XCMG XGS40E Instruction Manual

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XGS40E Instruction Manual

XCMG Fire-Fighting Safety Equipment Co., Ltd.

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Page 1 XGS40E Instruction Manual XCMG Fire-Fighting Safety Equipment Co., Ltd.
Page 3: Foreword
This Instruction Manual is not suitable reference for extensive maintenance and repair work. Such work shall be performed by XCMG’ service personnel or authorized specialists. The Operator’s safety is XCMG’s most important point of interest during XCMG’s efforts in designing, producing and maintaining their products.
Page 4 Reviewed by Data contained in this Instruction Manual meets the current state-of- the-art XCMG reserves the right to improve or modify the content, information, diagrams and specifications in this Instruction Manual at any time and without any notice. Foreword...
Page 5: Table Of Contents
XGS40E Instruction Manual Table of contents Foreword ........................III 1 About this manual ..................... 1-1 1.1 Main purpose 1-1 1.2 Product information.................... 1-2 1.3 Target group(s) 1-3 1.4 Layout of user’s instructions ................1-3 1.4.1 Safety notes 1.4.1.1 Layout of warning notice ..............1-3 1.4.1.2 Graduation of the warning notices ............
Page 6 XGS40E Instruction Manual 2.5.3 Risks of damaging the machine and property..........2-14 2.5.4 Environmental risk ..................2-14 2.5.5 Performance and service life reduction ............2-14 3 General safety information and instructions ............3-1 3.1 Introduction ......................3-1 3.2 Responsible parties ..................... 3-1 3.3 Detailed tasks and responsibilities ..............
Page 7 XGS40E Instruction Manual 3.3.7.3 Lessee as user 3-24 3.3.7.4 Lessee as owner 3-24 3.3.7.5 Lessee as operator 3-24 3.3.8 Agent responsibilities ................3-24 3.3.8.1 Sales responsibilities 3-24 3.3.8.2 Re-rent, lease or other forms for profit ..........3-24 3.3.9 The maintenance personnel (technician/engineer): ........3-24 3.3.10 General requirements for all responsible parties ........
Page 8 XGS40E Instruction Manual 4.7 Operator’s safety ....................4-7 4.8 Pre-inspections before machine operation ............4-8 4.8.1 Pre-operation safety rules ................4-8 4.8.2 Location of safety signs on the machine............ 4-10 4.8.3 Daily inspection and visual checks before operation ......... 4-18 4.8.4 Inspection before engine starting ...............
Page 9 XGS40E Instruction Manual 5.7 Braking and stopping the machine ..............5-34 5.8 Operation of battery pump ................5-35 5.9 Operation functions ..................5-35 5.9.1 Engine's DPF regeneration ................ 5-35 5.9.1.1 Precaution for regeneration..............5-35 5.9.1.2 Regeneration mode 5-36 5.9.1.3 Regeneration temperature ..............5-42 5.9.2 Oil filling...
Page 10 XGS40E Instruction Manual 6.6 Bolt tightening torques ..................6-69 7 Faults and troubleshooting ..................7-1 7.1 Engine 7.2 Electrical system ....................7-4 7.3 Hydraulic system ....................7-6 7.4 Parts that need periodic replacement ..............7-8 8 Transport, storage and protection ................8-1 8.1 Transport safety requirements ................
Page 11: Chapter 1 About This Manual
• For repair and maintenance supplementary documents may apply (i.e. for the engine), please contact your XCMG representative for further information. Figure 1-1 Designated storage location of this Instruction Manual on the machine is the box beneath work platform control box.
Page 12: Product Information
Use only genuine XCMG spare and wear parts. Within warranty period, XCMG’s specialists as well as our representatives will help you in repairing or even maintaining your machine. Please refer to your warranty conditions attached to your purchase contract.
Page 13: Target Group(S)
Maintenance/repair errors by service personnel not authorized by XCMG • In case of use of non-genuine XCMG parts • In case of not XCMG approved modifications of the machine • Resulting damage/defects due to delayed warranty/repair request • Follow-up damage is unexceptionally excluded from warranty.
Page 14: Graduation Of The Warning Notices
XGS40E Instruction Manual 1.4.1.2 Graduation of the warning notices Warning notices addressed to hazards affecting personnel injuries vary with decreasing hazard gravity as follows: DANGER! "Danger", a signal word used to indicate imminently hazardous situation. If not avoided, will result in death or irreversible serious injury.
Page 15: Additional Information
XGS40E Instruction Manual Always carry out handling instructions stepwise and in pre-defined sequence. Step I Indicate the potential Hazard (and if appropriate the cause of it) Step II Describe the consequence of Hazard – if not avoided Step III Describe how to avoid the mentioned Hazard – further Steps –...
Page 16 XGS40E Instruction Manual About this manual...
Page 17: Chapter 2 Product Description
Chapter 2 Product description 2.1 General description The mobile elevating work platform with a platform height of 38.2 meters developed by XCMG is self- equipped with a jib, thus having a certain capacity in obstacle crossing and being stretchable to the inac- cessible position;...
Page 18 XGS40E Instruction Manual Product description Figure 2-1 Machine overview...
Page 19 XGS40E Instruction Manual Main Sections – see Table 2-1 Table 2-1 Main components of machine: S/N. Description S/N. Description S/N. Description Work platform Telescopic boom assembly Turntable Slewing bearing Slewing mechanism assembly Electrical Hydraulic system Hydraulic system system schematic piping...
Page 20 XGS40E Instruction Manual Figure 2-3 Declaration of Conformity Product description...
Page 21: Intended Use Of The Machine
Intended use as defined in this Section is a basic requirement for any safe operation! Your XCMG machine is designed by following recognized standard (EN 280) and manufactured accord- ing the state of art methods and technologies at the time of placing to the market.
Page 22: Not Intended Use Of The Machine
XGS40E Instruction Manual Refer to the information in Section 10, Technical specifications and performance parameters Comply with this information completely. Intended use requires the following: • Install all safety devices properly and ensure their correct function • Provide and perform all maintenance and repair work as stated in this Instruction Manual and according to the given specifications •...
Page 23 XGS40E Instruction Manual Misuse or improper use of the machine may lead to severe injuries or death and consequently to expiration of the warranty! The machine operator and/or owner will be fully responsible for all damages done due to machine “unin- tended use”.
Page 24: Scope Of Application
XGS40E Instruction Manual • Transport the machine without appropriate lashing on the transport vehicle. • Parking, storing the machine unsecured or accessible to unauthorized persons (i.e. in inclined areas, open areas, with ignition key at the machine, open covers, etc.).
Page 25: Permitted Environmental Conditions
XGS40E Instruction Manual • Environmental factors-related limits – weather – altitude – slope inclination – steepness • Energetic limits – Types of energy – Interfaces supply/discharge – Material limits – Starting materials/auxiliary operating materials, waste products 2.4.5 Permitted environmental conditions Considerations on environmental conditions shall be taken in order to ensure machine’s safe operation,...
Page 26 XGS40E Instruction Manual Table 2-3 Ground bearing load(continued) S/N. Soil type Ground loading ca- pacity kg/cm Non-cohesive soil: Sand, gravel, rock, and mixture Clayed soil a. Mixture of clayed silt and topsoil b. Powdered coal, composed of coarse clay and few clay c.
Page 27: Environmental Protection Limitations
Slight structure damage. 2.4.6 Environmental protection limitations Environmental protection shall be a common task. XCMG implemented several measures to enhance envi- ronmentally friendly design, production, operation and maintenance methods on this machine. Owners, Operators and Maintenance Personnel are responsible to take sustainable precautions to further contribute to environment protection: Follow environmental protection rules and regulations applying in your area.
Page 28: Residual Risks
2.5 Residual risks 2.5.1 Overview XCMG evaluated and designed the machine having safety as main task. Although it is not possible to fore- see all events that may occur, existing residual risks are mentioned in this manual as possible at the time this manual has been edited.
Page 29: Risks Of Injury Up To Death By
XGS40E Instruction Manual WARNING! Danger of slipping skidding and falling Danger of burns • Weather influences, such as wetness, snow, ice, frost and dirt, change the grip of the treads, walkways and handrails. • Persons may seriously be injured or even killed! •...
Page 30: Risks Of Damaging The Machine And Property
XGS40E Instruction Manual • insufficient safety precautions at your site. • insufficient use of personal protective equipment. • smoking and/or open fire when dealing with flammable substances (i.e. when refueling). • refueling while engine is running or spilling fuel over hot surfaces.
Page 31 XGS40E Instruction Manual Figure 2-5 Become familiar with safety precautions and devices installed at your site. Figure 2-6 Use personal protective equipment according local Occupational Health and Safety regulations. Product description 2-15...
Page 32 XGS40E Instruction Manual 2-16 Product description...
Page 33: Chapter 3 General Safety Information And Instructions
The following advice to the users and operators: Read and respect all safety instructions. 3.2 Responsible parties For the purpose of communication, this Instruction Manual defines the following participant’s groups: 1. Manufacturer–as producer of the unit/machine (XCMG) 2. Dealer 3. Owner 4. User 5.
