagnosis and
1: voltage is higher than troubleshooting, “sensor
174 3 174-3 1
normal signal (simulation, passive)
- test”
Engine fuel temperature Fault diagnosis and
1: voltage is lower than troubleshooting, “sensor
174 4 174-4 1
- test”
Engine oil temperature 1: Fault diagnosis and
175 3 175-3 1
- test”
Engine oil temperature 1: Fault diagnosis and
175 4 175-4 1
- test”
Engine speed: abnormal Fault diagnosis and
190 8 190-8 1 frequency, pulse width or troubleshooting, “speed/
period timing- test”
Engine exhaust gas Fault diagnosis and
recirculation (EGR) troubleshooting, “sensor
411 3 3387-3 1 voltage difference: signal (simulation, active) -
voltage is higher than test”
normal
411 4 3387-4 1 voltage difference: signal (simulation, active) -
voltage is lower than test”
normal

Flash
tion
Engine exhaust gas Fault removal requirement,
recirculation (EGR) “sensor calibration -
411 13 3387-13 2
voltage difference: test”
calibration required
412 3 3386-3 1
temperature: voltage is signal (simulation, passive)
higher than normal - test”
412 4 3386-4 1
temperature: voltage is signal (simulation, passive)
lower than normal - test”
Auxiliary temperature Fault diagnosis and
#1: voltage is higher than troubleshooting, “sensor
441 3 1836-3 1
test”
#1: voltage is lower than troubleshooting, “sensor
441 4 1836-4 1
test”
442 3 3683-3 1
- test”
442 4 3683-4 1
- test”
Proprietary data link: Troubleshooting, “data
625 14 246-14 1 special instructions link configuration state -
test”
Engine start enabling Troubleshooting, “ether
626 5 2417-5 1 device 1: current is lower starting aid device - test”
than normal

Flash
tion
Engine start enabling Troubleshooting, “ether
626 6 2417-6 1 device 1: current is starting aid device - test”
higher than normal
Calibration memory: Troubleshooting,
630 2 268-2 1 unstable, intermittent or “configuration
incorrect parameters”
Calibration module: Troubleshooting, “ECM
631 2 253-2 1 unstable, intermittent or software - installation”
incorrect
Engine timing sensor: Fault diagnosis and
637 11 261-11 1 other fault modes troubleshooting, “timing-
calibration”
Engine timing sensor: Fault diagnosis and
637 13 261-13 2 calibration required troubleshooting, “timing-
calibration”
J1939 network #1: Troubleshooting, “data
639 9 247-9 1
abnormal updating speed link - test”
J1939 software #1: Troubleshooting, “data
639 14 247-14 1
special instructions link - test”
Engine #01 cylinder oil Troubleshooting, “oil
651 5 1-5 1 injector: current is lower injector solenoid valve -
than normal test”
651 6 1-6 1 injector: current is higher injector solenoid valve -
than normal test”
than normal test”
than normal test”
than normal test”

Flash
tion
than normal test”
than normal test”
than normal test”
than normal test”
than normal test”
than normal test”
than normal test”
Engine starter motor Troubleshooting,
677 5 444-5 1 relay: current is lower “solenoid valve - test”
than normal
Engine starter motor Troubleshooting,
677 6 444-6 1 relay: current is higher “solenoid valve - test”
than normal
ECU 8V DC power: Fault diagnosis and
678 3 41-3 1 voltage is higher than troubleshooting, “sensor
normal power - test”
ECU 8V DC power: Fault diagnosis and
678 4 41-4 1 voltage is lower than troubleshooting, “sensor

Flash
tion
Engine rotation speed Fault diagnosis and
sensor #2: abnormal troubleshooting, “speed/
723 8 342-8 1
frequency, pulse width or timing- test”
period
Engine fuel supply pump Fault diagnosis and
931 5 1627-5 2 actuator: current is lower troubleshooting, “solenoid
than normal valve - test”
Engine fuel supply pump Fault diagnosis and
931 6 1627-6 2 actuator: current is higher troubleshooting, “solenoid
than normal valve - test”
Engine (compression) Troubleshooting, “retarder
1072 5 2533-5 1 brake output #1: current - test”
is lower than normal
is higher than normal
Engine (exhaust) brake Troubleshooting,
1074 5 2232-5 1 output: current is lower “solenoid valve - test”
than normal
Engine (exhaust) brake Troubleshooting,
1074 6 2232-6 1 output: current is higher “solenoid valve - test”
than normal
Sensor supply voltage 1: Fault diagnosis and
1079 3 1 voltage is higher than troubleshooting, “power -
normal test”
1079 4 1 voltage is lower than troubleshooting, “power -
normal test”

Flash
tion
Engine turbocharger 1 Fault diagnosis and
compressor inlet troubleshooting, “sensor
1176 3 2738-3 1
pressure: voltage is signal (simulation, active) -
higher than normal test”
Engine turbocharger 1 Fault diagnosis and
compressor inlet troubleshooting, “sensor
1176 4 2738-4 1
pressure: voltage is lower signal (simulation, active) -
than normal test”
1231 9 2348-9 1
abnormal updating speed link - test”
1231 14 2348-14 1
1235 9 5856-9 1
abnormal updating rate link - test”
J1939 software #3: Troubleshooting, “data
1235 14 5856-14 1
Engine fuel pump Fault diagnosis and
pressurizing group #1: troubleshooting, “fuel
1347 5 1779-5 1
current is lower than injection pump - test”
normal
1347 6 1779-6 1
current is higher than injection pump - test”
normal
1348 5 1780-5 1
current is lower than injection pump - test”
normal
1348 6 1780-6 1
current is higher than injection pump - test”
normal

Flash
tion
1385 3 1836-3 1
- test”
1385 4 1836-4 1
- test”
Auxiliary voltage #1: Fault diagnosis and
1387 3 1835-3 1
test”
Auxiliary voltage #1: Fault diagnosis and
1387 4 1835-4 1
test”
Fan speed: voltage is Fault diagnosis and
1639 3 1 higher than normal troubleshooting, “cooling
fan speed - test”
Fan speed: abnormal Fault diagnosis and
1639 8 1 frequency, pulse width or troubleshooting, “cooling
period fan speed - test”
Fan speed: engine Fault diagnosis and
E1363
1639 17 1 cooling fan in low speed troubleshooting, “cooling
（1）
fan speed - test”
After-treatment 1 DEF Fault diagnosis and
1761 3 3130-3 1 tank level: voltage is troubleshooting, “DEF
higher than normal tank sensor - test”
1761 4 3130-4 1 tank level: voltage is troubleshooting, “DEF
lower than normal tank sensor - test”
Engine air-intake cooler Fault diagnosis and
2630 3 3372-3 1
outlet temperature: troubleshooting, “sensor

Flash
tion
voltage is higher than signal (simulation, passive)
normal - test”
Engine air-intake cooler Fault diagnosis and
outlet temperature: troubleshooting, “sensor
2630 4 3372-4 1
voltage is lower than signal (simulation, passive)
normal - test”
Engine exhaust gas Troubleshooting,
recirculation (EGR) “solenoid valve - test”
2791 5 3405-5 1
valve control: current is
lower than normal
Engine exhaust gas Troubleshooting,
recirculation (EGR) “solenoid valve - test”
2791 6 3405-6 1
valve control: current is
higher than normal
Engine air cut-off Troubleshooting, “air cut-
2813 5 3239-5 1 instruction state: current off device - test”
Engine air cut-off Troubleshooting, “air cut-
2813 6 3239-6 1 instruction state: current off device - test”
Engine air-intake valve Fault diagnosis and
drive system oil pressure: troubleshooting, “sensor
2948 3 1924-3 1
normal test”
drive system oil pressure: troubleshooting, “sensor
2948 4 1924-4 1
normal test”
Engine air-intake valve Troubleshooting,
drive system oil pressure: “solenoid valve - test”
2949 5 1922-5 1
current is lower than
normal
Engine air-intake valve Troubleshooting,
2949 6 1922-6 1
drive system oil pressure “solenoid valve - test”

Flash
tion
control valve: current is
higher than normal
drive system oil pressure troubleshooting, “variable
2949 7 1922-7 1
control valve: incorrect valve actuator response -
response test”
Engine air intake valve Troubleshooting,
2950 5 1901-5 1 actuator #1: current is “variable valve actuator -
lower than normal test”
Engine air intake valve Fault diagnosis and
actuator #1: incorrect troubleshooting, “variable
2950 7 1901-7 1
response valve actuator response -
test”
2951 7 1902-7 1
test”

Flash
tion
2952 7 1903-7 1
test”
2953 7 1904-7 1
test”
2954 7 1905-7 1
test”
2955 7 1906-7 1
test”

Flash
tion
3031 3 3134-3 1 tank temperature: voltage troubleshooting, “DEF
is higher than normal tank sensor - test”
3031 4 3134-4 1 tank temperature: voltage troubleshooting, “DEF
is lower than normal tank sensor - test”
After-treatment #1 NOx Troubleshooting, “NOx
3216 5 3655-5 1 sensor air inlet: current is sensor supply - test”
lower than normal
After-treatment #1 Nox Troubleshooting, “NOx
3216 6 3655-6 1 sensor air inlet: current is sensor supply - test”
higher than normal
After-treatment #1 NOx Fault diagnosis and
inlet air: other fault troubleshooting,
3216 11 3655-11 1
modes “sensor(data link type) -
test”
inlet air: fault troubleshooting,
3216 12 3655-12 2
“sensor(data link type) -
test”
3226 5 3609-5 1 sensor air outlet: current sensor supply - test”
3226 6 3609-6 1 sensor air outlet: current sensor supply - test”
outlet air: other fault troubleshooting,
3226 11 3609-11 1
modes “sensor(data link type) -
test”
outlet air: fault troubleshooting,
3226 12 3609-12 2
test”

Flash
tion
Exhaust gas temperature Fault diagnosis and
1: voltage is higher than troubleshooting, “sensor
3241 3 3485-3 1
test”
Exhaust gas temperature Fault diagnosis and
1: voltage is lower than troubleshooting, “sensor
3241 4 3485-3 1
test”
Particulate filter inlet air Fault diagnosis and
3242 3 2452-3 1
test”
Particulate filter inlet air Fault diagnosis and
3242 4 2452-4 1
test”
Particulate filter pressure Fault diagnosis and
difference: unstable, troubleshooting, “sensor
3251 2 2458-2 1
intermittent or incorrect signal (simulation, active) -
test”
difference: voltage is troubleshooting, “sensor
3251 3 2458-3 1
test”
difference: voltage is troubleshooting, “sensor
3251 4 2458-4 1
test”
Particulate filter pressure Fault removal requirement,
3251 13 2458-13 1 difference: out of “sensor calibration -
calibration range test”
recirculation (EGR) inlet troubleshooting, “sensor
3358 3 3385-3 1

Flash
tion
recirculation (EGR) inlet troubleshooting, “sensor
3358 4 3385-4 1
than normal test”
Engine exhaust gas Fault removal requirement,
recirculation (EGR) inlet “sensor calibration -
3358 13 3385-13 1
pressure: calibration test”
required
3358 21 3385-21 1 recirculation (EGR) inlet troubleshooting, “sensor
pressure: low data drift power - test”
3360 3 3820-3 1 controller: voltage is troubleshooting, “power -
3360 4 3820-4 1 controller: voltage is troubleshooting, “power -
After-treatment #1 DEF Troubleshooting, “data
3360 9 3820-9 1 controller: abnormal link - test”
updating rate
controller: fault troubleshooting,
3360 12 3820-12 2
test”
Catalyst injection unit: Troubleshooting,
3361 5 3821-5 1 current is lower than “solenoid valve - test”
normal
Catalyst injection unit: Troubleshooting,
3361 6 3821-6 1 current is higher than “solenoid valve - test”
normal
Catalyst injection unit: Fault diagnosis and
3361 7 3821-7 1 incorrect response troubleshooting, “DEF
module no response”

Flash
tion
3361 11 3821-11 2 other fault modes troubleshooting, “DEF
3361 14 3821-14 1 special instructions troubleshooting, “DEF
After-treatment 1 DEF Troubleshooting,
3363 5 3126-5 1 tank heater: current is “solenoid valve - test”
lower than normal
3363 6 3126-6 1 tank heater: current is “solenoid valve - test”
higher than normal
3363 7 3126-7 1 tank heater: incorrect troubleshooting, “DEF
response low temperature”
After-treatment #1 fuel Troubleshooting,
3479 5 2461-5 1 pressure control: current “solenoid valve - test”
3479 6 2461-6 1 pressure control: current “solenoid valve - test”
After-treatment #1 fuel Fault diagnosis and
pressure #1: voltage is troubleshooting, “sensor
3480 3 2460-3 1
test”
3480 4 2460-4 1
test”
After-treatment #1 Troubleshooting, “ARD
3484 5 2465-5 1 ignition: current is lower ignition - test”
than normal

Flash
tion
3484 6 2465-6 1 ignition: current is higher ignition - test”
than normal
After-treatment #1 air Troubleshooting, “ARD
3487 5 2489-5 1 pressure control: current combustion air - test”
3487 6 2489-6 1 pressure control: current combustion air - test”
3487 13 2489-13 1 pressure control: out of combustion air valve -
calibration range replace”
pressure actuator combustion air - test”
3488 3 2490-3 1
position: voltage is
higher than normal
pressure actuator combustion air - test”
3488 4 2490-4 1
position: voltage is lower
than normal

Flash
tion
3511 11 2131-11 1 other fault modes troubleshooting, “DEF
pump sensor power - test”
Catalyst reagent Fault diagnosis and
concentration: unstable, troubleshooting,
3516 2 3100-2 1
intermittent or wrong “sensor(data link type) -
test”
Catalyst reagent Troubleshooting, “NOx
3516 11 3100-11 2 concentration: other fault low conversion
modes efficiency”
Catalyst reagent Fault diagnosis and
concentration: fault troubleshooting,
3516 12 3100-12 2
test”
#1 absolute pressure: troubleshooting, “sensor
3563 3 1785-3 1
normal test”
#1 absolute pressure: troubleshooting, “sensor
3563 4 1785-4 1
normal test”
Engine intake manifold Fault removal requirement,
3563 13 1785-13 1 #1 absolute pressure: “sensor calibration -
calibration required test”
3563 21 1785-21 1 #1 absolute pressure: low troubleshooting, “sensor
data drift power - test”
Engine intake manifold Fault removal requirement,
3563 10 1 #1 absolute pressure: “sensor calibration -
variation is out of normal test”
DPF #1 air intake Fault diagnosis and
3609 3 3464-3 1 pressure: voltage is troubleshooting, “sensor
higher than normal

Flash
tion
signal (simulation, active) -
test”
DPF #1 air intake Fault diagnosis and
pressure: voltage is lower troubleshooting, “sensor
3609 4 3464-4 1
test”
DPF #1 intake air Fault removal requirement,
3609 13 3464-13 1 pressure: calibration “sensor calibration -
required test”
DPF #1 intake air Fault diagnosis and
3609 21 3464-21 1 pressure: low data drift troubleshooting, “sensor
power - test”
injector actuator #2: injector solenoid valve -
3659 5 2602-5 1
current is lower than test”
normal
3659 6 2602-6 1
current is higher than test”
normal
3660 5 2604-5 1
normal
3660 6 2604-6 1
normal
3661 5 2606-5 1
normal

Flash
tion
3661 6 2606-6 1
normal
3662 5 2608-5 1
normal
3662 6 2608-6 1
normal
3663 5 2610-5 1
normal
3663 6 2610-6 1
normal
3664 5 2612-5 1
normal
3664 6 2612-6 1
normal
After-treatment 1 Fault diagnosis and
auxiliary air pressure: troubleshooting, “sensor
3837 3 3493-3 1
normal test”
3837 4 3493-4 1
auxiliary air pressure: troubleshooting, “sensor

Flash
tion
normal test”
After-treatment 1 Fault removal requirement,
3837 13 3493-13 1 auxiliary air pressure: “sensor calibration -
calibration required test”
3837 21 3493-21 1 auxiliary air pressure: troubleshooting, “sensor
low data drift power - test”
4077 3 2497-3 1
test”
4077 4 2497-4 1
test”
Fan drive bypass Fault diagnosis and
4212 5 291-5 1 instruction state: current troubleshooting, “cooling
is lower than normal fan control - test”
Fan drive bypass Fault diagnosis and
4212 6 291-6 1 instruction state: current troubleshooting, “cooling
is higher than normal fan control - test”
Fan drive bypass Troubleshooting, “cooling
4212 13 291-13 1 instruction state: out of fan - calibrate”
calibration range
Engine fan reverse Fault diagnosis and
4214 5 485-5 1 rotation actuator: current troubleshooting, “cooling
is lower than normal fan reverse rotation - test”
Engine fan reverse Fault diagnosis and
4214 6 485-6 1 rotation actuator: current troubleshooting, “cooling
is higher than normal fan reverse rotation - test”
Start ground halt: voltage Fault diagnosis and
4215 3 267-3 1 is higher than normal troubleshooting, “machine
halt (ground) - test”

Flash
tion
Start ground halt: voltage Fault diagnosis and
4215 4 267-4 1 is lower than normal troubleshooting, “machine
halt (ground) - test”
transformer secondary ignition - test”
4265 5 3180-5 1
output: current is lower
than normal
After-treatment #1 oil Fault diagnosis and
injector #1 heater troubleshooting, “ARD
4301 3 3182-3 1
control: voltage is higher nozzle heater - test”
than normal\
After-treatment #1 oil Fault diagnosis and
injector #1 heater troubleshooting, “ARD
4301 4 3182-4 1
control: voltage is lower nozzle heater - test”
than normal\
After-treatment #1 oil Troubleshooting,
injector #1 heater “solenoid valve - test”
4301 5 3182-5 1
control: current is lower
than normal\
After-treatment #1 oil Troubleshooting,
injector #1 heater “solenoid valve - test”
4301 6 3182-6 1
control: current is higher
than normal
doser absolute pressure: troubleshooting, “DEF
4334 3 3090-3 1
voltage is higher than pump pressure sensor -
normal test”
doser absolute pressure: troubleshooting, “DEF
4334 4 3090-4 1
voltage is lower than pump pressure sensor -
normal test”
4334 7 3090-7 1 doser absolute pressure: troubleshooting, “DEF
incorrect response pressure no response”

Flash
tion
After-treatment #1 DEF Troubleshooting, “DEF
doser #1 temperature: pump motor - test”
4337 5 3096-5 1
normal
doser #1 temperature: pump motor - test”
4337 6 3096-6 1
current is higher than
normal
injection temperature: troubleshooting, “DEF
4337 8 3096-8 1
abnormal frequency, pump - replace”
pulse width or period
4354 5 3110-5 1 pipeline heater 1: current troubleshooting, “DEF
is lower than normal pipeline heater - test”
is higher than normal pipeline heater - test”
After-treatment 1 SCR Fault diagnosis and
catalyst air inlet troubleshooting, “sensor
4360 3 3105-3 1
temperature: voltage is signal (simulation, active) -

Flash
tion
After-treatment 1 SCR Fault diagnosis and
catalyst air inlet troubleshooting, “sensor
4360 4 3105-4 1
temperature: voltage is signal (simulation, active) -
After-treatment #1 DEF Fault diagnosis and
pump motor speed: troubleshooting, “DEF
4374 5 3118-5 1
current is lower than pump motor - test”
normal
4374 6 3118-6 1
current is higher than pump motor - test”
normal
4374 8 3118-8 1
abnormal frequency, pump - replace”
pulse width or period
4376 5 3862-5 1 return valve: current is troubleshooting, “DEF
lower than normal return valve - test”
4376 6 3862-6 1 return valve: current is troubleshooting, “DEF
higher than normal return valve - test”
4376 7 3862-7 1 return valve: incorrect troubleshooting, “DEF
response pump - replace”
4376 14 3862-14 1 return valve: special pump motor - test”
instructions
Engine exhaust manifold Troubleshooting,
#1 exhaust flow balance “solenoid valve - test”
5276 5 3409-5 1 valve actuator control:
normal

Flash
tion
Engine exhaust manifold Troubleshooting,
#1 exhaust flow balance “solenoid valve - test”
5276 6 3409-6 1 valve actuator control:
normal
Engine accelerator Troubleshooting, “engine
5419 3 3514-3 1 actuator 1: voltage is throttle valve - test ”
higher than normal
5419 4 3514-4 1 actuator 2: voltage is throttle valve - test ”
lower than normal
5419 5 3514-5 1 actuator 2: current is throttle valve - test ”
lower than normal
5419 6 3514-6 1 actuator 2: current is throttle valve - test ”
higher than normal
pump relay control: “solenoid valve - test”
5423 5 3427-5 1
normal
pump relay control: “solenoid valve - test”
5423 6 3427-6 1
normal
flow diverter valve “solenoid valve - test”
5424 5 3413-5 1
than normal
flow diverter valve “solenoid valve - test”
5424 6 3413-6 1
than normal

Flash
tion
pressure #2 actuator “solenoid valve - test”
5425 5 3391-5 1
than normal
pressure #2 actuator “solenoid valve - test”
5425 6 3391-6 1
than normal
After-treatment #1 Fault diagnosis and
hydrocarbon feeder air troubleshooting, “sensor
5456 3 2
inlet temperature: voltage signal (simulation, active) -
is higher than normal test”
After-treatment #1 Fault diagnosis and
hydrocarbon feeder air troubleshooting, “sensor
5456 4 2
inlet temperature: voltage signal (simulation, active) -
is higher than normal test”
pipeline heater relay: troubleshooting, “DEF
5491 5 3822-5 1
current is lower than pipeline heater - test”
normal
pipeline heater relay: troubleshooting, “DEF
5491 6 3822-6 1
current is higher than pipeline heater - test”
normal
5491 12 3822-12 1 pipeline heater relay: troubleshooting, “sensor
fault (data link type) - test”
After-treatment #1 Troubleshooting, “after-
5576 2 3468-2 1 identification: unstable, treatment identification
intermittent or incorrect module - test”
identification: abnormal treatment identification
5576 8 3468-8 1
frequency, pulse width or module - test”
period

Flash
tion
After-treatment #1 Troubleshooting, “data
5576 14 3468-14 1 identification: special link configuration state -
instructions test”
5577 2 3469-2 1 identification: unstable, treatment identification
intermittent or incorrect module - test”
identification: abnormal treatment identification
5577 8 3469-8 1
frequency, pulse width or module - test”
period
After-treatment #2 Troubleshooting, “data
5577 14 3469-14 1 identification: special link configuration state -
instructions test”
Engine oil delivery Fault diagnosis and
absolute pressure: troubleshooting, “sensor
5578 3 289-3 1
normal test”
absolute pressure: troubleshooting, “sensor
5578 4 289-4 1
normal test”
5578 21 289-21 1 absolute pressure: low troubleshooting, “sensor
data drift power - test”
Engine filtered fuel Fault diagnosis and
delivery absolute troubleshooting, “sensor
5580 3 460-3 1
delivery absolute troubleshooting, “sensor
5580 4 460-4 1
than normal test”

Flash
tion
5580 21 460-21 1 delivery absolute troubleshooting, “sensor
pressure: low data drift power - test”
After-treatment diesel Fault diagnosis and
particulate filter troubleshooting, “sensor
5742 12 5405-12 2
temperature sensor (data link type) - test”
module: fault
After-treatment #1 intake Fault diagnosis and
5758 11 3621-11 1 air sensor power: other troubleshooting, “power -
fault modes test”
After-treatment #1 outlet Fault diagnosis and
5759 11 3619-11 1 air sensor power: other troubleshooting, “power -
fault modes test”
control module relay “solenoid valve - test”
5965 5 3838-5 1
than normal
control module relay “solenoid valve - test”
5965 6 3838-6 1
than normal
control module power: troubleshooting, “DEF
5966 5 3965-5 1
current is lower than control module power -
normal test”
control module power: troubleshooting, “DEF
5966 6 3965-6 1
current is higher than control module power -
normal test”
control module power troubleshooting, “DEF
6309 6 3966-6 1
#2: current is higher than control module power -
normal test”

Fault diagnostic code severity is defined as below:
• Level 1 - Operator needs to pay attention to engine system Operator should immediately inspect or
maintain related systems.
Flash indication: Yellow flash Buzzer: Off.
• Level 2 - Operator needs to change engine running situation or conduct maintenance procedure. Failing
to remove any fault that triggers this warning may cause engine component damage.
Flash indication: Red flash Buzzer: Off.
• Level 3 - Operator needs to immediately shut down the engine in case of damaging it or causing injury
to surrounding people. The fault that may cause trouble must be removed before engine resumption.
Flash indication: Red flash constantly on Buzzer: On.

Table 4-9 Engine Event Code Table
Flas-
h
CDL Event inspection and troubleshoot-
SPN FMI indi- Event description
code ing procedure
cati-
on
Engine fuel supply Fault diagnosis and troubleshooting,
94 0 pressure: high - highest “High fuel pressure”
severity state (3)
94 1 pressure: low - highest “low fuel pressure”
severity state (3)
94 15 pressure: high - lowest “High fuel pressure”
severity state (1)
94 17 pressure: low - lowest “low fuel pressure”
severity state (1)
94 18 pressure: low - moderate “low fuel pressure”
severity state (2)
Moisture-in-fuel Fault diagnosis and troubleshooting,
E232
97 15 1 indicator: high - lowest “water contained in water-oil
（1）
severity level (1) separator”

Table 4-9 Engine Event Code Table(continued)
Flas-
h
code ing procedure
cati-
on
Moisture-in-fuel Fault diagnosis and troubleshooting,
E232
97 16 2 indicator: high - moderate “water contained in water-oil
（2）
severity level (2) separator”
E360 Engine oil pressure: low - Fault diagnosis and troubleshooting,
100 1 3
（3） highest severity level (3) “low engine oil pressure”
E360 Engine oil pressure: low - Fault diagnosis and troubleshooting,
100 17 1
（1） lowest severity level (1) “low engine oil pressure”
Engine oil pressure: low - Fault diagnosis and troubleshooting,
E360
100 18 2 moderate severity level “low engine oil pressure”
（2）
(2)
Engine crankcase Troubleshooting, “high crankcase
E1036
101 15 1 pressure: high - lowest pressure”
（1）
severity level (1)
Engine crankcase Troubleshooting, “high crankcase
E1036
101 16 2 pressure: high - moderate pressure”
（2）
severity level (2)
Engine intake manifold Troubleshooting, “intake manifold
E1045
102 1 3 #1 pressure: low - highest air pressure is low”
（3）
severity level (3)
102 15 #1 pressure: high - lowest air pressure is low”
severity level (1)
#1 pressure: high - air pressure is low”
102 16
moderate severity level
(2)
E1045 #1 pressure: low - air pressure is low”
102 18 2
（2） moderate severity level
(2)

Flas-
h
code ing procedure
cati-
on
105 0 #1 temperature: high - air temperature is high”
highest severity level (3)
E1690
105 1 1 #1 temperature: weakest air temperature is high”
（3）
(3)
E539
105 15 1 #1 temperature: high - air temperature is high”
（1）
lowest severity level (1)
E539 #1 temperature: high - air temperature is high”
105 16 2
(2)
Engine air filter 1 Troubleshooting, “inlet air
E583
（1）
- lowest severity level (1)
Engine air filter 1 Troubleshooting, “inlet air
E583 pressure difference: high prevented”
107 16 2
（2） - moderate severity level
(2)
Engine coolant pressure: Fault diagnosis and troubleshooting,
E2112
109 1 3 low - highest severity “low coolant pressure”
（3）
level (3)
E2112
109 17 1 low - lowest severity “low coolant pressure”
（1）
level (1)
E2112
109 18 2 low - moderate severity “low coolant pressure”
（2）
level (2)