Page 34: Detailed Tasks And Responsibilities
XGS40E Instruction Manual 3.3 Detailed tasks and responsibilities 3.3.1 General requirements for all responsible parties Any responsible party involved should be committed to: • use and apply the Instruction Manual for operation of machine. • notify involved parties of any safety related defects observed on a machine.
Page 35 XGS40E Instruction Manual • Instruction Manual shall be supplied with each lease, rental or sold machine in weatherproof storage box of MEWP. Manuals are considered as an indispensable part of MEWP, which is an important media to send necessary safety information to owners, users and operators.
Page 36 XGS40E Instruction Manual 1. Training 2. Familiar with the operation of MEWP to operate 3. Clarify the responsibilities of the operator 3.3.2.4 Record preservation and distribution 1. Record preservation The dealer shall preserve the following records at least 4 years:...
Page 37: User Responsibilities
XGS40E Instruction Manual The dealer shall observe the bulletins from the manufacturer. 3.3.2.6 Sales responsibilities When the MEWP is sold, the dealer: Shall ensure that the Instruction Manual delivered to the owner 1. Shall provide the copy of current responsibilities manual.
Page 38 XGS40E Instruction Manual 1) Purchased used machine The routine and annual inspections shall be conducted unless it is confirmed that the inspections are current. 2) Machine servicing for three months or 250 hours (whichever comes first) 3) No operation for more than 3 months The inspection shall be carried out by a qualified technician on MEWP or one has similar design charac- teristics.
Page 39: Replacement Of Components Or Parts
XGS40E Instruction Manual 9) Guardrail device 10) Other items specified by the manufacturer 4. Maintenance safety precautions Before performing adjustment and repair of MEWP, the following precautions should be taken: 1) Power plants stopped and start switches do not work 2) All control mechanisms are in "off"...
Page 40: Work Site Inspection
XGS40E Instruction Manual 1. Know where the weatherproof storage box is located. 2. Know that the manufacturer’s operation and maintenance manuals are stored in weatherproof storage boxes and be familiar with Instruction Manual. 3. Be ware of all control functions, bulletins and warnings.
Page 41 XGS40E Instruction Manual 3. Guardrail device The guardrail shall be installed and secured, and entrance doors or openings shall be properly closed as directed by the manufacturer. 4. Load distribution The load on the platform and its distribution and any the extension of platform shall comply with the rated load requirements specified by the manufacturer for a given condition.
Page 42 XGS40E Instruction Manual The user shall instruct the operator to ensure that there are no personnel or equipment around the MEWP before lowering platform. Oil filling The engine shall be turned off during fueling. Fueling should be performed in well-ventilated areas away from open flames, sparks or other fire and explosion hazards.
Page 43: User As Operator
In case of any suspected MEWP failure or dangerous or potentially unsafe conditions, the user shall ap- prove and instruct the operator to stop the MEWP operation and consult the owner, dealer or XCMG for more information on safe operation before resuming work.
Page 44: Modification
XGS40E Instruction Manual The dealer shall preserve the following records at least 4 years: 1) Name of operator received training and retraining. 2) Name of the operator received the familiarization. 3) The owner (or an individual designated by the owner) is responsible for ensuring that routine and an- nual inspections are carried out and the written records are maintained.
Page 45: Owner
• Use or add configurations according to the original XCMG configuration table. 3.3.4.1 Basic principle Given that the reasonable principles of personnel, safety, training, inspection, maintenance, application...
Page 46 XGS40E Instruction Manual The owner of the MEWP shall ensure that the maintenance detailed in this standard is implemented on the principle of timeliness. The owner shall establish a preventive maintenance program in accordance with the manufacturer’s recommendations and the operation environment and intensity of the MEWP.
Page 47 XGS40E Instruction Manual 3.3.4.8 Maintenance safety precautions Before performing adjustment and repair of MEWP, the following precautions should be taken: 1. Power plants stopped and start switches do not work. 2. All control mechanisms are in "off" gears to protect all control systems from unintentional action caused by braking, obstruction, or other means.
Page 48 XGS40E Instruction Manual from the manufacturer or a qualified person (if the manufacturer is no longer in business) and provide it to the user or operator. 3.3.4.15 Record preservation and distribution 1. Record preservation The owner shall specify the record date and preserve the record at latest 4 years: 1) Name and address of each MEWP purchaser by delivery number and date 2) Written record of routine inspection and annual inspection performed.
Page 49: Operators
• immediately take the machine out of operation in case of safety-impairing defects • perform on-time maintenance and inspections on the machine according to XCMG’s Instruction Manual • report every accident involving the machine, especially: –...
Page 50 XGS40E Instruction Manual make decisions about the use and operation of the MEWP with considering their own safety and the safety of others. 3.3.5.2 Instruction manual The operator shall ensure that operation and maintenance manuals are kept in the weatherproof storage box of MEWP.
Page 51 XGS40E Instruction Manual 12.The trainee shall, under the guidance of qualified personnel, operate the MEWP for a sufficient period of time to achieve proficiency in practical operation. 3.3.5.6 Retraining When instructed by the user, the operator shall be retrained based on the user's observation and evaluation of the operator.
Page 52 XGS40E Instruction Manual 4. All personnel on a MEWP are equipped with appropriate safety devices for the intended work and environment 3.3.5.10 Understanding of hazardous locations It is the operator’s responsibility to understand the hazard classification of the work place according to relative standard.
Page 53 XGS40E Instruction Manual 10. Precautions for other mobile equipment In the presence of other mobile equipment and vehicles, special precautions should be taken to comply with local regulations or safety standards related to the work environment. Warning signs, such as but not limited to flags, rope-fenced zones, flashing lights and barricades, shall be used appropriately.
Page 54 XGS40E Instruction Manual 1) Maintain a clear view of the supporting surfaces and driving routes. 2) Make sure that personnel in the working area who can be harmed are aware of the motion of the machine. 3) Maintain a safe distance from obstacles, debris, holes, potholes, ramps and other hazards to ensure safe driving.
Page 55: Responsibilities Of Lessor
XGS40E Instruction Manual When bridge machine or similar equipment operates within its stroke, measures shall be taken to pre- vent collisions with MEWP. Appropriate supporting requirement The user shall ensure that the supporting surface is sufficient to bear MEWP. The user shall instruct the operator not to use, rent, lease or supply the MEWP in any way for benefit without prior permission.
Page 56: Lessee Responsibilities
XGS40E Instruction Manual 3.3.7 Lessee responsibilities 3.3.7.1 Basic principle Given that the reasonable principles of personnel, safety, training, inspection, maintenance, application and operation shall be applied in personnel training, inspection, maintenance, application and operation, these principles shall be consistent with all available data on rational use and external environment parameters.
Page 57: General Requirements For All Responsible Parties
XGS40E Instruction Manual 1) operating instructions of the machine and its components 2) operating instructions from other manufacturers (e.g. interchangeable equipment) 3) where required, knowledge of the technical data sheets 2. Maintain the machine regularly to ensure safe and reliable operation.
Page 58: Personal Protection Equipment
XGS40E Instruction Manual 3.4 Personal protection equipment Become familiar with safety related precautions at your site Figure 3-1 Personal protection equipment is recommended and possibly mandatory at your site. Wear PPE when working on any machine as required. PPE may include:...
Page 59: Fire And Explosion Hazards
XGS40E Instruction Manual – Do not reach into areas with moving machine parts (such as engine, fan) – Keep cover and platform gate closed 3.5.2 Fire and explosion hazards • Before refueling or filling with hydraulic fluid, shut off the machine and secure against unintentional restart.
Page 60 XGS40E Instruction Manual • Dusty environment and improper handling of the machine in dusty environments (e.g. surface dust formation) follows in: • Increased risk of fire. • Increased risk of dust-explosion • Make sure that the operator prevents dust formation through technical or organiza- tional measures.
Page 61: Lighting Strike
Move the slewing device slowly to watch any abnormal noise or action. • Move the boom to watch any abnormal noise or action. Check boom and belt buckle for damage. Contact XCMG for after-sales service. General safety information and instructions 3-29...
Page 62 • Never attempt to locate the leakage point with your hand or other parts of the body • Damaged hydraulic components must be replaced immediately with original XCMG spares • Check all hydraulic lines regularly (at least once a year) for damage and leaks.
Page 63 XGS40E Instruction Manual Warning! Risk of burns Contact with hot surfaces and consumables! High surface and equipment temperatures can lead to burns or scalding. Observe handling-specific and situation-specific safety notes. Observe the following safety notes: • Always wear suitable protective gloves when working on hot components.
Page 64 XGS40E Instruction Manual Warning! Asbestos dust Contact with the asbestos dust! If too much asbestos dust in the air is breathed, it is possible to suffer a lung cancer. Observe handling-specific and situation-specific safety notes. Observe the following safety notes: •...
Page 65: Safety Distance
XGS40E Instruction Manual Observe the following safety notes: • In the event of leakage of fuel or operating consumable, rectify the causes immediately. • Eliminate leaking fuels or operating materials immediately with binders. • Dispose of used binder safely and in an environmentally friendly manner.