Flas-
h
code ing procedure
cati-
on
Engine coolant Fault diagnosis and troubleshooting,
E361
110 0 3 temperature: high - “high coolant temperature”
（3）
E361
110 15 1 temperature: high - “high coolant temperature”
（1）
E361 temperature: high - “high coolant temperature”
110 16 2
(2)
E199
110 17 1 temperature: low - lowest “low coolant temperature”
（1）
severity level (1)
Engine coolant level: low Troubleshooting, “low coolant
111 0 - highest severity level level”
(3)
E2143
111 1 3 - highest severity level level”
（3）
(3)
E2143 Engine coolant level: low Troubleshooting, “low coolant
111 17 1
（1） - lowest severity level (1) level”
E2143
111 18 2 - moderate severity level level”
（2）
(2)
Battery potential/power Troubleshooting, “power - test”
E1378
168 15 1 input 1: high - lowest
（1）
severity (1)
Battery potential/power Troubleshooting, “power - test”
E1379
168 17 1 input 1: low - lowest
（1）
severity (1)

Flas-
h
code ing procedure
cati-
on
E441 Storage battery potential/ Fault diagnosis and troubleshooting,
168 31 1
（1） power input #1 “high idle speed”
Engine exhaust gas Fault diagnosis and troubleshooting,
temperature: high - “NRS high exhaust temperature”
173 16
(2)
Engine fuel temperature Fault diagnosis and troubleshooting,
E363
174 0 3 1: high - highest severity “high fuel temperature”
（3）
level (3)
E363
174 15 1 1: high - lowest severity “high fuel temperature”
（1）
level (1)
E363
174 16 2 1: high - moderate “high fuel temperature”
（2）
severity level (2)
Engine oil temperature 1: Fault diagnosis and troubleshooting,
E197
175 0 3 high - highest severity “high engine oil temperature”
（3）
level (3)
E197
175 15 1 high - lowest severity “high engine oil temperature”
（1）
level (1)
E197
175 16 2 high - moderate severity “high engine oil temperature”
（2）
level (2)
Engine rotation speed 1: Fault diagnosis and troubleshooting,
E362
190 0 3 high - highest severity “engine over speed”
（3）
level (3)
Engine rotation speed: Fault diagnosis and troubleshooting,
E362
190 15 1 high - lowest severity “engine over speed”
（1）
level (1)

Flas-
h
code ing procedure
cati-
on
Engine rotation speed: Fault diagnosis and troubleshooting,
190 16 high - moderate severity “engine over-speed”
level (2)
Engine total running Requiring to manually align the clock,
E861
247 13 1 time: out of calibration use Perkins EST synchronous ECM
（1）
range working hour meter
Engine exhaust gas Troubleshooting, “NOx reduction
E1094 recirculation (EGR) system (NRS) - test”
411 15 1
（1） pressure difference: high
- lowest severity level (1)
411 17 1
（1） pressure difference: low -
Engine exhaust gas Troubleshooting, “NRS exhaust
E1092 recirculation (EGR) system temperature is high”
412 15 1
（1） temperature: high -
Engine exhaust gas Troubleshooting, “NRS exhaust
recirculation (EGR) system temperature is high”
E1092
412 16 2 temperature: high -
（2）
(2)
Auxiliary temperature 1: Troubleshooting, “symptom
E445
441 0 3 low - highest severity troubleshooting” fault removing
（3）
level (3) procedure is up to the symptom.
E445
441 15 1 high - lowest severity troubleshooting” fault removing
（1）
E445
441 16 2 high - moderate severity troubleshooting” fault removing
（2）
Flas-
h
code ing procedure
cati-
on
Engine idle stop system Troubleshooting, “engine idle stop”
E1171 enables engine to halt:
593 31 1
（1） low - highest severity
level (3)
Engine idle stop system Troubleshooting, “In idling state,
E1172 turns off operator engine stops”
594 0 2
（3） warning mode: high -
highest severity (3)
E1172 Engine idle stop system Troubleshooting, “engine idle stop”
594 31 2
（2） actuator warning mode
Engine auxiliary stop When activating remote emergency
switch shutdown switch, 970-31 engine
assistance - engine shutdown switch
E264 event code. This event will prevent
970 31 3
（3） engine
Related operations under such
situations. ECM power must be turned
off for 3s in order to clear this event.
Engine derate switch Monitoring system override switch
E97
971 31 1 activated. When this event is in active
（1）
state, engine derate is stopped.
Engine stop override When ECM shuts down engine due to
switch events other than induction related
events, using engine stop override
switch can keep engine running. If this
E85
1237 31 1 code exists, it means engine may have
（1）
been damaged. This code instructs the
operator to keep engine running under
typical situations that may cause
damage.

Flas-
h
code ing procedure
cati-
on
Auxiliary pressure #1: Troubleshooting, “symptom
E443
1387 0 3 high - highest severity troubleshooting” fault removing
（3）
E443
1387 15 1 high - lowest severity troubleshooting” fault removing
（1）
E443
1387 16 2 high - moderate severity troubleshooting” fault removing
（2）
E1363 Fan speed: low - lowest Fault diagnosis and troubleshooting,
1639 17 1
（1） severity level (1) “cooling fan speed - test”
E225 Engine cannot Fault diagnosis and troubleshooting,
1664 31 2
（2） automatically start “engine turning overtime occur”
After-treatment 1 DEF Fault diagnosis and troubleshooting,
E954
1761 1 3 tank level: low - highest “DEF tank level is low”
（3）
severity level (3)
E954
1761 17 1 tank level: low - lowest “DEF tank level is low”
（1）
severity level (1)
E954 tank level: low - “DEF tank level is low”
1761 18 2
(2)
Engine air-intake cooler Troubleshooting, “intake manifold
E1107
2630 1 3 outlet temperature: low - air pressure is low”
（3）
2659 15 1
（1） quality flow rate: high -

Flas-
h
code ing procedure
cati-
on
2659 17 1
（1） quality flow rate: low -
Engine air-intake valve Fault diagnosis and troubleshooting,
E1101
2948 7 2 drive system oil pressure: “variable valve actuator response -
（2）
incorrect response test”
Engine air-intake valve Fault diagnosis and troubleshooting,
E488 drive system oil pressure: “variable valve actuator response -
2948 17 2
（2） low - moderate severity test”
level (2)
E1441
3031 7 2 tank temperature: “DEF low temperature”
（2）
incorrect response
E960 tank temperature: high - “DEF tank high temperature”
3031 16 2
(2)
E1398 tank temperature: low - “DEF low temperature”
3031 18 2
(2)
After-treatment #1 NOx Fault diagnosis and troubleshooting,
E1431
3216 7 2 inlet air: incorrect “NOx sensor - test”
（2）
response
After-treatment #1 02 Fault diagnosis and troubleshooting,
E1407 intake air: high - “clean exhaust system has high
3217 16 2
（2） moderate severity level oxygen level”
(2)
After-treatment #1 NOx Fault diagnosis and troubleshooting,
E1432
3226 7 2 outlet air: incorrect “NOx sensor - test”
（2）
response

Flas-
h
code ing procedure
cati-
on
After-treatment #1 02 Fault diagnosis and troubleshooting,
E1408
3227 16 2 outlet air: high - moderate “clean exhaust system has high
（2）
severity level (2) oxygen level”
Particulate filter intake Troubleshooting, “diesel particulate
E1008
3242 15 1 air temperature: high - filter temperature is high”
（1）
E1008 air temperature: high - filter temperature is high”
3242 16 2
(2)
E1014 air temperature: low - filter temperature is high”
3242 18 2
(2)
Particulate trap intake air Troubleshooting, “diesel particulate
3251 18 1020-2 1 temperature: low - filter inlet pressure is low”
moderate level (2)
After-treatment fuel Troubleshooting, “AFTFD (After-
3556 7 1 injector 1: incorrect treatment fuel filling) - test”
response
E114
3362 14 1 injection unit input line: “DEF not completely drained”
（1）
special instructions
E1025 After-treatment #1 Troubleshooting, “ARD ignition
3473 31 2
（2） ignition failure failure”
After-treatment #1 Troubleshooting, “ARD combustible
E1026
3474 14 1 combustible loss: special loss”
（1）
instructions
E1026 After-treatment #1 Troubleshooting, “ARD combustible
3474 31 2
（2） combustible loss loss”

Flas-
h
code ing procedure
cati-
on
After-treatment #1 fuel Troubleshooting, “ARD fuel pressure
E1050
3480 15 1 pressure #1: high - lowest is high”
（1）
severity level (1)
E1050 pressure #1: high - is high”
3480 16 2
(2)
E1052
3480 17 1 pressure #1: low - lowest is high”
（1）
severity level (1)
E1052 pressure #1: low - is high”
3480 18 2
(2)
E1305
3483 11 1 regeneration state: other deactivated”
（1）
fault modes
After-treatment #1 air Troubleshooting, “ARD combustion
E1041
3487 7 1 pressure control: air - test”
（1）
incorrect response
Catalyst reagent Fault diagnosis and troubleshooting,
E1365 concentration: high - “low NOx conversion”
3516 16 2
(2)
Catalyst reagent Fault diagnosis and troubleshooting,
E1364 concentration: low - “low NOx conversion”
3516 18 2
(2)
E1040 After-treatment #1 Troubleshooting, “ARD
3530 31 2
（2） regeneration manual stop deactivated”

Flas-
h
code ing procedure
cati-
on
DPF #1 intake air Troubleshooting, “diesel particulate
E1156
3609 15 1 pressure: high - lowest filter inlet pressure is high”
（1）
severity level (1)
DPF #1 intake air Fault diagnosis and troubleshooting,
E1154
3609 17 1 pressure: low - lowest “diesel particulate filter inlet
（1）
severity level (1) pressure is low”
DPF #1 intake air Fault diagnosis and troubleshooting,
E1154
3609 18 2 pressure: low - moderate “diesel particulate filter inlet
（2）
severity level (2) pressure is low”
DPF initiative Troubleshooting, “ARD
regeneration is inhibited deactivated”
E1300
3616 15 1 because engine isn't
（1）
preheated: High - lowest
severity level (1)
Engine air-cutoff state: Fault diagnosis and troubleshooting,
E2088
3667 2 1 unstable, intermittent or “air cut-off valve - test”
（1）
incorrect
E2087 Engine air-cutoff state Fault diagnosis and troubleshooting,
3667 31 3
（3） “air cut-off valve - test”
Particulate filter initiative Troubleshooting, “ARD
E993
3703 31 2 regeneration is inhibited deactivated”
（2）
by inhibition switch
Particulate filter initiative Troubleshooting, “ARD low
E593 regeneration is inhibited temperature”
3711 31 2
（2） due to low exhaust gas
temperature
regeneration is inhibited deactivated”
E1301
3712 15 1 due to system active
（1）
fault: High - lowest
severity level (1)

Flas-
h
code ing procedure
cati-
on
Particulate filter initiative Troubleshooting, “too much dust is
E992 regeneration is inhibited trapped by diesel particulate filter”
3714 31 3
（3） by temporary system
locking
Particulate filter initiative Troubleshooting, “too much dust is
E991 regeneration is inhibited trapped by diesel particulate filter”
3715 31 3
（3） by permanent system
locking
After-treatment Troubleshooting, “ARD
E1300 regeneration fail to start deactivated”
3716 15 1
（1） due to low engine
temperature
E1300 regeneration is inhibited deactivated”
3716 31 2
（2） because engine isn't
heated
Particulate filter #1 ash Troubleshooting, “too much dust is
E995
3719 0 3 load percentage: high - trapped by diesel particulate filter”
（3）
Particulate filter #1 ash Troubleshooting, “too much dust is
E995 load percentage: high - trapped by diesel particulate filter”
3719 16 2
(2)
Particulate filter #1 ash Troubleshooting, “diesel particulate
E997
3720 15 1 load percentage: high - filter ash load is high”
（1）
Particulate filter #2 ash Troubleshooting, “diesel particulate
E997 load percentage: high - filter ash load is high”
3720 16 2
(2)
E1302 DPF #1 Conditions fail to Troubleshooting, “ARD
3750 15 1
（1） meet initiative deactivated”

Flas-
h
code ing procedure
cati-
on
regeneration: high -
DPF #1 Conditions fail to Troubleshooting, “ARD
E1239 meet initiative deactivated”
3750 17 2
（2） regeneration: low -
meet initiative deactivated”
E1239
3750 18 3 regeneration: low -
（3）
(2)
E1239 meet initiative deactivated”
3750 31 1
（1） regeneration
requirements
After-treatment 1 Troubleshooting, “ARD combustion
E1170 auxiliary air pressure: supply air pressure is low”
3837 17 1
（1） low - lowest severity
level (1)
After-treatment #1 fuel Troubleshooting, “fuel metering
4077 0 2 pressure #2: low - valve - replace”
moderate level (2)
E1051
4077 15 1 pressure #2: high - lowest is high”
（1）
severity level (1)
E1051 pressure #2: high - is high”
4077 16 2
(2)
E1053
4077 17 1 pressure #2: low - lowest is low”
（1）
severity level (1)