Page 66: How To Act In Dangerous Situations
XGS40E Instruction Manual 3.7 How to act in dangerous situations 3.7.1 If the machine contacts with a power supply line First response Remain calm. Alert the relevant power supply company. • If the control machine is still functioning: • Move the machine out of the danger area.
Page 67 XGS40E Instruction Manual First response • Incorrect behavior in case of fire • Danger of backlash! • Even if the fire appears to be extinguished, leaking fuel or oil coming in contact with hot components may reignite • Shut off the engine.
Page 68: Safety Notes
If any safety sign is missing/damaged, contact XCMG Fire-fighting Safety Equipment Co. Ltd. immedi- ately to have them replaced. • Do not hesitate to contact an XCMG agent for any other ambiguity or issue as well 3.8.2 Mandatory signs Mandatory signs: Generally, it is a safety sign enforcing behavior preventing or reducing a risk to health or safety.
Page 69: Prohibition Signs
XGS40E Instruction Manual Meanings Mandatory signs: Meanings Wear head protection Wear a face shield Wear a safety harness Wear safety belts Read operating Refer to Instruction Instruction Manual Manual 3.8.3 Prohibition signs A “prohibition sign” is a safety sign prohibiting behavior likely to cause a risk to health or safety.
Page 70: Warning Signs
XGS40E Instruction Manual No climbing for unauthorized personnel Do not lift load High-pressure cleaning prohibited 3.8.4 Warning signs Warning signs indicate potential risks or hazards. (ISO 7010) Common warning signs: Meanings Warning signs Meanings Warning of non- Warning of obstacles...
Page 71: Rescue Signs
XGS40E Instruction Manual Meanings Warning signs Meanings Warning of crushing Warning of dangers hazard from above through hydraulic oil Warning of getting Refer to Instruction rolled over Manual 3.8.5 Rescue signs Rescue signs mark the locations of first aid equipment and emergency exits.
Page 72: Machine-Specific Signs And Labels
Ensure that the safety signs and symbols remain legible. If one is missing, damaged or unrecognizable, have it replaced immediately. • If you have any questions, contact an XCMG representative or XCMG Fire-fighting Safety Equipment Co. Ltd. 3.9.2 Machine-specific warning signs...
Page 73 XGS40E Instruction Manual Meaning and description Labels Warning! Non-professional is not allowed to changer internal elements! Warning! Electrical devices are inside and do not directly spray pressurized water for washing! Warning! Tip-over Hazard! • Max manual force: 400 N. •...
Page 74 XGS40E Instruction Manual Meaning and description Labels Warning! Risk of severe crushing or cutting injuries! • Fingers or hands can be crushed or severed by the motor fan. • Do not start any maintenance/repair work before the fan has come to a complete stop.
Page 75 XGS40E Instruction Manual Meaning and description Labels Warning! Do not use the vehicle as a ground for welding. There is the whole machine limited condition when the machine is overloaded. The operation of emergency pump can be released by trig- gering the front area detection toggle switch;...
Page 76 XGS40E Instruction Manual Meaning and description Labels 1. Minors under age of 18 are prohibited from entering the platform. 2. Do not operate the machine at a tilt angle that exceeds the allowable angle specified by the manufacturer. 3. Do not operate the machine when the wind speed may exceed 12.5 m/s.
Page 77: Information Signs- Machine-Specific Functions
XGS40E Instruction Manual 3.9.3 Information signs- machine-specific functions defines which function is triggered by moving the respective operating lever in the corresponding direction. Machine’s moving direction display Indicates the machine current movement direction. Position of the machine’s center of gravity indicates the usual/actual position of the machine’s center of gravity.
Page 78 XGS40E Instruction Manual Lifting point symbol Shows the position of spots made for attaching loads to be lifted. Hydraulic oil Tank symbol It indicates hydraulic oil inlet/outlet/tank position. Diesel Tank symbol Indicates a diesel inlet/outlet or the location of the oil tank.
Page 79: Chapter 4 Safety Guidelines
XGS40E Instruction Manual Chapter 4 Safety guidelines 4.1 Safety regulations • Become familiar with the machine’s Instruction Manual. • Become familiar with: • Safety instructions, rules and regulations applicable at your area/site. • Safety devices installed and available at your site.
Page 80: Personnel Access
XGS40E Instruction Manual • In case additional documents related to machine’s safety and its operation, they must be attached to this Instruction Manual. • Ensure safety related systems are operational and not damaged: • Same apply to the related bolts and nuts.
Page 81: Installation And Assembly
XGS40E Instruction Manual 4.3 Installation and assembly DANGER! Beware of risks and hazards duringinstallation and assembly • Installation and assembly tests can present the hazards for the life (operator himself, co- workers, bystanders) and/or property! • Be careful! Not respecting the basic safety rules presented hereafter – serious injuries or death casualties and/or significant property damage will result! 4.3.1 Requirements for the installation and assembly personnel...
Page 82: Commissioning
XGS40E Instruction Manual 4.4 Commissioning 4.4.1 Requirements for commissioning personnel • Commissioning will be carried out only by trained personnel of manufacturer or his local representative • The commissioning will be carried out according to the commissioning check-list and when com- pleted–will be countersigned from the customer or his representative.
Page 83: Construction Sites Safety
XGS40E Instruction Manual • Before start installation – assembly – commissioning and operation of the machine - note down all important local emergency phone numbers – doctors, – ambulances, – hospitals and – fire departments. • Before doing anything not related to specific machine operation : –...
Page 84: Safety For Children
XGS40E Instruction Manual NOTICE! Be aware of soil and surface stability! A significant machine damage may result. • Construction site safety shall be guaranteed; • Limit access of unauthorized persons entering your construction site according your local regulations and best practices, i.e. as per: •...
Page 85: Operator's Safety
XGS40E Instruction Manual 4.7 Operator’s safety DANGER! Fasten your seat-belt always before start to operate the machine. • Be careful! Not respecting the basic rules presented hereafter – serious injuries or deaths and/ or significant property damage may result! •...
Page 86: Pre-Inspections Before Machine Operation
XGS40E Instruction Manual WARNING! Signals and gestures of the signalman • If there is poor sight, ask for a co-worker to act as a signalman. • The operator shall pay close attention to the signs and follow the signalman’s commands diligently.
Page 87 XGS40E Instruction Manual Figure 4-6 Become familiar with this instruction manual and other safety instructions applying at your site • Comply with additional regulations, standards and laws that may apply in your area or at your work site. • If required wear personal protection equipment, such as reflective vest, gloves, safety glasses, safety shoes, etc.
Page 88: Location Of Safety Signs On The Machine
Be familiar with safety precautions at you site (i.e. emergency phones, fire extinguishers, first aid kits, defibrillators, etc.) • Bolts and nuts shall be screwed tightly. In case of damage, contact immediately your XCMG service partner. • Seatbelt and seatbelt lock shall be undamaged and functional.
Page 89 XGS40E Instruction Manual Please replace damaged or lost decals immediately, the exact part numbers you can find in the attached spare parts list, in case you need support please contact your XCMG service partner. Figure 4-11 Location of safety signs and labels...
Page 90 XGS40E Instruction Manual 1. Lifting indication sign 32. Machine travel arrow (front axle) 2. Anti-collision warning sign (counterweight) 33. Machine traveling arrow (turn left) 3. Mountain-shaped decorative sign (only graph) 34. Driving operation notice sign 4. Model sign on turntable Ⅰ...
Page 91 XGS40E Instruction Manual Table 4-1 Signs description Item Labels Description Lifting indication sign T1190080 Indicate this position is the lifting hole. Anti-collision warning sign (counterweight) T1120525 Attention on collision and keep away from this operating area. Tyre load sign XGS40E.97-2...
Page 92 XGS40E Instruction Manual Table 4-1 Signs description(continued) Item Labels Description Tip-over warning sign T1120512 Do not change the limit switch, or the tipping-over hazard will be caused. Non-lifting indication sign T1190089 No lifting is allowed here. Lifting position instruction label T1190082 Holes here is used for fixing the machine.
Page 93 XGS40E Instruction Manual Table 4-1 Signs description(continued) Item Labels Description Comprehensive warning plate (straight-boom series) T1120521 ○ Read the manual carefully and understand the operation and dealing method before operation. ○ The operating person shall wear helmet and safety belt correctly.
Page 94 XGS40E Instruction Manual Table 4-1 Signs description(continued) Item Labels Description Towing instruction label T1120527 Relieve the brakes before towing operation. Do not tow on a downward slope. After towing, release the machine immediately to restore the brakes. Traveling operation instruction label...
Page 95 XGS40E Instruction Manual Table 4-1 Signs description(continued) Item Labels Description Warning sign for reading instruction manual T1120305 You must read and under the operation manual, responsibility manual and safety manual as well as all the safety signs. Foot pedal warning sign...
Page 96: Daily Inspection And Visual Checks Before Operation
10 kg shall be calibrated for unladen calibration; m+10 kg shall be calibrated for calibration when loading load m. Refer to Instruction Manual or consult in XCMG for weights of optional accessories. Warning sign for emergency pump hazard release...