Flas-
h
code ing procedure
cati-
on
E1053 pressure #2: low - is low”
4077 18 2
(2)
E678 Start ground halt Fault diagnosis and troubleshooting,
4215 31 3
（3） “machine halt (ground) - test”
After-treatment #1 DEF Fault diagnosis and troubleshooting,
E930 #1 pressure (absolute “high DEF pressure”
4334 15 1
（1） value): high - lowest
severity level (1)
E930 dosing meter absolute “high DEF pressure”
4334 16 2
（2） pressure: high - moderate
severity level (2)
E931 dosing meter absolute “low DEF pressure”
4334 18 2
（2） pressure - moderate
severity level (2)
After-treatment #1 SCR Fault diagnosis and troubleshooting,
catalyst air inlet “SCR catalyst inlet air temperature
E946
4360 16 2 temperature: high - sensor - test”
（2）
(2)
E947 catalyst air inlet “SCR catalyst inlet air temperature
4360 17 1
（1） temperature: low - lowest sensor - test”
severity level (1)
catalyst air inlet “SCR catalyst inlet air temperature
E947
4360 18 2 temperature: low - sensor - test”
（2）
(2)

Flas-
h
code ing procedure
cati-
on
E1410 catalyst conversion “low NOx conversion”
4364 2 2
（2） efficiency: unstable,
intermittent or incorrect
catalyst conversion “low NOx conversion”
E1309
4364 18 2 efficiency: low -
（2）
(2)
After-treatment #1 Diesel Troubleshooting, “Diesel oxidation
E2165 oxidation catalyst inlet catalyst low temperature”
4765 18 1
(2) temperature: low -
moderate (2)
E2571 oxidation catalyst outlet catalyst high temperature”
4766 16 1
moderate (2)
E2512 oxidation catalyst outlet catalyst low temperature”
4766 18 1
moderate (2)
After-treatment #1 SCR DEF (DEF) not closed as planned.
E1390
4792 14 2 system: Special Please contact dealer support network
（2）
instructions (DSN) for further help.
After-treatment #1 SCR Engine ECM produces this code. Use
catalyst system: Perkins EST to connect to after-
4792 31
conditions exist treatment ECM, so as to acquire a
special code that can prompt warning.
After-treatment SCR Fault diagnosis and troubleshooting,
E1389 operator induction “SCR warning system failure”
5246 0 3
（3） severity level: high -

Flas-
h
code ing procedure
cati-
on
E1389 operator induction “SCR warning system failure”
5246 15 1
（1） severity level: high -
operator induction “SCR warning system failure”
E1389
5246 16 2 severity level: high -
（2）
(2)
Engine accidental
5272 31
shutdown
E1370 After-treatment DEF Fault diagnosis and troubleshooting,
5392 31 2
（2） injection unit filling loss “low DEF pressure”
Engine accelerator Troubleshooting, “engine throttle
E1262
5419 7 1 actuator #1: incorrect valve - test ”
（1）
response
E1430 controller temperature: “DEF control module temperature is
5480 16 2
（2） high - moderate severity high”
level (2)
Auxiliary fan speed: low Fault diagnosis and troubleshooting,
E1190
5562 1 3 - highest severity level “after-treatment cooling fan - test”
（3）
(3)
Engine filtered fuel Troubleshooting, “fuel pressure is
E096 delivery absolute high”
5580 16 2
（2） pressure: high - moderate
severity level (2)
E198 delivery absolute low”
5580 17 1
（1） pressure: low - lowest
severity level (1)

Flas-
h
code ing procedure
cati-
on
E198 delivery absolute low”
5580 18 2
（2） pressure: low - moderate
severity level (2)
Engine fuel filter Fault diagnosis and troubleshooting,
E390
5584 15 1 degrade: high - lowest “fuel filter blockage”
（1）
severity level (1)
Engine fuel filter Fault diagnosis and troubleshooting,
E390
5584 16 2 degrade: high - moderate “fuel filter blockage”
（2）
severity level (2)
E1132 Special network #2: Troubleshooting, “data link

5588 14 2
（2） special instructions configuration state - test”
E1427 injection unit heater “DEF low temperature”
5798 7 1
（1） temperature: incorrect
response
E1465
6322 31 1 desulfurization is too “frequent desulfurization”
（1）
frequent
Operator shuts down Fault diagnosis and troubleshooting,
E1466
6588 31 1 engine when exhaust gas “engine shutdown occurs”
（1）
temperature is high
It detects that after- Troubleshooting, “data link
E1585
7105 31 1 treatment #1 inconsistent configuration state - test”
（2）
configuration
E1598 Requires SCR operator Troubleshooting, “SCR induction

7343 31 2
（2） induction override update emergency substitution”

Flas-
h
code ing procedure
cati-
on
After-treatment #1 SCR Troubleshooting, SCR catalytic agent
E1738
7504 0 2 system sulfate level: high is excessively vulcanized
（3）
- highest severity (3)
After-treatment #1 SCR Troubleshooting, SCR catalytic agent
E1738 system vulcanization is excessively vulcanized
7504 16 2
（2） level: high - moderate
severity (2)
Event description code severity is defined as below:
• Level 1 - Operator needs to pay attention to engine system Operator should immediately inspect or
maintain related systems.
Flash indication: Yellow flash Buzzer: Off.
• Level 2 - Operator needs to change engine running situation or conduct maintenance procedure. Failing
to remove any fault that triggers this warning may cause engine component damage.
Flash indication: Red flash Buzzer: Off.
• Level 3 - Operator needs to immediately shut down the engine in case of damaging it or causing injury
to surrounding people. The fault that may cause trouble must be removed before engine resumption.
Flash indication: Red flash constantly on Buzzer: On.

Table 4-10 Engine Trouble Shooting Table
Symptoms Causes Solution

No fuel Add fuel and exhaust air
Engine rotates Wrong fuel Drain fuel tank and use correct fuel
but doesn’t Fuel is polluted Drain fuel tank and add clean fuel
or is difficult Low battery Charge it or install a new battery
to start Injection pump fault Contact Xugong Mining Machinery’s
authorized dealers

Table 4-10 Engine Trouble Shooting Table(continued)

Preheating wire or ignition plug fault Contact Xugong Mining Machinery’s
authorized dealers
Poor circuit contact Clean and tighten the connection between
battery and starter motor
Start motor failure Replace start motor
Wrong engine oil Drain engine oil and use correct oil.
Air filter blockage Replace filter element
Clogged fuel filter Exhaust air from fuel system and clean
screen net of filter tank
Low compression ratio of engine Contact Xugong Mining Machinery’s
authorized dealers
Nozzle is dirty or works improperly Contact Xugong Mining Machinery’s
authorized dealers
Fuel cut-off interlocks fault Adjust or repair interlocks
Fuel system has leakage Inspect fuel system connection
Fuel system has air Exhaust air
Fuel delivery pump plunger springs Push down and tighten hand wheel
Delivery pump filter net is dirty Clean or replace
Engine oil level is low Add oil
Air intake system is blocked Clean filter system
Delivery pump filter net is dirty Clean or replace
Injection pump is not on time Contact Xugong Mining Machinery’s
Engine gives authorized dealers
out bursting Clogged fuel filter Replace a new filter
sound, runs
Coolant temperature is low Thermostat works incorrectly or is to
abnormally or
“cold”
stops
Fuel system has water, dirt or air Purge fuel system of air, and clean filter
tank outlet net
Injection nozzle is dirty or faulty Contact Xugong Mining Machinery’s
authorized dealers
Fuel cut-off interlocks fault Adjust or repair interlocks
Engine fails to Air filter blockage Replace filter element
work at its full Fuel pipe is blocked Repair or replace fuel pipe
capacity


Fuel is polluted Drain fuel tank, clean outlet net, add fuel
Clogged fuel filter Replace filter
Fuel tank cover venting hole is blocked Clean it or install a new cover
Fuel injection nozzle is dirty or faulty Contact Xugong Mining Machinery’s
authorized dealers
Injection pump interlocks needs adjusting Contact Xugong Mining Machinery’s
authorized dealers
Wrong fuel Use correct fuel
Wrong engine oil Use correct engine oil
Turbocharger is faulty Contact Xugong Mining Machinery’s
authorized dealers
authorized dealers
Exhaust gas is blocked Remove muffler and run the engine
Engine is overheated or too cold Refer to contents below
Engine fault Contact Xugong Mining Machinery’s
authorized dealers
Air intake or exhaust system leakage Contact Xugong Mining Machinery’s
authorized dealers
Coolant level is low Add coolant
Thermostat failure Contact Xugong Mining Machinery’s
authorized dealers
Engine overload Inspect hydraulic safety valve
Radiator cover is damaged Install a new cover
Radiator core and oil cooler core are Clean radiator and oil cooler
blocked
Engine is Radiator screen net blockage Clean the screen net
overheated
authorized dealers
Fan damage Replace the fan
Air filter blockage Clean air filter
Alternator and fan belt are loose Tighten or install a new belt
Belt pulley is abraded Replace the belt pulley
Dirty pipes of cooling system Rinse cooling system.

Thermometer or delivery unit is faulty Contact Xugong Mining Machinery’s
authorized dealers
Thermostat failure Contact Xugong Mining Machinery’s
Coolant
authorized dealers
temperature is
Thermometer or delivery unit is faulty Contact Xugong Mining Machinery’s
low
authorized dealers
Engine oil pump or pump drive system is Contact Xugong Mining Machinery’s
faulty authorized dealers
Engine oil level is low Add oil
Engine oil pressure regulating valve is Contact Xugong Mining Machinery’s
faulty authorized dealers
Engine oil Oil pump suction screen net is blocked Contact Xugong Mining Machinery’s
pressure is authorized dealers
low Oil filter blockage Replace a new oil filter
Engine oil leakage Inspect for leakage
Engine oil is diluted by fuel or cooling Contact Xugong Mining Machinery’s
water authorized dealers
Engine temperature is too high Inspect cooling system
Engine oil leakage Inspect engine oil drain valve
Engine
Engine temperature is too high Inspect cooling system
consumes too
Air filter blockage Clean or install a new filter element
much oil
Engine internal components abrasion Contact Xugong Mining Machinery’s
authorized dealers
Air intake system is blocked or dirty Clean air intake system
Wrong fuel Use correct fuel
Engine
Fuel injection nozzle is dirty Contact Xugong Mining Machinery’s
consumes too
authorized dealers
much fuel
authorized dealers
Exhaust gas is Wrong fuel Drain fuel tank and use correct fuel
too black or Air intake or exhaust system is blocked Clean air intake or exhaust system
grey or dirty


authorized dealers
Fuel injection nozzle is dirty or works Contact Xugong Mining Machinery’s
incorrectly authorized dealers
Engine main body failure Contact Xugong Mining Machinery’s
authorized dealers
Battery fault Charge or replace it
Engine does
ECM fault Contact Xugong Mining Machinery’s
not work
authorized dealers
Connection is loose or corroded Clean, tighten or replace the battery
Alternator belt is loose Tension it up or install a new belt
Insufficient
Alternator fails to be charged Contact Xugong Mining Machinery’s
battery
authorized dealers
capacity
Fuse fault Replace fuse
Engine key switch failure Replace the starter switch
Battery is flat or damaged Charge or replace it.
Battery wire is in poor connection Clean the connecting part
Fuse blowup Replace fuse
Engine key switch failure Contact Xugong Mining Machinery’s
authorized dealers
Start relay fault Contact Xugong Mining Machinery’s
Starter motor authorized dealers
fails to rotate Start motor solenoid coil fault Contact Xugong Mining Machinery’s
authorized dealers
Start motor failure Repair or replace start motor
Starter motor pinion is stuck on flywheel Repair or replace start motor
gear
Engine main body failure Contact Xugong Mining Machinery’s
authorized dealers
Poor wire connection of battery or of Clean the connecting part
Start motor starter motor
electromagnet Low battery Charge or replace it.
ic vibration Start motor solenoid “maintaining’ Contact Xugong Mining Machinery’s
coil is open authorized dealers


Start motor pinion fails to mesh with Contact Xugong Mining Machinery’s
flywheel gear authorized dealers
Start motor Pinion position-changing mechanism is Contact Xugong Mining Machinery’s
rotates but stuck or faulty authorized dealers
fails to start Pinion tooth breaks Contact Xugong Mining Machinery’s
engine authorized dealers
Flywheel gear tooth breaks Contact Xugong Mining Machinery’s
authorized dealers
Storage battery wire is internally Inspection and replace wire
Engine starts damaged or breaks
slowly Battery or start motor wire connection is Clean and tighten up the connection
loose or corroded
Wrong fuel Drain fuel tank and use correct fuel
Engine temperature is low Run the engine till it heats up
Thermostat is faulty or too “cold” Contact Xugong Mining Machinery’s
Engine
authorized dealers
exhausts white
gas Injection pump is not on time Contact Xugong Mining Machinery’s
authorized dealers
Coolant leaks into engine cylinder Contact Xugong Mining Machinery’s
authorized dealers
Bearing is not lubricated Oil pressure is deficient, inspect the
blocked turbocharger oil pipe
Bearing has been abraded Contact Xugong Mining Machinery’s
Turbocharger
authorized dealers
noise is too
Engine, intake or exhaust pipe is leaking Check and repair
loud, or
air
vibrates too
Improper gap between turbine and Contact Xugong Mining Machinery’s
much
turbine box authorized dealers
Turbine blade breaks Remove exhaust elbow and air inlet hose
for inspection
Turbocharger Bearing is not lubricated Oil pressure is deficient, inspect the
noise is too blocked turbocharger oil pipe
loud, or Bearing has been abraded Contact Xugong Mining Machinery’s
vibrates too authorized dealers
much


Engine, intake or exhaust pipe is leaking Check and repair
air
Improper gap between turbine and Contact Xugong Mining Machinery’s
turbine box authorized dealers
Turbine blade breaks Remove exhaust elbow and air inlet hose
for inspection
Bearing is damaged or abraded, and (or) Contact Xugong Mining Machinery’s
seal has abraded authorized dealers
Turbocharger
Crankcase pressure is too high Inspect breather pipe, ensure it is not
connector
blocked, clean it necessary
drops oil
Turbocharger return oil pipe is blocked at Remove, inspect and clean the pipe
exhaust pipe
Combustion deposits cause turbine rear Inspect and wash
carbon block
Air intake pipeline leakage causes Inspect and wash
Turbocharger compressor wheel back blockage by dirt
rotary parts
High temperature, unbalanced impeller,
face much
dirt oil
resistance Contact Xugong Mining Machinery’s
Lack of oil or insufficient lubrication
authorized dealers
causes bearing stuck,
Dirty or bearing abrasion

Electrical system
Table 4-11 Electrical System Trouble Shooting Table

Battery has leakage of electricity or fails Battery
to maintain electricity
Engine starts
Starter motor “drag” Contact Xugong Mining Machinery’s
slowly
authorized dealers
Low battery voltage Charge or replace it.
Start relay fault Contact Xugong Mining Machinery’s
authorized dealers
After engine Starter motor solenoid coil sucks Contact Xugong Mining Machinery’s
starts, starter authorized dealers
motor keeps Starter motor fails to disconnect Contact Xugong Mining Machinery’s
running authorized dealers
Engine key switch failure Contact Xugong Mining Machinery’s
authorized dealers
Alternator belt is loose or slips Inspect belt for slip; if so, replace it; if
loose, tighten it.
Engine runs slowly Adjust engine speed to specified value
Additional accessories cause power Remove additional accessories or install a
When engine overload more powerful alternator
is running, Battery, ground steel strip, starter motor Inspect, clean or tighten the electrical
charging or alternator becomes loose or electrical connection.
indicator lamp connection is corroded.
is on Low battery voltage Charge or replace it.
Alternator fault Contact Xugong Mining Machinery’s
authorized dealers
Monitor fault Contact Xugong Mining Machinery’s
authorized dealers
Drive belt has abraded Replace the belt
Belt pulley has abraded Replace belt pulley and the belt
Improper belt pulley adjustment Adjust the installation of alternator
Alternator is
noisy Loose alternator belt loose, manually
rotate the belt
Alternator bearing fault
Pulley, if it's difficult to do so, repair the
alternator

Table 4-11 Electrical System Trouble Shooting Table (continued)

authorized dealers
Monitor
Electrical wiring is faulty Contact Xugong Mining Machinery’s
indicator lamp
authorized dealers
is not on
Sensor fault Inspect sensor
Coolant Monitor fault Contact Xugong Mining Machinery’s

temperature authorized dealers
gauge doesn't Temperature sensor fault Inspect coolant temperature gauge sensor
work Electrical line faulty Contact Xugong Mining Machinery’s
authorized dealers
Auto idling
speed
authorized dealers
indicator isn't
Auto idling switch fault Contact Xugong Mining Machinery’s
on.
authorized dealers
Fuel sensor fault Contact Xugong Mining Machinery’s
authorized dealers
Electrical line faulty Contact Xugong Mining Machinery’s
Fuel gauge
authorized dealers
doesn't work
Main controller fault Contact Xugong Mining Machinery’s
authorized dealers
authorized dealers
Electrical line faulty Contact Xugong Mining Machinery’s
authorized dealers
Working
Monitor key fault Contact Xugong Mining Machinery’s
mode fails to
authorized dealers
be switched
Main controller fault Contact Xugong Mining Machinery’s
authorized dealers

Table 4-11 Electrical System Trouble Shooting Table (continued)

Walking mode switch fault Contact Xugong Mining Machinery’s
authorized dealers
Fast/slow
authorized dealers
walking speed
Solenoid valve fault Contact Xugong Mining Machinery’s
doesn't work
authorized dealers
Walking motor has been damaged Contact Xugong Mining Machinery’s
authorized dealers
Pilot pressure switch is faulty Contact Xugong Mining Machinery’s
authorized dealers
Auto idling Electrical line faulty Contact Xugong Mining Machinery’s
doesn’t authorized dealers
work Main controller fault Contact Xugong Mining Machinery’s
authorized dealers
Engine ECM fault Contact Xugong Mining Machinery’s
authorized dealers
ECM Refer to engine diagnostic switch, page Contact Xugong Mining Machinery’s
indicator lamp rolling switch descriptions. authorized dealers
flashes or a
fault code
appears

Hydraulic system
Table 4-12 Hydraulic System Trouble Shooting Table

Hydraulic oil level is low Add hydraulic oil to FULL mark
Hydraulic oil temperature is low Preheat the machine
Mistaken use of hydraulic oil Drain oil tank and use a correct oil
Hydraulic
Engine speed is too low Increase speed or contact Xugong Mining
function
Machinery’s authorized dealers
works
slowly Hydraulic pump is abraded Contact Xugong Mining Machinery’s
authorized dealers
Oil suction pump pipe is blocked Contact Xugong Mining Machinery’s
authorized dealers
Mistaken use of hydraulic oil Use correct hydraulic oil
Oil suction pump pipe is leaking air Contact Xugong Mining Machinery’s
authorized dealers
Hydraulic pipe is blocked Contact Xugong Mining Machinery’s
authorized dealers
Hydraulic oil level is low Add hydraulic oil to FULL mark
Filter blockage Install a new filter
Hydraulic pump is abraded Contact Xugong Mining Machinery’s
Hydraulic
authorized dealers
oil is too hot
Radiator or oil cooler is blocked Clean it and straighten the blade
Oil cooler by pass Contact Xugong Mining Machinery’s
authorized dealers
safety valve fault Contact Xugong Mining Machinery’s
authorized dealers
Hydraulic oil has been stained Drain the polluted oil and refill the tank
Hydraulic components have been Contact Xugong Mining Machinery’s
improperly adjusted authorized dealers
Air escapes from the pipeline between oil Contact Xugong Mining Machinery’s
tank and pump authorized dealers
Hydraulic Hydraulic pipe has twist or dent Inspection of pipeline
oil has
Wrong hydraulic oil Use correct hydraulic oil
bubbles
Hydraulic oil contains water Replace hydraulic oil
Oil level is too high or low Calibrate oil level

Table 4-12 Hydraulic System Trouble Shooting Table(continued)

Wrong hydraulic oil Use correct hydraulic oil
Hydraulic components have been Contact Xugong Mining Machinery’s
improperly adjusted authorized dealers
Low or
No hydraulic oil in the system Fill up hydraulic tank with correct oil
without oil
pressure Hydraulic tank has internal component Contact Xugong Mining Machinery’s
abrasion authorized dealers
safety valve fault Contact Xugong Mining Machinery’s
authorized dealers
authorized dealers
No Main valve setting pressure of control Contact Xugong Mining Machinery’s
hydraulic valve decreases authorized dealers
function Hydraulic oil level is low Fill up hydraulic oil tank
(pump is oil suction pipe or hose damage Contact Xugong Mining Machinery’s
noisy) authorized dealers
Suction filter is blocked, air is sucked into Wash filter system
oil suction port.
authorized dealers
Hydraulic Main safety valve pressure is low Contact Xugong Mining Machinery’s
tank moves authorized dealers
but fails to
Hydraulic oil level is low Fill up hydraulic oil tank
lift loads
Suction filter blockage Wash filter system
Pump oil suction pipe leakage Inspect oil suction pipe
Safety valve pressure is low Contact Xugong Mining Machinery’s
authorized dealers
Pipe or hose is damaged Repair or replace
One of Hydraulic connector is loose Tighten up
control
The O ring of connector is damaged Install a new O ring
levers
Hydraulic pump failure Contact Xugong Mining Machinery’s
doesn’t
work authorized dealers
Pilot valve failure Contact Xugong Mining Machinery’s
authorized dealers
Pilot pipe damage Repair or replace


Control valve stem is damaged or stained Contact Xugong Mining Machinery’s
by dirt authorized dealers
One Hydraulic pipe is damaged Repair or replace
hydraulic
Connector is loose Tighten up
cylinder
The O ring of connector is damaged Install a new O ring
doesn’t
work Pilot valve failure Contact Xugong Mining Machinery’s
authorized dealers
Hydraulic cylinder seal leaks Contact Xugong Mining Machinery’s
One
authorized dealers
hydraulic
Hydraulic cylinder piston rod is damaged Contact Xugong Mining Machinery’s
cylinder
authorized dealers
doesn’t
work or has
almost no Pilot valve failure Contact Xugong Mining Machinery’s
driving authorized dealers
power Wire damage Contact Xugong Mining Machinery’s

authorized dealers
Neither of Central joint body is damaged Contact Xugong Mining Machinery’s
two to authorized dealers
walking
motors work
Walking motor is damaged Contact Xugong Mining Machinery’s
authorized dealers
One walking Brake doesn't release Contact Xugong Mining Machinery’s
motor authorized dealers
doesn't work Pilot valve failure Contact Xugong Mining Machinery’s
authorized dealers
Crawler needs adjusting Adjust crawler sag
Crawler guide wheel, track roller or carrier Contact Xugong Mining Machinery’s
Walking is drive wheel is damaged authorized dealers
not stable Chassis frame bends Contact Xugong Mining Machinery’s
authorized dealers
chassis frame has rocks or mud “stuck” Remove and repair


Walking brake doesn't release Contact Xugong Mining Machinery’s
authorized dealers
Rotary motor fault Contact Xugong Mining Machinery’s
Rotation authorized dealers
doesn't work Pilot valve failure Contact Xugong Mining Machinery’s
authorized dealers
Sewing gear fault Contact Xugong Mining Machinery’s
authorized dealers
Rotation is
Slewing bearing fault Contact Xugong Mining Machinery’s
not smooth
authorized dealers
Lack of lubricating grease Grease

4.5 Periodical replacement of components and parts

To ensure safety work, be sure to conduct regular inspection to this machine. Severe accidents or a fire ac-
cident will occur if following parts are damaged. It's difficult to determine by appearance how much have
following parts deteriorated, for this reason, these parts must be periodically replaced at following time in-
tervals. But, if these parts are found in poor conditions during an inspection, then they must be replaced
disregard of time intervals. During replacement of hoses, their clamps should be likewise inspected for de-
formation, crack or damage and be replaced when necessary. See to it that following hoses are regularly
inspected, replaced when necessary and whose loose parts are fastened.
Table 4-13 Components and Parts Periodical Replacement Table
Parts Needing Regular Replacement Replacement Intervals

Fuel hose (from fuel tank to filter) Every 2 years
Engine Fuel hose (from fuel tank to injection pump) Every 2 years
Fuel-filtration hose (from engine to fuel filter) Every 2 years
Fuel pump intake hose Every 2 years
Basic
Fuel pump outlet hose Every 2 years
bodywork
Hydraul Slewing device hydraulic oil hose Every 2 years
ic Boom hydraulic cylinder hose Every 2 years
System Working
Bucket rod hydraulic cylinder hose Every 2 years
device
Bucket hydraulic cylinder hose Every 2 years
accessories
Pilot pipeline hose Every 2 years

Chapter 5 Transport, Storage and Protection
5.1 Transportation
Transport Points for Attention
When loading or unloading the machine onto or off a truck or a platform trailer:
• Be certain to observe local regulations in case of road transportation.
• Use a proper truck or trailer to transport the machine.
Notices on loading or unloading the machine
• Select a consolidated even area.

• Be certain to use a platform or an in-
clined plane 10°
° ~1
90°
• A signalman must be on site when load-
ing or unloading the machine.
• Select Slow Mode by pressing the walk-
ing way switch.
Figure5-1
• It’s extremely dangerous to steer on an
inclined plane, which should be avoided
no matter you’re on an ascent or de-
scent. Don’t turn directions on a slope;
instead, working staff must drive it on
even ground or on a trailer plate and then
turn it around.
• When driving on an ascent or descent, don’t manipulate any other control levers except walk control
levers
• The junction between slope tip and trailer plate is convex, so be careful to pass it.
• Take measures to prevent the excavator from rolling over when slewing the upper structure, which may
cause personal injury.
• Keep bucket rod retracted and slowly rotate upper structure so as to gain the max. stability.
• Use a chain or rope to fasten the frame of an excavator.
Road transportation
Get to know and be sure to observe local regulations in case of road transportation.
• To transport the excavator with a trailer, be clear about trailer’s length, width and height.
Transport, Storage and Protection 5-1

CAUTION!
Information relating weight and dimensions may vary with different types of track shoes and
working devices.
• Investigate transport route beforehand, like limitation on weight and dimensions and rules of road traf-
fic. Sometimes the machine must be taken into pieces for transport, so as to satisfy local regulations on
limits of weight and dimension.
Load onto or off a trailer
Always select a solid even area to load the excavator onto or off a trailer.
CAUTION!
Be certain to use a platform or an inclined plane for a loading or unloading job.
Use an inclined plane or platform
• Before loading, thoroughly clean the in-

clined slope and trailer plate; oil stain,
mud or icy on slope, platform or trailer
plate may slip the vehicle.
• Put cushion blocks under wheels of each ＜15°
vehicle when using a slope or platform
Figure5-2
for the loading job.
• The platform or slope must have suffi-
cient bearing capacity and suitable di-
mensions; besides, the gradient of the
platform or slope must be less than 15°.
Loading
5-2 Transport, Storage and Protection

• Machine direction is as below: position

working device at front and walk for-
ward; without a front working device:
walk backwards, please refer to the
figure.
• Machine center line should be on the
Figure5-3
center line of the trailer.
• Slowly drive the machine towards the
slope. With front-end working device:
1. Support the plane side of bucket on the

trailer; the inclination angle between
bucket rod and boom should be within
90º - 110º.
小于 15°
2. When the machine is about to tilt to- Figure5-4

wards the trailer plate, staff should oper-
ate the excavator and support the bucket
on the trailer, and then slowly walk for-
ward till the entire crawler lands on the
trailer and firmly touches the plate.
3. Slightly raise the bucket, retract bucket

rod and keep it staying at lower position,
refer to the figure, slowly rotate upper
structure by 180º.
4. Lower the bucket onto sleepers.
• Stop the engine and extract engine key

switch.
• Move control levers for several times till
the pressure is completely released out
of hydraulic cylinder.
• Pull safety locking lever to locking Figure5-5
position.
• Close cab window, skylight, door and re-
cap air outlet for prevention of rain and
wind.