Page 97 XGS40E Instruction Manual 1. The operator solely use this particular machine frequently and takes it into operation after a short interruption (i.e. daily). He knows the condition of the machine he left and the scope can be re- duced on standard visual safety checks 2.
Page 98: Inspection Before Engine Starting
XGS40E Instruction Manual • Notify any defects on checks carried out at the roadside, • Inform site manager or service to enable service department to schedule workflow and more impor- tantly, order parts required. • Ensure that no person or animal can be endangered before operating 4.8.4 Inspection before engine starting...
Page 99: Starting The Engine
XGS40E Instruction Manual – ambient temperature is very low 4.8.6 Starting the engine WARNING! Check all safety guards prior engine start • Approve prior to engine starting! CAUTION! • Any not approved start may lead to injuries and/or additional property damage! Do not start ever the engine or touch any part of the machine •...
Page 100: Inspection After Starting The Engine
XGS40E Instruction Manual • The iced ground surface becomes soft when the temperature rises up, and the machine will tip over. • If the machine enters into deep snow areas, it may tilt or become buried in the snow. 4.8.7 Inspection after starting the engine •...
Page 101: Inspection Before Starting To Operate Machine
XGS40E Instruction Manual 4.8.8 Inspection before starting to operate machine WARNING! Ensure that no person or animal can be endangered before operating • Before moving, check always that there is no person or obstacle in the action radius. • Sound the horn to alert other people working in the nearby area.
Page 102: General Risks In Operation
XGS40E Instruction Manual • Select the appropriate machine, required equipment and ancillary devices for a function/purpose/task of the machine. • Use the machine according to its intended use (See intended use in the product description chapter). • Always read–understand–and apply the recommendations as described in this Instruction manual.
Page 103 XGS40E Instruction Manual • Take extra care when swinging the upper structure while on a slope. • Make sure enough space is available to stop the swing process. • The swing of a long and heavy equipment will increase danger of slippage of the equipment additionally.
Page 104 XGS40E Instruction Manual • Only enter and exit through the door. Pay extreme attention when entering or leaving the platform. En- sure that the work platform assembly is fully lowered. Face the machine when entering or leaving the platform. Ensure to maintain "three-point contact" with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit.
Page 105 XGS40E Instruction Manual • Maintain safety distance from electrical power lines, apparatus, or any electrified (exposed or insulated electrical) parts according to the Minimum Approach Distance (MAD) as shown in Table 4-2. • The factors of machine movement and electrical line swaying shall be taken into consideration.
Page 106 XGS40E Instruction Manual • Do not operate the machine or transport any personnel in prohibited area (MAD). Assume all electrical parts and wires are live unless known otherwise. Tip-over hazard • The user must be familiar with road condition before driving. Do not exceed the allowable side slope grade and positive slope grade while driving.
Page 107 XGS40E Instruction Manual Crushing and collision hazards • Approved safety helmet must be worn by all operators and ground personnel. • Clearances above, around and below the working area must be checked when raising or lowering the work platform and when traveling.
Page 108: Safety Rules For Towing
XGS40E Instruction Manual • The workers shall be warned not to work, stand, or walk under the elevated platform. Place roadblocks on the ground if necessary. • Notice: Not respecting the basic rules presented hereafter – serious injuries or deaths and/or significant property damage may result! •...
Page 109 XGS40E Instruction Manual 4.9.41 Operating in harsh environmental conditions NOTICE! • Be aware of operations at low temperatures: • Not respecting the safety steps for special working conditions may have impact to the lifetime of machine, machine functions and finally safety of machine operation! •...
Page 110 XGS40E Instruction Manual NOTICE! • Continuous operation in a very hot environment will cause overheat. • Not respecting the safety steps for special working conditions may have impact to the lifetime of machine, machine functions and finally safety of machine operation! •...
Page 111: Optional Components/Equipment
4.9.5 Optional components/equipment The standard package include/Not include optional equipment • Contact an authorized special parts dealer or XCMG Construction Machinery Co., Ltd. • Listen carefully to the installation instructions to manage the task by yourself in the future •...
Page 112: Hazards Related To The Battery
XGS40E Instruction Manual WARNING! • Installation of optional equipment may be hazardous for life and property! • Installation of the optional equipment may bring possible hazards and risks for the service stuff and environment. • Be careful! Not respecting the basic rules presented hereafter–serious injuries or deaths and/or significant property damage may result! •...
Page 113 XGS40E Instruction Manual • Never smoke or use open fire at any time when close to the battery • Wash out clothes or skin thoroughly with water if sulfuric acid splashes on any. • In case sulfuric acid has entered your eyes, wash them out abundantly with water and contact the closest hospital for immediate treatment.
Page 114 XGS40E Instruction Manual Switch the battery OFF when: • Not operating the machine for more than one month. • Maintaining the electrical system. • Disposing of the battery. • Replacing the fuse and/or fuse link. • Connecting the auxiliary cables.
Page 115: Safety Related Parts
XGS40E Instruction Manual Observe the following instructions: • Starting the engine using auxiliary start-cables requires 2 people: • When using another machine’s battery to start your own, do not connect the two machines together. • Turn all engines off before connecting the cables to prevent un- expected movements when supplying power.
Page 116 XGS40E Instruction Manual 4-38 Safety guidelines...
Page 117: Chapter 5 Operation Instructions
XGS40E Instruction Manual Chapter 5 Operation Instructions 5.1 General overview of machine 5.1.1 Machine overview • This equipment is a mobile self-propelled mobile elevating work platform with work platform attached at the end of boom structure. • It is widely used in municipal construction ,bridge construction, shipyard and petrochemical industries and general supporting construction work at other related construction areas.
Page 118: Basic Functional Description
Foot pedal 5.1.2 Basic functional description XGS40E straight-arm mobile elevating work platform, the maximum height of the whole machine is 40.2 m, the maximum load is 460 kg, and the maximum slope rate is 40% the vehicle is equipped with a four-section telescopic boom + jib, with a certain ability to overcome obstacles, large working radius;...
Page 119: Environmental Machine Limits
XGS40E Instruction Manual 5.1.3 Environmental machine limits NOTICE! Respect environmental machine limits Altitude: Below 3280 ft Ambient Temperature: -20℃ to +40℃ • All machines must be inspected, prepared and adjusted before delivery by the manufacturer or his authorized representative. •...
Page 120: Platform Control Box
XGS40E Instruction Manual • After the first 250 h working hours: – Replace diesel filter element and engine oil filter element. – Change the gear oil in the swing reducer. • After the first 1000 working hours, change the gear oil in the travel reducer.
Page 121 XGS40E Instruction Manual Table 5-3 Switches on control panel S/N. Switch Symbol Function Platform searchlight switch E-stop Button: In the case of emergency, press this button to stop current movement and turn off the engine; Reset this button manually after troubleshooting.
Page 122 XGS40E Instruction Manual Table 5-3 Switches on control panel(continued) S/N. Switch Symbol Function Horn: Horn alarm switch Driving directional unlock switch: When the driving function is selected, if the boom rotates beyond any rear wheel or further more clockwise or anticlockwise, the driving directional indicator light turns on.
Page 123 XGS40E Instruction Manual Table 5-3 Switches on control panel(continued) S/N. Switch Symbol Function Jib boom raising/lowering switch: Pull up to raise and pull down to lower. Engine start switch: Push the switch to the left to start engine. Battery pump start switch;...
Page 124 XGS40E Instruction Manual Table 5-3 Switches on control panel(continued) S/N. Switch Symbol Function Travel mode selector switch Turn to the right to choose climbing gear. Boom extend-retract switch: Pull up to retract the boom; pull down to extend the boom.
Page 125 XGS40E Instruction Manual Table 5-3 Switches on control panel(continued) S/N. Switch Symbol Function Platform lifting switch: Pull up to raise the platform and pull down to lower the platform. Platform horizontal moving switch: Pull left to move the platform horizontally leftward and pull right to move the platform horizontally rightward.
Page 126: Indicator Lights Panel
XGS40E Instruction Manual Table 5-3 Switches on control panel(continued) S/N. Switch Symbol Function Axle deploy/retraction switch: Pull the switch to the right, the axle will retract. 5.2.2 Indicator lights panel Figure 5-3 Indicator light Table 5-4 Indicator lights description: S/N.
Page 127 XGS40E Instruction Manual Table 5-4 Indicator lights description: (continued) S/N. Indicator light Function description symbols Glow plug indicator light It indicates the glow plug is operating. Wait unit the indicator light turns off before turning the key and starting the engine.
Page 128 XGS40E Instruction Manual Table 5-4 Indicator lights description: (continued) S/N. Indicator light Function description symbols Platform overload warning light The warning light will turns on when the work platform load is greater than rated load and all movements are prohibited.
Page 129: Control Joystick
XGS40E Instruction Manual Table 5-4 Indicator lights description: (continued) S/N. Indicator light Function description symbols Food pedal/function enable indicator light The indicator light will turns on when the food pedal is stepped and turns off if no movement in 15 seconds.
Page 130 XGS40E Instruction Manual Figure 5-5 Proportional control joystick-R The joystick on the right side of control box adopts proportional joystick with thumb rocker on the top. Operation of joystick: Move the joystick to the direction of blue arrow on control panel to drive the ma- chine forward;...
Page 131: Control Box
XGS40E Instruction Manual 5.3 Control box Figure 5-6 Control box on turntable 5.3.1 Turntable display Operation Instructions 5-15...
Page 132 XGS40E Instruction Manual Figure 5-7 Display interface Figure 5-8 Display interface 5-16 Operation Instructions...
Page 133 XGS40E Instruction Manual Table 5-5 Display function introduction Icon Content Basic setting options: can realize basic setting, such as language selection, inch or metric, time, and brightness. Debug setting option: It can perform sensor calibration, movement speed debug, function option configuration, controller parameter backup and other debug setting.
Page 134 XGS40E Instruction Manual Figure 5-9 Display interface Table 5-6 Display function introduction Working time display: Display the current total working time of the machine, unit: hour. Engine oil pressure display: Show current engine oil pressure, unit: bar. Engine oil pressure display: Show current engine oil temperature, unit: ℃.
Page 135 XGS40E Instruction Manual 3. Engine speed selection/function enable switch: Turn the switch to rabbit position, the engine operates at high speed. Turn the switch to turtle position, the engine operates at middle speed. This switch is also used as enable switch, pull the switch to either side to enable functions on ground control panel for operation.
Page 136 XGS40E Instruction Manual Figure 5-10 Components in control cabinet Table 5-7 Functions of control components Component Function 1. Controller The controller is the core of the machine operation, which directs and coordinates the orderly work of various components of machine. It supplies logic operation and date storage for machine.
Page 137: Compartment Electrical Devices
XGS40E Instruction Manual 5.4 Compartment electrical devices 5.4.1 Warning light • The warning light is located above the right housing, right side of the boom. • OFF: In this state, the warning light does not work. • ON: In this status, the warning light works.
Page 138: Sensor Device
XGS40E Instruction Manual Data logger: − The data logger is located on the right side of the turntable and fixed above the control box. − The data logger turns on and off along with the machine to record each machine motion, data parameters, faults information, etc., which can be used for vehicle data consultation, fault...
Page 139: Machine Startup And Shutdown
XGS40E Instruction Manual Length and angle sensor: − The length and angle sensor can be used to detect extension length and raising angle of the main boom; The sensor will give an alarm when the length or angle reaches the limit to ensure the safety of the machine operation.
Page 140 XGS40E Instruction Manual NOTICE! • Check the engine compartment! • Engine start may result in damage of the equipment or drive system components. • Always make checks/inspections if you come to the machine for the fist time. • Inform you always by the service stuff if the engine start is allowed when performing mainte- nance/repair.
Page 141 XGS40E Instruction Manual Figure 5-12 Control box on platform 1. Ground/platform selector switch 2. Engine start/auxiliary power switch (turntable) 3. Engine speed selection/function enable switch (turntable) 4. Emergency stop button (turntable) 5. Engine start/auxiliary power switch (platform) 6. Emergency stop button (platform) 7.
Page 142 XGS40E Instruction Manual 7) Check the following parts or areas for presence of damage, improper installation, missing part, and unauthorized modification: ①Electrical components, wirings and cables; ②Hydraulic hoses, connectors, hydraulic cylinders, and manifolds; ③Fuel oil and hydraulic oil tank; ④Motor and running reducer;...
Page 143 XGS40E Instruction Manual 5) Surface supports in the working area that cannot bear all the load applied by the MEWP; 6) Wind, rain, thunder, lightening and other weather conditions; 7) Presence of unauthorized personnel; 5.5.1.3 Starting procedure 1. Turn platform/ground selection switch to "ground" position;...
Page 144: Engine Jump Starting
XGS40E Instruction Manual 1. Drive the machine to a secured place. 2. Endure the boom is fully retracted and lowered over the (drive) rear axle; All maintenance panels and doors are closed and latched. 3. Remove all load and let the engine run at low speed for 3-5 minutes to further reduce the engine temperature.
Page 145 XGS40E Instruction Manual 5.5.2.1 Connecting boosting battery NOTICE! − Connect correct the boost battery! Wrong connecting may damage battery or cause fire 1. Shut off the engine on the equipment connected with the boosting battery. 2. Connect one end of the red wire to the positive pole of the battery on the MEWP and the other end to that of the boosting battery.
Page 146 XGS40E Instruction Manual In case battery of the machine is empty connect it with an external power supply (i.e. as shown in figure). Ensure GND pole (-) is connected to machine’s frame! 5.5.2.2 Connection scheme Figure 5-13 Jump starting of loading battery A.
Page 147: Driving The Machine
XGS40E Instruction Manual NOTICE! Remove correctly the boost-battery: 1. First, remove the black negative connection (b) from the main frame of the equipment. 2. Remove the other end of the black negative connection from the boosting battery 3. Remove the red positive connection (a) from the boosting battery.
Page 148 XGS40E Instruction Manual Figure 5-14 Diagram of driving slope WARNING! • Do not allow the machine to be driven with the boom above the horizontal position unless it is on a flat, solid, and horizontal surface. Do not drive the machine on a slope with a slope grade great- er than that marked on the nameplate to avoid losing control or overturning.
Page 149 XGS40E Instruction Manual WARNING! Only leveling override function can be used to level the platform slightly. Improper operation may result in displacement or falling of load/occupants. Failure to follow above instructions may result in serious injury or death. Platform Leveling To adjust the level up and down—Move the platform/level control switch to "up"...
Page 150: Braking And Stopping The Machine
XGS40E Instruction Manual 5.7 Braking and stopping the machine WARNING! • An emergency stop switch must be used to stop the machine in case of emergency • Triggering the anti-squeeze device can also stop the machine in an emergency 5.7.1 E-stop switch Figure 5-15 Devices for stopping the machine The emergency stop operation can be fulfilled from either turntable or platform.
Page 151: Operation Of Battery Pump
XGS40E Instruction Manual NOTICE! • Park the machine in monitored area to prevent possible accidents or the entrance of unauthor- ized personnel. • Remove the ignition key and cover the machine with cover to avoid misuse. • Park the machine on stable and flat ground to prevent hazards or damage to the machine.
Page 152: Regeneration Mode
XGS40E Instruction Manual • The Engine’s Diesel Particle Filter (DPF for short) requires periodical regeneration. • In this process, carbon particles filtered in the DPF are burned to ensure normal function of DPF. • To ensure engines performance, DPFs service life and legal exhaust gas emission limits it is strongly recommended to enable automatic regeneration.
Page 153 XGS40E Instruction Manual Figure 5-17 Regeneration status display 2. Regeneration mode selection 1) Automatic regeneration: Turn the regeneration switch to the auto regeneration position (the middle position of the switch), as shown in Figure 5–18. Figure 5-18 Automatic regeneration position In this position, once the DPF exhaust gas pressure in front of the DPF gets high, the system will as- sume that the DPF is clogged and regeneration is required.
Page 154 XGS40E Instruction Manual After regeneration, the regeneration-in-progress indicator light will turn off and the dis- player will show corresponding indication, as shown in Figure 5–17. 2) Inhibit/Interrupt regeneration Turn the regeneration switch to inhibit/Interrupt regeneration position (press the switch down), see Figure 5–19...
Page 155 XGS40E Instruction Manual Figure 5-20 Manual regeneration position When the switch is in the bottom non-auto regeneration position, the regeneration delay will cause high exhaust temperature and the system will show warning message SPN：3701，FMI：15 . The machine will restrict the boom raising and extending. Stop the machine and perform manual regener-...
Page 156 XGS40E Instruction Manual Table 5-8 DPF automatic regeneration permit(continued) Level 2 Parking (parked regenera regenera tion tion is available required) Level 3 Automatic Alarm (Parked regenera Slow down regenera tion disable and boom tion) Parking raise and regenera extension is tion restricted.
Page 157 Slow down repair) and boom raise and extension is restricted. NOTICE! • Perform parking regeneration while machine is stands still • Force regeneration if the DPF’s contamination is too high. • Contact your XCMG representative if that happens. Operation Instructions 5-41...
Page 158: Regeneration Temperature
During this process, do not stop the engine except in case of emergency. In case of warning message SPN: 3701, FMI:15, forced regeneration is mandatory; consult engines man- ual and contact your XCMG representative. If it is foreseeable that the regeneration may not be possible next time, regenerate reasonably in advance.
Page 159 XGS40E Instruction Manual Figure 5-21 Use only approved fuel! NOTICE! • Use of fuel supplements is prohibited • Always Refuel the machine with sulfur free fuel according EN 590 or ASTM 0975-10 grade No. 1 or 2 -S15, containing less than 15 mg/Kg sulfur.
Page 160 XGS40E Instruction Manual 5-44 Operation Instructions...
Page 161: Chapter 6 Maintenance
XGS40E Instruction Manual Chapter 6 Maintenance 6.1 General hints and overall safety DANGER! Beware of maintenance risks and hazards! • Maintenance of the machine may lead to potential hazards for operator himself, co-workers and bystanders, to possible death casualties and/or damage to property.