Note: When in cold weather, be sure to warm the machine before the loading job.

Transport
CAUTION!
Tie the chain or rope onto the frame of excavator, neither reeve it through hydraulic pipes nor
place it on the hoses.
• Place cushion blocks under the front and back of crawler in order to stabilize the machine.
• Fasten the four corners and the front working device of excavator onto the trailer by using chains or
ropes.
Unloading
CAUTION!
The junction between the slope and the rear part of trailer plate is convex, so be careful to pass it.
Important: To prevent potential damage caused to front working device, when unloading the exca-
vator, remember to always keep the inclination angle between bucket rod and boom within 90°～
110°, retracting the bucket rod may damage the machine.
• When driving the machine to pass the

rear part of trailer and is about to march
onto the slope or platform, support the 90 °
°~
plane side of bucket on the ground; the 110
°
inclination angle between bucket rod and
boom should be within 90º - 110º.
Important: To prevent potential

Figure5-6
damage caused to the hydraulic cylinder,
don’t let bucket violently bump the
ground.
• The bucket must be placed on the ground

before starting the machine.
• When the machine is moving forward,
remember to raise the boom, extend
bucket rod and keep this state till the ma-
chine completely gets out of the slope or
Figure5-7
platform.


Machine lifting method
CAUTION!
Lifting rope and other lifting tools may break, causing severe personal injury; so don’t use
damaged or aged steel rope or lifting tools.
Please contact Xugong Mining Machinery’s authorized dealer for correct lifting method, types
and sizes of lifting rope and other lifting tools.
• Always pull safety locking lever to locking position, so when the machine is being lifted, it won’t ac-
cidentally move.
• Incorrect lifting method and incorrect installation of lifting rope will cause the lifted machine to make
movement, causing machine damage and personal injury.
• Don’t lift the machine too fast; otherwise, the wire rope and lifting tools will be overloaded, causing
fracture.
• Don’t let anyone approach or go under the lifted machine.
• The indicated center of gravity is based on a standard-configuration machine; the actual center of grav-
ity may change as accessories will be attached on the machine. Therefore, be cautious not to lose bal-
ance when lifting the machine.
• Fully extend bucket rod, bucket-rod hydraulic cylinder and lower the boom; keep the machine in this
state till the working device entirely lands on the ground.
• Always pull safety locking lever to locking position.
• Stop the engine and extract the key switch.
• Use a sufficiently long wire rope and
Supporting rod
supporting rods so as to ensure they are
Center of gravity
not touching the machine.

• Wrap the wire rope and supporting rods
with protective materials in order to pre-
vent the machine from being damaged.
• Drive the crane onto a proper position Figure5-8
for lifting operation.
• As shown in the figure, reeve the wire
rope through the lower space under both
sides of chassis frame and then install
the wire rope onto the crane.

Procedure to extend or retract track gauge of crawler frame
CAUTION!
When crawler is in retracted state, never operate the machine to work.
Retract track gauge of crawler frame
• Remove crawler frame mounting bolt ①

(single side, front + rear: 24 bolts)
Figure5-9
• Rotate upper structure, let it and the

crawler frame (that is about to be re-
tracted) form 90°, and then lift up the
crawler frame with working device.
• Place a 20-30cm cushion (B) on the ex-
terior of crawler frame (A), and then use
the boom cylinder to slowly put it down.
Crawler frame (A) will slowly slide and
stop on the cushion.
Figure5-10

• Carefully lower the machine and then in-

stall bolt ② (single side, front + rear: 12
bolts).
• Tightening torque: 2750±300 N•m.
• Retract the crawler frame of the other
side in the same way.
Figure5-11
Extend track gauge of crawler frame

• Remove the central mounting bolt ② on

the frame side that's about to be ex-
tended. (single side, front + rear: 12
bolts) Rotate upper structure, let it and
the crawler frame (that is about to be ex-
tended) form 90°, and then lift up the
crawler frame with working device.
Figure5-12
CAUTION!
The lifting height (H) of crawler frame should be
lower than 50mm. Donot lift crawler frame too high
in case of damaging catch bolt.
Figure5-13
• Use bucket rod to pull the machine for-

ward, and the crawler frame will slide to
extend.
• Extend crawler frame till it touches stop-
per, and then slowly lower the machine
down to ground; after that, install bolt ①
(single side, front + rear: 24 bolts). 1
• Tightening torque: 2750±300 N•m. Figure5-14

• Extend the crawler frame of the other
side in the same way. 1

CAUTION!
• Before extending or retracting crawler-frame track gauge, place the machine on flat ground.
• When extending or retracting crawler-frame track gauge, never suddenly operate cylinders, be-
cause abrupt operation on cylinders will result in danger.
5.2 Transport and protection

Daily and short-term storage and protection
• Inspect the machine, repair abraded and damaged parts; if it’s necessary, you should install new parts.
• Clean air filter element.
• If possible, retract all hydraulic cylinders; if impossible, apply grease on exposed hydraulic cylinder
rod.
• Lubricate all the lubricating positions.
• Place the crawler on long and firm cushion blocks.
• Wash the machine.
• Fully charge the storage battery, remove it and store it at a dry and safe place. If it’s not necessary to
remove the battery, disconnect the negative pole from terminal (-).
• Add anti-rust in Engine coolant. In winter, be sure to use antifreeze or drain up coolant; if cooling sys-
tem is drained up, a sign writing “No Water in Radiator” must be hung on a conspicuous position.
• Loosen the belts of AC alternator and cooling fan.
• Apply anti-rust paint on crucial positions.
• Place the machine on dry and safe places; cover a water shield on the machine if it’s stored indoors.
Long-term storage
• Place of storage
1. Normally, the machine should be stored in a ventilated dry warehouse, temperature is among -25℃
～50℃.
2. If it’s stored in an open air, it should be covered with weather-proof canvas and then parked on solid
ground where there is no risk of being affected by natural disasters and no corrosive harmful matters
and gases.
• Storage
1. Ensure to monthly operate the machine to walk, make slewing and excavating movements for 2 or 3
times, so as to lubricate related components; before operation, by all means inspect coolant level and
state of lubrication.
2. Regularly inspect machine appearance quality, protection face and corrosive.

Use after storage
• Remove coverings of the machine.

• Remove protection from exposed machine parts.
• Charge, install and wire the battery.
• Drain engine oil from crankcase and fill it with new oil.
• Drain gear oil from slewing reduction gear and walking reduction gear, and fill in new gear oil.
• Drain impurities and mixed water from hydraulic oil tank and fuel tank.
• Add grease in pivots.
• Inject coolant as specified.
• Conduct pre-operational inspection as specified.

Chapter 6 Technical Specifications
6.1 Product specifications
Figure 6-1
Item Model XE750G/XE800GA/XE750D/XE800D

Whole machine weight, kg 75000——78000
Bucket capacity range, m3 3.8-5.6
Perkins 2506J/2506EA（XE750G/XE800GA）
Model
Perkins 2506D（XE750D/XE800D）
Engine Rated power, kW 403
Rated rotation
2100
speed,r/min
A: Overall length (transport),mm 12600
B: Overall width (transport),mm 4420
C: Overall height (transport), mm 4690
D: Turntable width,mm 3470
E: Crawler length, mm 5955
F: Chassis overall width, mm 4360
G: Standard track shoe width,mm 650
H: Wheel base,mm 4691/4700
I: Track gauge, mm 2750/3410
J: Counterweight ground clearance, mm 1610
K: Minimum ground clearance,mm 850
L: Tail turning radius,mm 4015
M: Crawler height,mm 1420
Ground pressure, kPa 110/113
Technical Specifications 6-1

Max. slewing speed, r/min 7

Max. travel speed (fast/slow) km/h 4.1/2.8
Maximum grade ability ° ≤35 (70%)
Max. slewing speed, r/min 7
Max. travel speed (fast/slow) km/h 4.2/3.0
Maximum grade ability ° ≤35 (70%)
6-2 Technical Specifications

6.2 Working range
Figure 6-2
XE750G/XE750D/XE800GA/XE800D
Item Model
7m boom, 2.57m bucket rod
A: Maximum digging height, mm 11830
B: Maximum unloading height, mm 7600
C: Maximum digging depth, mm 6660
D: 8 inches maximum digging depth, mm 6500
E: Maximum vertical digging depth, mm 3950
F: Maximum digging radius, mm 11690
G: Minimum turning radius, mm 4810

6.3 Hydraulic principle schematics (standard configuration)

6.4 Hydraulic principle schematics (optional configuration, adding

anti-explosion valve)

6.5 Electric principle schematics
XE750G Electrical principle schematics

XE750D/XE800D Electrical principle schematics

6-8
XE750GA.41
+D.2-F1
18-1 1 2
10A
-X12 10 +D.1-F01
L3-1 1 2 L1
18-2
60A
-X6 37
1 1 1 1 1 1 1 1 1 1 1 1 1
18-3
+D.2-F2 +D.2-F10 +D.2-F4 +D.2-F5 +D.2-F6 +D.2-F9 +D.2-F21 +D.2-F22 +D.2-F16 +D.2-F12 +D.2-F18 +D.2-F11 +D.2-F13
-X20 1 5A 2 10A 2 10A 2 10A 2 15A 2 10A 2 15A 2 5A 2 5A 2 5A 2 20A 2 10A 2 10A 2
87
89 03-1
75
90
B
L2
接线柱 L3-2
档位 B ACC BR C R1 R2
-X12 28 -X13 17 03
87-1
+P.2-S1 Ⅲ(反向)
04 -X13 16 -X13 18
钥匙开关 89-1
0(关) -X28 1 3
-X8 4 75-1 90-1
Ⅰ(开)
-X12 19 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85 87 87a 85 87a 87 85 87a 87 03-2 85 87a 87
87-2
Ⅱ(起动) +D.2-K3 +D.2-K11 +D.2-K5 +D.2-K6 +D.2-K7 +D.2-K8 +D.2-K9 +D.2-K10 +D.2-K13 +D.2-K14 +D.2-K15 +D.2-K12
ACC BR C 04-1
3 3
熄火延时 86 30 ECM钥匙电 86 30 驾驶室顶灯 86 30 转台工作灯 86 30 动臂工作灯 86 30 配重工作灯 86 30 报警灯 86 30 蜂鸣器 86 30 雨刮 86 30 喷水壶 86 30 背光灯 86 30 喇叭继电器 86 30
54
继电器继电器继电器 107-1 继电器 106-1 55 继电器 190-1 继电器继电器继电器继电器 70 继电器继电器 +D.4-S5
57 73
193-1 89-2 4 4
04 103-1 194-1 370-1 189-1 58 65 242-1 71 256-1 74
16 64 257-1 76 67 69
243-1
196-1
-X20 6 5 3 61-1
-X12 11 13
17-1 -X13 6 7 -X13 8 9 -X6 38
54-1
-X12 25 9 -X12 15 17 54-4 57-1
-X13 10 11 -X13 12 13 -X13 14 15 -X13 28 29 30 22 -X13 31 4 -X12 26 27 -X28 2 4 -X12 18 12
64-1
1
2 -X8 1 -X8 2 76-1 +P-E15 67-1
-X6 2 55-1 -X21 1 58-1 04
16-1 室内灯
370 04-29
54-5 70-1 61-2
54-2
74-1 -X6 9 -X6 44
-X8 3 90-2
73-1
71-1
-X22 1 65-1
-X15 1 -X15 2 64-2
67-2
69-1 69-2 69-3
+D.1-V2
17-2 1 2 54-3 57-2
57-4 57-5 1 2
57-3 58-2
-X15 3 242 196 1 +D.8-M2 1
256 257 润滑系统
54-6 54-8 54-9
54-7 106 190 189 193 243 工作复位电源 +P.1-S7
64-3 3 2 4 喇叭开关 2 +P-M3
M
+D.5-M5 1 M
1 1 1 1 1 1 1 1 1 P L
雨刮电机座椅风机
247-1 234-1 103 194 107 +B-E8 +B-E9 +B-E10 +B-E11 +D.9-E12 M 2 +D.7-B4 +D.7-B5 +D.7-B6
17-3 1 1 1 1 1 1 1 A M +D.4-E14 2
40W 2 40W 2 40W 2 40W 2 24W 2 +D.1-M6 24W 2 84W 2 84W 2 84W 2
04-19
+P.4-E1 +P.4-E2 +P.4-E3 +P.4-E4 +P.4-E5 +D.8-E7 左上动臂灯 04-8 左下动臂灯右上动臂灯右下动臂灯配重灯 04-13 +P.4-E13 +P.4-B3 喷水壶左高音喇叭
泵室检修灯 5 4 3
24W 2 24W 2 24W 2 24W 2 24W 2 40W 2 3.6W 2 4.8W B
2 04-22
+ 驾驶室顶灯左1 驾驶室顶灯左2 驾驶室顶灯右2 驾驶室顶灯右1 驾驶室后照灯右转台灯 04-10 04-11 04-12 旋转报警灯蜂鸣器 04-23 04-24 04-25 04-27
04-16 1
A1 1 04-7 04-15 04-18 04-21
04-5 04-6 04-4 -X22 2 地 -X8 9
04-2 04-3 -X21 2 244
04-14 04-20 237 248
+D.1-K1 04-17
04-9
DC24V120A A2 2 04 04 04 04 04 04 04 04 04 04 04 04 04 04 04 04 04 04 04 04 04 04
电源继电器 -
04-44 1 2 3 4 5 6 7 8 9 10 13 14 11 15 16 17 18
1 19
04 +D.1-F02
L4-5
60A 2
L4-3 L4-4
L3 / 2
Technical Specifications
1
+D.1-F03
100A 2
128
L4-1
10
1 83-3 1 1 1 1 1 1 1
+D.2-F19 +D.2-F7 +D.2-F26 +D.2-F28 +D.2-F17 +D.2-F15 +D.2-F20
2 1 20A 280 + 5A 2 5A 2 5A 2 2 10A 245 30A 291 15A 251
L4-2 -X5 10 44 79
L3 +D.1-K2 +D.2-F29
起动继电器 3 4 83-2 78 5A
+P-Ss +D.9-CAM1 77 318-1
04-45 -X12 1 日射传感器 20 14 21
-X13 -X12 -X13
-X6 16 -X12 20 -X13 23 51-1
- 45-1
80-2 CAN1_L 82-3 44-1 23
04 1 CAN1_H CAN1_L -X12 91-2
11 80-1 3 1 4 23
CAN1_H CAN1_H CAN1_L 79-1 -X6 4
黑白红 +P-X40 91-1 -X5
-X5 16 14
+D.3-F04 -X6 4 5 -X13 24 CAN1_H CAN1_L -X5 1 2 03-8
对讲插头 03-7
CAN1_S CAN1_H CAN1_L 39
100A -X5 9 -X5 22 78-1 77-1 -X6
2 82-2
83-1
51-3
03 03-6 318 / 2 2
+ S 31 1 51 /
L6 80-3 -X5 -X6 43 91-3
-X6 15 318-2 318-4 318-6
+D.1-G12 +D.1-G14 CAN1_S 45-2
XE800GA Electrical principle schematics
79-2 03-18 03-19 03-5 04-30