Page 162 XGS40E Instruction Manual To avoid any accident: Be sure to remember the maintenance regulations before you start working. Keep your workplace clean and dry. Do not lubricate or maintain the machine while moving. Avoid body limbs contact, or clothes getting sucked in, rotating parts.
Page 163 XGS40E Instruction Manual Avoid flying parts: Flying debris, particles or parts can cause severe injuries! Use the safety goggles or safety glasses to avoid injuries due to flying particles, fragments or debris of any material. Prevent others from entering the working place in case of hazard of flying objects.
Page 164 XGS40E Instruction Manual • High-temperature fluid and surface. During the operation, en- gine oil, gear oil and hydraulic oil may become hot; engine, hose, pipe and other parts will also become hot. • After the oil and parts cooled, start to check or maintain them.
Page 165 XGS40E Instruction Manual NOTICE! • Regularly maintain the machine for normal operation and safety! • Regular maintenance is the essential for the expected machine function and safety! • Use recommended oil products, greases and anti-freeze fluid only. • Any use of incorrect oil in the grease may lead to machine damage! •...
Page 166 XGS40E Instruction Manual When the warning sign is not in use, put it in the tool box. Warning label for Maintenance Keeping the work area clean and tidy • Do not scatter the hammer or other tools in the work area.
Page 167 XGS40E Instruction Manual Shut off the engine before maintenance • The machine should be stopped on solid and flat ground. • The place without fallen stones, collapses or is of no danger of being submerged should be chosen. • Lower the work platform completely and shut off the engine.
Page 168 XGS40E Instruction Manual WARNING! • Beware of risk and hazards from maintenance. • Only trained personnel is allowed to maintain or to repair the Work platform: • Appoint an observer if necessary • Attention! Not respecting the basic rules presented hereafter–serious personnel injuries or even...
Page 169: Welding Operation
XGS40E Instruction Manual • If the hammer is used to strike hard metal parts, such as pins, , blade or bearings, fragments may scatter and cause harm, and therefore, goggles and gloves should be worn during operating. • When striking the pins the fragments may fly out, ensure there are no people around to avoid personnel injuries.
Page 170 Stop operation and tighten the bolts to specified tightening torque if any loose bolt is found. If any damage is found to the hose, stop op- eration and contact your XCMG dealer. • Replace the hose if any following issue is found: –...
Page 171 Instructions for accessories and other components installation When install option components or spare parts, contact XCMG dealer in advance. XCMG does not take any liability in any injury, accident or product failure due to using the unauthorized accessories or spare parts.
Page 172: Work Site Safety
XGS40E Instruction Manual Work site safety Before operation, thoroughly check work site for dangers. • Be careful when operate near flammable materials (dry leaves or grass) which may cause a fire. • Check the ground condition of the work site and determine the most safe method. Do not operated in places with collapse or falling rocks hazards •...
Page 173 • Use good judgment in selecting lubricant types that are appropriate for climate conditions. • Contact MEWP dealer, agent or XCMG after-sales department. • Not respecting the maintenance schedules and steps presented hereafter–can reduce the machine lifetime and may lead to machine damage!
Page 174 Always use oil products, grease and anti-freeze fluid recommended in this Instruction Manual! Other- wise the machine can be damaged and the warranty of this machine will be lost. • Ask your XCMG dealer or manufacturer for approval if some products are not available. 6-14 Maintenance...
Page 175: New Machine
ASTM: American Society of Testing and Material * Engine oil must meet API CJ4/CK4 *** Hydraulic oil change interval is 2,000 hours, only when XCMG Genuine Oil is used. If other brand of oil is used, guaranteed change interval is 1,000 hours.
Page 176: Recommended Oils
XGS40E Instruction Manual 6.2.3 Recommended oils Table 6-2 Table Use listed below or equivalent only. Do not mix different brand oils. 6.2.4 Grease qualities Table 6-3 Oil and grease-qualities and quantities Lubricant Purpose Capacity (Lit.) Brand Remark varieties Lubrication Mobilux grease Pin shaft of equipment -20～40℃...
Page 177: Critical Lubrication Points
XGS40E Instruction Manual Table 6-3 Oil and grease-qualities and quantities(continued) Rotary reducer Diesel engine CF 15W/40 oil -10℃ Diesel engine CF 10W/30 oil -20～-10℃ Engine oil Diesel engine CF 5W/40 oil -30～-20℃ Running reducer L-CKD220 4×1.5 6.2.5 Critical lubrication points...
Page 178: Periodic Maintenance
XGS40E Instruction Manual Table 6-4 Lubrication points(continued) Symbol Specification Purpose Name Sulfur free diesel according to EN 590 ＞0℃ 0 # diesel oil Fuel oil ＜0℃ -10 # diesel oil Ambient temperature Coolant antifreeze FD-2B ＞ -36℃ 6.2.6 Periodic maintenance Overview of the minimum required maintenances shown in hereafter 1.
Page 179 XGS40E Instruction Manual Table 6-5 Scheduled service intervals(continued) Regular Service Interval Daily First week Weekly Monthly Semi- Annual Maintenance annual Items First 50 h 250 h 500 h 1000 h 50 h Check and drain ● the fuel water separator Check coolant ●...
Page 180 XGS40E Instruction Manual Table 6-5 Scheduled service intervals(continued) Regular Service Interval Weekly Monthly Daily First week Semi- Annual Maintenance annual Items First 50 h 250 h 500 h 1000 h 50 h Changing ● hydraulic oil filter element Check the bolt pre-tightening ●...
Page 181 XGS40E Instruction Manual Table 6-5 Scheduled service intervals(continued) Regular Service Interval Daily First week Weekly Monthly Semi- Annual Maintenance annual Items First 50 h 250 h 500 h 1000 h 50 h Check engine air- ● inlet pipes Check and clean ●...
Page 182: Maintenance Schedules
XGS40E Instruction Manual 6.3 Maintenance schedules 6.3.1 Lubrication schedule and lubrication progress label Figure 6-1 Maintenance chart decal on the machine 6-22 Maintenance...
Page 183: Operator Maintenance Checklist
XGS40E Instruction Manual NOTICE! Regular maintenance intervals or engine lubrication oil shall be performed/renewed every 12 months, even in case operating hours interval have not been achieved. 6.3.2 Operator maintenance checklist Table 6-6 Check items Service cycle Service Checking items...
Page 184: Specific Maintenance Instructions
XGS40E Instruction Manual Table 6-6 Check items(continued) Rotary reducer Check, grease 100 h Lubricate the front-end Running mechanism attachments Check, grease 500 h/time and slewing mechanism Steel wire rope Check, setting Daily 6.4 Specific maintenance instructions 6.4.1 Hydraulic system 6.4.1.1 Checking hydraulic oil level and temperature in tank Figure 6-2 Indicator for hydraulic level and temperature inside the hydraulic tank 6.4.1.2 Hydraulic oil filling requirement...
Page 185 XGS40E Instruction Manual WARNING! • Low viscosity of hydraulic oil is not recommended! • Hydraulic oil with too high viscosity may delay application or release of parking brake. NOTICE! • Use of other than recommended mineral oils is prohibited. •...
Page 186 XGS40E Instruction Manual Table 6-7 Hydraulic-oil cleanliness classes 6-26 Maintenance...
Page 187 XGS40E Instruction Manual Figure 6-3 Hydraulic-oil viscosity vs temperature charts Maintenance 6-27...
Page 188: Refilling The Hydraulic Oil Tank
XGS40E Instruction Manual 6.4.1.3 Refilling the hydraulic oil tank Figure 6-4 Hydraulic oil filler Refilling the hydraulic oil tank 1. Switch off engine and remove ignition key. 2. Enable hydraulic oil to cool down if necessary. 3. Open the air filter cover on the upper plane of oil tank.
Page 189: Hydraulic Oil Replacement
XGS40E Instruction Manual NOTICE! • Fill hydraulic oil through a special filter. Do not fill the new oil into hydraulic tank directly. • When replacing hydraulic oil, it is recommended to replace hydraulic oil filter and air filter at the same time.
Page 190: Hydraulic Hoses
XGS40E Instruction Manual 6. Disconnect the return circuit to the oil tank and connect it to other empty container. 7. Start engine and operate boom and outrigger (if equipped) to traveling state. 8. Clean or replace the return hose of the oil tank.
Page 191 XGS40E Instruction Manual WARNING! • Severe gangrene or death due to high pressured oil! • Damaged hydraulic lines will cause high-pressurized oil squirt, penetrating the skin up to the in- ner tissue layer. • In case of occurrence, call an ambulance immediately.
Page 192: Replacing The Hydraulic Oil Filter
XGS40E Instruction Manual 6.4.1.6 Replacing the hydraulic oil filter Figure 6-8 Hydraulic oil return filter The steps of replacing hydraulic oil return filters are as follows: 1. Switch off engine, open engine hood and enable engine and hydraulic oil to cool down if necessary.
Page 193 XGS40E Instruction Manual Figure 6-9 Unscrew the hydraulic filter end cap 6. Pull the filter element out and dispose properly. Figure 6-10 Pull out the filter element 7. Install the new filter element into the housing and then screw the end cap and tighten it.
Page 194 XGS40E Instruction Manual The steps of replacing the hydraulic oilreplacing the hydraulic oil suction filter are as follows: 1. Switch off engine, open engine hood and enable engine and hydraulic oil to cool down if necessary. 2. Save the hydraulic oil in a clean container.
Page 195: Inspection Of The Wire Rope
XGS40E Instruction Manual Figure 6-13 Removable of the filter cartridge A. Filter head B. Filter cartridge C. Oil plug 7. Remove the used filter element and install the new one. Dispose the used filter element properly. 8. Remove the elder O ring from filter cartridge and install the new one.
Page 196: Adjustment Of Wire Rope
XGS40E Instruction Manual 6.4.2.2 Adjustment of wire rope Figure 6-14 Assembly diagram of telescopic system Name Name 3rd extension rope Adjustable nut for 3rd retraction rope 3rd retraction rope Locknut for 3rd retraction rope 4th extension rope Adjustable nut for 4th...
Page 197: Work Platform
XGS40E Instruction Manual 3. Retract the boom inward, respectively adjust No. 5 and 9 adjustable nuts at both left and right sides, tension the extension rope. 4. According to the demand, repeat Step 2 and 3, check the boom movement according to the above-men- tioned inspection methods, confirm that the rope is properly adjusted, tighten and lock No.
Page 198: Slewing Mechanism
XGS40E Instruction Manual Safety belt anchorage 2 Work platform swing cylinder Safety belt anchorage 3 During the vehicle use, the work platform shall be regularly checked and maintained: • Check whether the slewing cylinder of work platform has oil leakage, and whether the rotation action is flexible and stable.
Page 199 • The user is not recommended to remove the hydraulic motor without permission. If the hy- draulic motor has problems, please directly contact the nearest XCMG agency. • Please be sure to remember the position of the interfaces and spare parts during removal.
Page 200 XGS40E Instruction Manual ②Insufficient brake torque: When the brake torque is reduced or the friction plate has deformation due to serious friction, the friction plate shall be replaced. 2. Gear oil change Determine the correct position of the oil ports on the reducer and brake.
Page 201 XGS40E Instruction Manual 1. Lubrication of slewing bearing: Proper lubrication is a must for the durability of track and gear. The lubrication cycle is determined ac- cording to the service condition and the environment, and one lubrication is recommended every 50 h in general case.
Page 202 XGS40E Instruction Manual Figure 6-18 Clearance adjustment of the slewing gear Name Name Name Motor Slewing Mounting bolt reducer Locknut Adjustable bolt The adjustment steps are as follows: 1. Loosen the locknut (No. 4), and it is unnecessary to completely screw out the locknut;...
Page 203: Running System
XGS40E Instruction Manual 6.4.5 Running system Figure 6-19 Running mechanism A. Travel motor B. Travel reducer C. Tyre 6.4.5.1 Tyre Figure 6-20 Compositions of the wheel 1. Rim 2. Tyre 1. Rim checking 1) Rust conditions of the rim; Maintenance...
Page 204 XGS40E Instruction Manual 2) Rim bending and deformation conditions; 3) Whether the rim parts have cracks; 4) Conditions of the rim spigot, mounting hole, and wheel and rim bolt and nut. 5) If discovering that the rim has damaged and deformed parts by inspection, they shall be repaired or replaced immediately.
Page 205 XGS40E Instruction Manual CAUTION! • Pay attention to followings during the tyre installation: • The tyre on the same shaft shall have the same model and pattern. • The retreaded tyre can’t be used. • It is forbidden to weld and repair deformed tyre bolts at the bolt connection. If above problems occur, the old parts shall be replaced by new ones.
Page 206 XGS40E Instruction Manual Figure 6-21 Travelling reducer Position Description S/N. Description Oil filling position Oil drain Oil discharge position Fuel level 3. Disengage The separator of the running reducer is as shown in Figure 6–22. The separation steps are as follows: 1) When the running reducer is in “brake”...
Page 207 XGS40E Instruction Manual Figure 6-22 Schematic diagram of the separator of the running reducer Position Description S/N. Description Engagement Bolt Disengagement Plug 6.4.5.3 Running motor Remove the hydraulic hose connecting to the travel motor; make marks and properly seal it, and then block the motor oil port.
Page 208: Checking The Electric System And Controls Functions
XGS40E Instruction Manual CAUTION! During the removal of the oil pipeline, the joint shall be loosened slowly to prevent the high- pressure hydraulic oil from splash damage. 6.4.6 Checking the electric system and controls functions NOTICE! • The installation of improper radio communicators and accessories may corrupt the machine’s electronic elements and cause it to move in an unexpected matter.
Page 209: Diesel Engine Maintenance
XGS40E Instruction Manual NOTICE! • Replacement of the battery • If battery system malfunctions, replace the maintenance free battery with new one. • Different types of batteries may charge at different speeds, which may cause one of the batteries is overloaded and malfuctions.
Page 210 XGS40E Instruction Manual Figure 6-23 Oil dipstick location To check engine lubrication oil level: 1. Park the machine on flat ground. 2. Shut down the engine, remove ignition key and open engine side panel. 3. When the engine lubrication oil’s cool down is completed, check engine lubrication oil level with the dipstick.
Page 211 XGS40E Instruction Manual Figure 6-24 Engine oil level 6.5.1.3 Refilling the engine’s lubrication oil NOTICE! • Shut down the engine before replacing engine lubrication oil or oil filter. • Only use lubrication oil specified either in the engine’s manual or this manual.
Page 212 XGS40E Instruction Manual Figure 6-25 (2) Oil filling port (3) Engine lubrication oil filter 6-52 Maintenance...
Page 213 XGS40E Instruction Manual Figure 6-26 (4) Engine lubrication oil drain 1. Engine oil replacement 1) Start the engine and warm up for about 5 minutes. 2) Place a 15 L container for engine oil under the engine. 3) Remove the drain plug (4) to drain the oil completely.
Page 214 6.5.1.4 Checking the engine’s crankcase ventilation valve WARNING! Risk of burns in contact with hot surfaces! For details, see engine operation and maintenance instructions or contact your XCMG-partner. 6.5.1.5 The engine’s lubrication hose WARNING! Risk of burns in contact with hot surfaces!
Page 215 XGS40E Instruction Manual For details, refer to the engine’s operation and maintenance handbook. 6.5.2 Engine fuel system 6.5.2.1 Fuel tank WARNING! • Before maintenance, shut down the engine and carry out maintenance after the engine cools down. • Inflammable fluid! •...
Page 216 XGS40E Instruction Manual Figure 6-29 Fuel water separator (1) Fuel water separator cartridge (2) Blocking sensor The fuel-water separator is equipped with a blocking sensor (2). Its status will be shown on the Dash- board’s display screen in a manner similar to Error code: XXXXXX explanations…...
Page 217 XGS40E Instruction Manual Figure 6-30 Fuel filter (1) NOTICE! • Before maintenance, shut down the engine and carry out maintenance after the engine cools down. • Avoid spilling fuel on the ground to prevent risk of fire or environmental pollution.
Page 218 XGS40E Instruction Manual Figure 6-31 Fuel piping Inspect the fuel supply piping regularly. In case of any signs of damage, replace them immediately. After replacement, de-aerate the fuel supply and start engine. Ensure leakage free operation. Replace filter element isolating filter when the info pops up.
Page 219 XGS40E Instruction Manual Figure 6-32 Fuel tanks drainage plug (1) is located on the lower left-hand side of the front frame (1)oil drain pug, located on the left side of the turntable WARNING! • Inflammable fuel or vapors! • No smoking or open fire while handling the fuel NOTICE! •...
Page 220 XGS40E Instruction Manual Figure 6-33 Engines air intake filter (1) location NOTICE! Any engine damage due to inappropriate maintenance of the intake filter voids the warranty. • Check whether the dust discharge valve is clean or clogged (e.g. by wet deposits).
Page 221 XGS40E Instruction Manual Figure 6-34 Engines air intake filter (1) Air filter cover (2) Dust discharge valve (3) Main filter element (4) Safety filter element (5) Housing Replacing the air intake filter 1. Switch off engine, remove the ignition key.
Page 222 XGS40E Instruction Manual Figure 6-35 Air intake system Inlet filter tube NOTICE! • Shut down engine and await complete cool down before maintenance • Do not operate the engine while the air intake system is not correctly assembled. • Replace the filter element instead of cleaning it every 6th time Replacing the air intake pipe 1.
Page 223 XGS40E Instruction Manual DANGER! • Protect your eyes and wear gloves for handling the cooler • Serious injury hazards due to rotating machine parts! (Ventilator and V-belts) • Risk of burns due to hot surfaces! • Risk of burns due to hot cooling fluids! •...
Page 224 XGS40E Instruction Manual Figure 6-36 Radiator (1) Cooling liquid filling port (2) Liquid level sensor (3) Liquid level observation window Switch off engine, remove the ignition key and open engine hood; let engine and radiator to cool down if necessary.