- 80-4 410
BAT L4 CAN1_H 411 318-11
B 80-5 44-2 44-3 77-2 1
+ + 82-1 78-2 -X30
03-12 03-13 03 -X26 1 3 -X8 8 5 -X27 1 3
03
+D.1-G11 +D.1-G13 +D.3-G1 G 51-2
CAN1_S
- - +D.3-M1 M 发电机 +P-KT +P-DMS +P-A2 +P-GPS 03-11 -X30 2
03-9 318-3 03-10 318-5 318-7
起动马达 04-31 52
空调行为监控仪表 GPS +P.3-S17 76-3 76-4 O 51-4
2 3 4 9 10 1 2 1 2 1 2 3 15 20 14 1 5 3 4 22 13 17 21 20 76-2 再生开关 +P.1-S16 I 04
E 1 3 1 3 1 3
-1 -1 -1 -2 -2 -2 -2 -2 -2 -1 -1 -1 GND VIDEO1 12VO CAM POWER CAN1 R CAN1 H CAN1 L GND POWER ACC CAN1H CAN1L 2 7 8 9 10 低温起动开关
+P-RD 9 8 7 2 6 1
电源电源电源 CANH CANL 日射日射 24V 24V CANH CANL CANS TER. +D.1-S2 +P-S3 +D.8-S4
收音机 2 7 8 3 2 1 7 8 9 10
POS. 左转台急停 2 4 驾驶室内 2 4 右转台 2 4
+P.3-S12 TER.
G 消音开关 POS. 2 3 7 8 3 344-4急停开关急停开关 +P-A3 4 1
172-1 344-6
344-5 192-1
191-1 12V电源
地外气温度外气温度压力开关压缩机 GND 5V CVBS_IN GND GND VIDEO TX+ RX- RX+ TX- 3 10 4 5 3 -X31 3 1 DC24V转DC12V模块
2
-1 -2 -2 -2 -2 -2 -3 -3 -3 -4 -4 -5 -5 -5 -5 VIDEO2F AHD GND
F AHD PWR
F AHD SIG PGND CAN2 R CAN2 H CAN2 L GND CAN2H CAN2L ETH_RX- ETH_RX+ETH_TX- ETH_TX+
1 3 4 5 6 4 1 2 3 2 4 2 4 5 1 21 10 9 8 2 13 6 7 12 19 18 2 3 4 5 1 -X5 15 3 6
48-1 49-1 1
47-1 95-1
-X26 2 4 -X8 7 6 -X27 2 4 92-1
3 52-1
03-3 3 1 344-2 344-3
0 0 0 CAN2_S
-X7 1 2 3 04-35
307 344-1 04-46
97-2 85-1 81-1 323 2
98-2 344 / -X6 7
405 407 409 406 CAN2_H
404 408
47 42 41
401 49 12 13 -X6
403 -X6 -X6
02-2
-X6 10 11 17 14 92-2 95-2
402
97-1 12
04-37 85-2 -X5 156-1 52-2
04-38 1 2 2 307 323

t CAN2_H 2 2
+P-B1 +P-B2 -X5 3
+D.5-BT5 1 +D.7-YR 3 1 4
02-1 8欧 1 8欧 1
P 81-3
CAN2_L 02-4
CAN2_L 低温起动 1 1
外气温度 2
81-2 -X5 13
2 CAN2_H +P.3-X34 +P-EH1
+D.5-SQ4 1 02-3 6 12V插座 2 24V插座 2
压力开关 +D.3-V3
-X6 6 -X6 1 48-3
98-1 04-41
1 2 03-4
04-34 04-36
04-33
+D.3-YC1 04-28
04-39 04-40
压缩机 48-2
04-43
2
04-42
04 04 04 04 04 02 2 2 2 2 02 02 03 04 04 04 04
CAN1_H CAN1_L CAN2_H CAN2_L
CAN2_H CAN2_L
CAN1_H CAN1_L
CAN1_H CAN2_H
CAN1_L CAN2_L -X6 24
-X6 18 19
L1 / 2
1 1 1 1 1 1 1
+D.2-F8 +D.2-F27 +D.2-F30 +D.2-F32 +D.2-F34 +D.2-F33

5A 5A 5A 2 2 5A 2 10A 10A
2 2 286 299
+D.2-F31 1 2 15 19 3 5 6 7 8 4 9 10 13 14 11 16 17 18
63 40A CAN1_H CAN1_L
CAN2_H CAN2_L
84 240-1
CAN1_H 27 26
245-1 201-1 -X13 -X13
CAN1_L
-X12 21 86-2
86-1
-X12 22
-X12 24 2 -X13 25 -X5 5 6
63-1
+D.8-SQ6A
99-1 99-2 99-3 99-4 99-5 99-6 99-7 99-8 99-9 99-10
-X5 25 26
84-1
-X6 8 L -X6 29 30
+D.8-SQ5
Power3
B C
1 1 1 1 1 1 1 1 1 1
-X5 30 L 03-14
GND 2 Sig 1 2 2 2 2 2 2 2 2 2 2
CAN2_H +D.4-Y14 +D.4-Y15 +D.4-Y16 +D.4-Y17 +D.4-Y18 +D.6-Y19 +D.6-Y20 +D.4-Y1 +D.4-Y2 +D.4-Y3
03-20 液压油位
CAN2_L 开关前主泵后主泵主泵水散散热泵油散散热泵油散马达水散马达先导高低速回转制动
CAN1_H 比例阀比例阀限流阀比例阀（前）比例阀（后）反转阀反转阀电磁阀电磁阀解除电磁阀
CAN1_L 03
CAN1_H 03
63-3 油水分离
CAN1_L
检测开关
84-2
63-2
CAN1_H CAN1_L
电源 CANH CANL CAN1_S 电源 CANH CANL CAN1_S

2 4 5 2 4 5
212 225 183 184 185 186 179 180 181 182 188 187 247 234 156 172 191 192 196 128 103 107 106 190 189 194 193 243 242 256 257 244 237 248
屏蔽屏蔽
1 1
CAN1_H CAN1_L CAN2_H CAN2_L
CAN1_S
201-5
+P.3-A4 +P.3-A5 201-3 油水分离液压油位前主泵后主泵主泵水散散热泵油散散热泵油散马达水散马达先导高低速回转制动钥匙开关钥匙开关消音开关信左转台急停驾驶室内右转台泵室检修起动熄火延时驾驶室顶灯转台工作灯动臂工作灯配重工作灯 ECM钥匙电报警灯蜂鸣器雨刮喷水壶背光灯润滑启动信润滑故障润滑液位低
201-4 检测开关开关比例阀比例阀限流阀比例阀（前比例阀（后反转阀反转阀电磁阀电磁阀解除电磁阀 ON信号起动信号号急停开关急停开关灯开关继电器继电器继电器继电器继电器继电器继电器继电器继电器继电器继电器继电器号
油门旋钮模块多媒体模块 245 245-2 201 240 240-2 240-3
201-2
+P-JLY ））
记录仪 1 6 5 7
EXT_GNDCAN1E_PCAN1E_NEXT_GND +D.1-A1
245 258 201 203 204 205 206 240 230 228 215 216 253 254 212 225 183 184 185 186 179 180 181 182 188 187 247 234 156 172 191 192 196 128 103 107 106 190 189 194 193 243 242 256 257 244 237 248
B B B B B B B KEY WAKE INH CAN H1 CAN L1 CAN H2 CAN L2 IN_28 IN_27 OUT_37 OUT_38 OUT_39 OUT_40 OUT_41 OUT_42 OUT_43 OUT_44 OUT_45 OUT_46 IN_25 IN_26 IN_46 IN_47 IN_48 IN_49 IN_50 OUT_19 OUT_20 OUT_21 OUT_22 OUT_23 OUT_24 OUT_25 OUT_26 OUT_27 OUT_29 OUT_30 OUT_32 OUT_31 IN_30 IN_29
控制器 RC28-14/30
GND GND GND GND GND GND GND GND OUT_1 OUT_2 OUT_3 OUT_4 OUT_5 OUT_6 OUT_7 OUT_8 OUT_9 OUT_10 IN_51 IN_23 VSS_3 GND_S1 IN_56 IN_2 IN_3 IN_4 IN_5 IN_6 IN_7 IN_8 IN_9 IN_10 IN_13 IN_11 IN_12 IN_14 IN_15 IN_34 IN_40 IN_41 IN_62 IN_63 IN_64 IN_65 GND_S2
GND CAN2E_PCAN2E_NEXT_GND
3 12 3 2 4 202 207 220 233 246 122 123 124 153 177 154 178 151 175 152 176 149 173 249 142 255 146 171 236 209 147 223 148 159 158 214 157 222 252 238 210 136 166 119 120 121 116 117 118 145
CAN2_S
3 02-6
地铲斗内收斗杆2外摆斗杆1内收备用备用左回转右回转斗杆2节流斗杆再生斗杆1节流先导开关液压油回油破碎动臂提升动臂下降斗杆外摆斗杆内收铲斗内收铲斗外摆左行走右行走左回转右回转主泵1压力主泵2压力主泵1 主泵2 斗杆水散散热油散散热液压油温水箱水温中冷温度燃油油位
比例阀比例阀比例阀比例阀比例阀比例阀比例阀比例阀比例阀比例阀压力开关先导压力先导压力先导压力先导压力先导压力先导压力先导压力先导压力先导压力先导压力先导压力控制压力控制压力大腔压力泵油压泵油压
02-9 02-10 02-11 02-12 02-13 02-14 02-15 02-16
CAN2_H
CAN2_L
171 236 209 147 223 148 159 158 214 157 222 252 238 210 136 166 119 120 121 116 117 118
153 177 154 178 151 175 152 176 149 173 249 142
-X6 45
-X6 36
02-5
146-1 146-2 146-3 146-4 146-5 146-6 146-7 146-8 146-9 146-10 146-11 146-12 146-13 146-14 146-15 146-16 146-17 146-18
249-1
1 50Bar 50Bar 50Bar 50Bar 50Bar 50Bar 50Bar 50Bar 50Bar 50Bar 50Bar 500Bar 500Bar 50Bar 50Bar 500Bar 500Bar 500Bar
02-7
0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V 0.5-4.5V
ComA ComA ComA ComA ComA ComA ComA ComA ComA ComA ComA Com3 Com3 ComA ComA Com3 Com3 Com3 1 1 1
02-8 2 P P P P P P P P P P P P P P P P P P t t t
1
+P.1-SQ1 B Out B Out B Out B Out B Out B Out B Out B Out B Out B Out B Out 2 Out 2 Out B Out B Out 2 Out 2 Out 2 Out
先导开关 +D.8-BT1 +D.6-BT2 +D.3-BT3 +D.8-BQ1
Power C Power C Power C Power C Power C Power C Power C Power C Power C Power C Power C Power 1 Power 1 Power C Power C Power 1 Power 1 Power 1 PT1000 2 PT1000 2 PT1000 2 30-240欧 2
1 1 1 1 1 1 1 1 1 1
1
+D.5-BP36 +D.5-BP1 +D.5-BP2 +D.5-BP3 +D.5-BP4 +D.5-BP5 +D.5-BP6 +D.5-BP7 +D.5-BP8 +D.5-BP9 +D.5-BP19 +D.4-BP10 +D.4-BP11 +D.4-BP12 +D.4-BP13 +D.7-BP15 +D.6-BP17 +D.6-BP18 液压油温水箱水温中冷温度燃油油位
2 2 2 2 2 2 2 2 2 2 P
+D.7-Y9 +D.7-Y10 +D.7-Y6 +D.7-Y4 +D.7-Y5 +D.7-Y13 +D.7-Y12 +D.7-Y7 +D.7-Y11 +D.7-Y8 2 255-1 255-2 255-3 255-4 255-5 255-6 255-7 255-8 255-9 255-10 255-11 255-12 255-13 255-14 255-15 255-16 255-17 255-18
铲斗内收斗杆2外摆斗杆1内收备用备用左回转右回转斗杆2节流斗杆再生斗杆1节流 145-4 145-3 145-2 145-1
+D.8-SQ3
比例阀比例阀比例阀比例阀比例阀比例阀比例阀比例阀比例阀比例阀液压油回油
压力开关
02-17 02-18 02-19 02-20 02-21 02-22 02-23 02-24 02-25 02-26 03-17
03-15
借用件登记
存储代号 02 02 02 02 02 02 02 02 02 02 02 02 02 03 03
02
旧底图总号
底图总号
316103589 XE750GA.41
图样标记重量比例
签字标记处数更改文件号签字日期
电气系统原理
设计李敏标准化郭中华
校对胡超版次共2 张第1 张
日期
审核文俊批准王勇
工艺刘贵维日期 2021-06-30
徐工矿机
1
1 1 CAN1_H
51 CAN1_L
CAN1_H
1 1 1 1 1 1
CAN1_L
1/
370 L1 318 344 323 307 01
L3
01-8
1 1 F G
-DIAG
+D.1-F05 +D.2-F25 诊断接头 A B C D E H J
100A 2 5A 2
L5
1
370-3
1 382-1 382-2
CAN2_H
+D.1-L3 323-1 2 1
-X12 16 307-1 01
1 1 1 1 1 1 2 304
42
1 GND2 1
+D.2-F35 85 30 +D.6-SQ8A t P t 1 2
3 1
10A +D.1-K16 +D.6-BT6 燃油压力 SIG +D.8-BT4 +D.8-S18 +D.8-Y30
2 +D.2 2 +D.2 2 +D.2 2 +D.2 2 +D.2 2 1 L 1 CRS电磁阀
燃油泵继电器 86 87 2 Pow
燃油泵开关 M
-F36 -F37 -F38 -F39 -F23 1 2
333-2 P 进气温度 CAN2_L +D.8-M4
10A 10A 10A 10A 20A B C 传感器 +D.8-BP33 燃油温度燃油泵
326 370-2
2 386 390 387 392
+D.3-SQ2 318-10
388 2
空滤 317 303
-X12 4 5 6 7 8 3 349 381 384
338 337 385
333-1 堵塞报警 389
364 CAN2_H
339 冷却液位
318-8 318-9 CAN2_L
01-1 01-2 01-3 01-4 01-5 01-6 01-7
357
348 352 353 355
+D.3-ECM
发动机控制器 48 52 53 55 57 33 26 70 38 37 39 64 18 44 23 7 46 47 4 49 17 3 50 34 36 42 27 61 63 65 69 1 4 2 5 6 10 7 12 8 9
-EN-C120-EN-C120-EN-C120-EN-C120-EN-C120-EN-C120 -EN-C120-EN-C120-EN-C120-EN-C120-EN-C120 Air -EN-C120-EN-C120-EN-C120-EN-C120-EN-C120-EN-C120-EN-C120 -EN-C120-EN-C120-EN-C120-EN-C120-EN-C120-EN-C120-EN-C120-EN-C120-EN-C120-EN-C120-EN-C120-EN-C120-EN-C677-EN-C677-EN-C677-EN-C677-EN-C677-EN-C677-EN-C677-EN-C677-EN-C677-EN-C677
B+ B+ B+ B+ B+ B+ Purge KEY Priming Priming Priming Inlet Digital Remote CRS CRS LSR HSR Digital Coolant AirInlet Analog CAN A+ CAN A- B- B- B- B- B- B- B- +5V Fuel Analog Fuel Return Fuel CRS CRS Pump Pump
LAMP pump pump pump Restriction Sensor Shutdown Force disable Sensor Level Temp Sensor Press Return Temp Pump Power Return Power Return
Relay - Relay + Load B+ Return Regen +8V Return Switch
NOx NOx NOx DEF

DPF DPF Driver Driver Driver DPF Nox Smart DEF DEF Pump SP Coolant Quality Digital
Intake +5V Analog DIFF Digital (AFTM In) DEF (AFTM Out)(AFTM In) Intake +5V Analog DPF Diff Ignition Ignition Nozzle Driver DEF DEF Nox Chassis Relay Nozzle Pump Analog Pump Digtal COM Reverter +5V Diverter Sensor Sensor
Pressure Supply Return Pressure CAN C+ CAN C- Return GND Injector+ B+ B+ Battery- Pressure Supply Return Pressure coil+ coil- Heater GND Injector+ Injector- Driver Barrery- GND B+ GND Heater Pressure Return PWR Return Driver Valve Supply Valve B+ Return CAN C+ CAN C-
-EN-C956-EN-C956-EN-C956-EN-C956-EN-C956-EN-C956-EN-C956-EN-C956-EN-C956-EN-C956-EN-C956-EN-C956-EN-C957-EN-C957-EN-C957-EN-C957-EN-C957-EN-C957-EN-C957-EN-C957-EN-C957-EN-C957-EN-C957-EN-C957-EN-C958 -EN-C960-EN-C960-EN-C960-EN-C959-EN-C959-EN-C959-EN-C959-EN-C959-EN-C959-EN-C959-EN-C959-EN-C959-EN-C959-EN-C959-EN-C959
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12
580
561 562 563 571 572 573 574-1 575 576 577 578 579
CANC_H
CANC_L
502-1
501-1
574-2 574-3
+D.8-PETU
尿素箱 1 2 1 3 4 5 6 7 8 9 10 12 1 8 9 10 11
PF-C1 PF-C1 PF-C917 PF-C917 PF-C917 PF-C917 PF-C917 PF-C917 PF-C917 PF-C917 PF-C917 PF-C917 PF-C918 PF-C918 PF-C918 PF-C918 PF-C918
CANC_L_1
531 Smart GND Nozzle DEF Pump Analog DEF PumpDigital Pump SPReverter Digital +5V Coolant - DEF Can C+ Can C- Digital
532
508 509 Relay B+ Heater Pressure Return PWR Return COM Valve Return Supply Diverter Quality Sensor
502-2 CANC_H_1 Driver Valve Sensor B+ Return
507
501-2
503 504 544-1
525 551
544-2 CANC_L_3
CANC_L_2
CANC_H_2 CANC_H_3
511 541
512 513 514 515 516 517 520 521 522
+D.3-CEM
借用件登记后处理 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 20 21 22 23 24 25 31 32 1 4 5 6 1 4 5 6
PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C686 PJ-C913 PJ-C913 PJ-C913 PJ-C913 PJ-C911 PJ-C911 PJ-C911 PJ-C911
存储代号 DPF +5V DEF Analog DPF +5V DPF DIFF Digital Battery- DEF NOx Ignition Ignition Analog DPF DIFF Nozzle NOx DPF +5V CAN C+ CAN C- Relay B+ NOx DEF NOx Barrery- CAN C- CAN C+ NOx Barrery- CAN C- CAN C+
Intake Supply Injector+ Return Intake Supply Pressure Return Injector- Driver coil+ coil- Return Pressure Heater Driver Intake Supply Driver Injector+ Driver Driver
Pressure Pressure (AFTM Out) (AFTM In) Pressure (AFTM In) (AFTM Out) (AFTM In)
GND GND B+ B+
旧底图总号
底图总号
316103589 XE750GA.41
图样标记重量比例
签字标记处数更改文件号签字日期
电气系统原理
设计李敏标准化郭中华
校对胡超版次共2 张第2 张
日期
审核文俊批准王勇
Technical Specifications
工艺刘贵维日期 2021-06-30
徐工矿机
6-9

Chapter 7 Appendix
7.1 Types of crawlers and their applications

Select a proper track shoe that meets conditions of operation. To select a track shoe with proper width the
float ability and ground contact pressure as two crucial points should be factored in and the most desirable
track shoe should be as narrow as possible. Ifthe one in use is wider than needed, track shoe will bear more
loads, which will bend it and fracture the chain link.
Category Application Use notices

Walk in slow speed on rugged road with big
A Rocky ground
obstacles like round stones and fallen trees.
It’s allowed to walk on only even ground in
high or moderate speed; if it has to pass
obstacles, slow down and walk in half of low
B General soil and soft ground
speed; don’t walk on rugged road with big
obstacles, which may fracture pin shaft and
loosen crawler shoe bolt, etc.
Track shoe type list
Technical Specifications Category
Standard 650 mm triple-tooth track shoe A

750mm triple-tooth track shoe
Optional B
900mm triple-tooth track shoe
750mm (width) track shoes are forbidden to use on rugged stony road.
Appendix 7-1
7.2 Types of buckets and their applications
• Bucket application list

Bucket ca- Boom 7000 mm
Types of bucket Filling rate
pacity m3 Bucket rod 2570 mm
3.8 100 ■
Heavy load
4.0 100 ■
excavation
4.6 100 ■
General 5.0 100 □
excavation 5.2 100 □
Light load 5.3 100 ⊙
excavation 5.6 100 ⊙
Symbols in the table above has following meanings:

■：2100 kg/m³（3500 lb/yd3）
□: 1800 kg/m³（3000 lb/yd3）
⊙：1500 kg/m³（2500 lb/yd3）
○: 1200 kg/m³（2000 lb/yd3）
△：900 kg/m³（1500 lb/yd3）
• The figures above are based on the recommended maximum dynamic working weight, and front
linkage fully extends on flat ground and bucket rolls up. The stability is not over 1.25.
• Capacity is based on ISO 7451.
Use classes:
Heavy-load excavation: excavate or load gravels, exploded rocks, firm clay and soft rocks.
General excavation: excavate or load sand, gravels, clay and general soil.
Light-load excavation: excavate or load dry loose soil, sand or mud.
Important:
1. Use an unsuitable bucket may cause severe damage to working devices like the boom, bucket rod
and hydraulic oil cylinder.
2. The recommended type of bucket for excavating or loading firm clay or rocks is high-strength
highly wear resistant rock bucket.
7-2 Appendix
7.3 Weight of working load
CAUTION!
Weight is an approximate value of estimated average volume and volume of capacity.
Table 7-1 Materials density table
Low density Middle density High density

Material
≤1100kg/m3 ≤1600kg/m3 ≤2000kg/m3
Charcoal 400
Carbon coke 500
Coal and asphalt 880
Coal and anthracite 900
Cracked boulder clay 1000
Wet clay of natural
1750
subgrade
Dry particles of
1500
common cement
Dolomite chippings 1500
Dry and soft mud 1200
Solid dry mud 1500
Wet muddy soil 1750
Calcined limestone 960
Crushed limestone, 3
1500
inches
Dry chips of compacted
1800
gravel
Wet chips of compacted
1900
gravel
Limestone of grade 2 or
1300
above
Crushed limestone 1500
High quality limestone 1600
Phosphate rock 1300
Salt 930
Low density snow 530
Appendix 7-3
Table 7-1 Materials density table(continued)
Low density Middle density High density

Material
≤1100kg/m3 ≤1600kg/m3 ≤2000kg/m3
Dry and soft sand 1500
Compacted wet sand 1900
Crushed shale 1400
Cracked sulfur 530
7-4 Appendix
XUZHOU XUGONG MINING MACHINERY CO., LTD.
No. 169, Heping Avenue, Xuzhou City, Jiangsu Province, P.R.CHINA
Service Hotline：400–110–9999
Service Tel: 400-110-9999 0516-83113333
Service Fax: 86-0516-83113222
Post Code：221004
Web Sites：Http：//www.xcmg.com
Version：2021.9
All rights reserved，Violators will surely be prosecuted

Xe800d操作与保养手册 en Omm

Uploaded by

Copyright:

Available Formats

Xe800d操作与保养手册 en Omm

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Xe800d操作与保养手册 en Omm

Uploaded by

Copyright:

Available Formats

XE750D/XE800D Hydraulic Excavator Operation and Maintenance Manual

XUZHOU XUGONG MINING MACHINERY CO., LTD.

1.1 Safety signs

and “Note” — is an additional description of individual information.

– Fuel or lubricating grease that’s not recommended.

Safety signs and other descriptive signs

Safety signs description

1. Read through warning signs illustrated

Warning ! Read through maintenance man-

2. Notice on safety belt (329900203)

Warning ! Fasten the seat belt during

3. Warnings signs on keeping off HV line

There is an electric shock risk if the ma-

4. Warning signs on locking front window

There is a risk that front window may fall;

5. Warning notice on machine start-up

Warning! Read carefully the warning no-

6. Warning sign of leaving operator’s

It indicates a potential danger that the

Before leaving the machine, the operator

7. Warning notice on prohibiting storage of

Warning ! No articles shall be stored here.

8. Warning signs on safety exit

If the operator is under an emergency and

9. Warning signs on engine inspection

It’s dangerous to maintain or repair the

10.Warning signs on inspection of engine

It’s dangerous to maintain or repair the

11.Warning signs of accidental fall

Don't stand on the edge, staff may fall off

12.Warning signs of staying away from

Upper structure may extrude persons with-

13.Lifting and strapping signs (329900225)

Lifting point and strapping point

14.Warning sign of no stamping

Indicating a danger of fall. Prohibit stand-

15.Signs of preventing from being scalded

It may cause scald injury if auxiliary radia-

16.Signs of preventing explosion

There is a risk of explosion around fuel

17.Fuel sign 329900226, 329901334,

If water is accumulated water in engine

Refer to Operation and Maintenance

18.warning notice on crawler adjustment

Crawler may burst out and cause injury

19.Warning notice on use of battery

20.Warning notice on operating on lock

Warning ! Be cautious when opening or

When the lock lever is unlocked,

21.Warning signs on prohibiting operation

If this sign is hung on the control lever of a

22.Operation indicating diagram

Directions of excavator control lever.

23.Walking direction (329900222)

Standard walking direction of machine.

24.Warning on staying away from working

There is a danger that staff may get

25.Hydraulic oil sign (329900228)

26.Warning signs on prevention from being

If radiator or hydraulic oil tank cover is