Page 225 XGS40E Instruction Manual Figure 6-37 Cooling systems piping (1) (1) Water inlet pipe of radiator (2) Water outlet pipe of radiator (3) Water drain switch (4) Vent pipe (5) Water supply pipe • Inspect the radiator’s piping regularly on fractures and leaks.
Page 226 XGS40E Instruction Manual 2. Dismantles the radiator cap (1), turns on the row of fluid valve (2), discharges completely the refrigerant. 3. After discharges all refrigerants, close the drain valve (2). 4. Pour in the coolant until the radiator is filled.
Page 227 • Ignoring this equals to violating the exhaust emission regulations. Inspection of the EGR system For details, see engine operation and maintenance instructions or call your assigned XCMG partner. Replacing the EGR cooling hose NOTICE! Do not operate engine while engine’s EGR system is not correctly assembled! For details, see engine’s Instruction Manual...
Page 228 XGS40E Instruction Manual Figure 6-39 V-Belt installation 1. V-belt 2. Tension bolt for V-belt 1 Adjust the tension of the V-Belt Push the V-Belt between the shaft wheel and the alternator, refer to Figure 6–39 V-belts tension is sufficient as long as maximum deflection stays below 8 mm.
Page 229: Bolt Tightening Torques
XGS40E Instruction Manual 6.6 Bolt tightening torques NOTICE! • Inspect the tightening torques of bolt and nut every 500 hours. • Inspect the tightness of bolts and nuts after the breaking-in period of the machine. (usually first 50 hours of operation) •...
Page 230 XGS40E Instruction Manual Table 6-8 Table Bolt tightening torque table (1/3)(continued) The following values apply to galvanized/zinc chrome fasteners. 8.8 metric bolts/8 metric nuts Torque Torque Torque Torque Tensile (Dry or (Loctite Dimen- Applied (Lubrica- (Loctite Pitch stress Loctite 242 or...
Page 231 XGS40E Instruction Manual Table 6-9 Bolt tightening torque table (2/3) (continued) The following values apply to galvanized/zinc chrome fasteners. Metric bolt at grade 10.9/metric bolt at grade 10/below hexagonal nut M6 at grade 12.9 Torque Torque (Dry or Torque Torque...
Page 232 XGS40E Instruction Manual Table 6-10 Bolt tightening torque table (3/3) (continued) The following values apply to galvanized/zinc chrome fasteners. Grade 12.9 hexagon socket M6 or above Torque Torque Torque Tensile Applied (Dry or (Lubrica- (Loctite 262 Dimension Pitch stress area...
Page 233: Chapter 7 Faults And Troubleshooting
XGS40E Instruction Manual Chapter 7 Faults and troubleshooting 7.1 Engine Table 7-1 Engine faults and troubleshooting Fault Cause Solution Blockage of air filter Replace Blockage of fuel oil pipe Repair or replace Drain the fuel tank and clean the filter...
Page 234 XGS40E Instruction Manual Table 7-1 Engine faults and troubleshooting(continued) Fault Cause Solution Over low Thermostat fault Contact your assigned XCMG-dealer coolant Thermometer or transfer device fault temperature Engine oil type error Drain and replace with correct engine oil Engine oil...
Page 235 XGS40E Instruction Manual Table 7-1 Engine faults and troubleshooting(continued) Fault Cause Solution starting Low capacity of battery Charge or replace the battery motor Open magnetic holding coil of start motor Contact your assigned XCMG-dealer Disengagement of starting motor pinion The starting...
Page 236: Electrical System
XGS40E Instruction Manual Table 7-1 Engine faults and troubleshooting(continued) Fault Cause Solution Too large The combustion deposits cause the check or clean resistance blockage of coal behind the turbine. of turbo Leaks of air suction pipe cause the charger blockage of dirt behind the compressor...
Page 237: Troubleshoot
XGS40E Instruction Manual Table 7-2 Electric system–faults and troubleshooting(continued) S/N. Fault Possible Causes Solutions Fuel-water separator damage Replace Fuel line damaged and other oil Troubleshoot line fault Water temperature sensor (or Replace switch) is damaged Sensor plug-ins and connecting Find out loose point, closely insert...
Page 238: Hydraulic System
XGS40E Instruction Manual 7.3 Hydraulic system Table 7-3 Hydraulic system faults and troubleshooting S/N. Fault Possible Causes Solutions Under-low setting of pressure Adjust the pressure to 21 cutoff value for open variable The pressure of displacement pump superstructure hydraulic Under-low pressure setting of...
Page 239 XGS40E Instruction Manual Table 7-3 Hydraulic system faults and troubleshooting(continued) S/N. Fault Possible Causes Solutions causing the impact when opening The brake enable pressure for Repair brake 1 slewing reducer is too high or malfunction Malfunction of electro- Check and repair electro-...
Page 240: Parts That Need Periodic Replacement
XGS40E Instruction Manual 7.4 Parts that need periodic replacement Table 7-4 Parts for periodic replacement Replacement Parts that need periodic replacement interval Fuel hose (from fuel tank to filter) Fuel hose (from fuel tank Engine to injection pump) Oil filter hose (from...
Page 241: Chapter 8 Transport, Storage And Protection
XGS40E Instruction Manual Chapter 8 Transport, storage and protection 8.1 Transport safety requirements 8.1.1 Transport on public roads 8.1.1.1 General requirements NOTICE! • Secure the machine properly while transporting! • Do not engage untrained or insufficient qualified personnel in loading, transport and unloading the machine.
Page 242: Loading & Unloading Instructions
XGS40E Instruction Manual 8.1.1.2 Loading & unloading instructions DANGER! • Risk of serious injuries or death. • Consider the load distribution on transport vehicle! • Machine may slip uncontrollable on a smooth slope! • Make sure the slope is wide enough for safety loading and unloading •...
Page 243 XGS40E Instruction Manual Transport lashing Before transportation, securely fix the chassis on the transportation vehicle and take corresponding safety protection measures. The chain cable with sufficient load-bearing capacity is required and the number is at least 5. The rigging should be adjusted appropriately to avoid damage to the chain cable. As shown in the following figure.
Page 244: Hoisting The Machine
XGS40E Instruction Manual WARNING! Disengage articulation lock prior driving the machine. 8.1.2 Hoisting the machine DANGER! • Risk of serious injuries or death. • Consider the load distribution! • Follow the loading machine’s instructions for use precisely! • Do not overload the machine! •...
Page 245: Towing The Machine
XGS40E Instruction Manual • Prior hoisting machine ensure all precautions mentioned in machines safety and operation manual are met, including securing the potential danger zone. • Use only permitted tools, lugs, ropes, etc. and ensure grounds stability as required for the machine.
Page 246 XGS40E Instruction Manual Figure 8-5 Disengagement of drive hub. Bolt Plug To disengagement of drive hub: • When the running reducer is in “brake” state, remove the bolts with a wrench. • Remove the plug. • Flip the plug and install it to the original position.
Page 247: Parking, Storage And Protection
XGS40E Instruction Manual DANGER! • Risk of serious injuries or death! • Use only approved towing devices. Carry out the towing steps in the following order: 1. Connect the towing bar to the front of framework by accessory pin and tow the machine by traction bar.
Page 248 XGS40E Instruction Manual • Grease all greasing points; • Secure greasing points with the respective caps; • Grease all plain metal surfaces (i.e. cylinder rods); • Clean the machine with appropriate cleaning agent dry it with soft rags. 8.2.2 Long-term storage (longer than 1 month) In case long term storage is required following shall be carried out additional to the previous points.
Page 249: Chapter 9 Cleaning
XGS40E Instruction Manual Chapter 9 Cleaning 9.1 Cleaning exterior of the machine Do not directly aim at electrical control cabinet and joints of wiring when cleaning the machine with high- pressure water; Never aim water or steam jet at electrical components! Otherwise, it will result in electric shock!
Page 250 XGS40E Instruction Manual CAUTION! Personal injury • Burn hazard due to hot engine parts! Can cause severe physical burns. Stop the engine and let it cool down. Wear protective equipment. Clean machine, the engine and the combi cooler only when the engine is switched off and cooled down Keep all guards and covers securely fastened to the equipment.
Page 251 XGS40E Instruction Manual NOTICE! Property damage • Damage to machine due to cleaning work. Do not clean the engine compartment with high-pressure cleaners, steam jets or high-pressure water. High pressure water can penetrate seals get into the electrical system cause short circuits and disable the controls.
Page 252 XGS40E Instruction Manual Wear protective clothing, safety shoes, goggles and protective mask for cleaning work with compressed air and/or a high-pressure cleaner. With PPE use an effective deflector shield for particles Work carefully. Do not direct the compressed air at the skin or at other persons.
Page 253 XGS40E Instruction Manual WARNING! Fire, explosion and inhalation hazards Volatile, easy flammable cleaning solvents, agents inhibitors and sprays in closed compartments or rooms always present danger of fire or even explosion. Provide fully ventilation with fresh air in rooms or compartments prior to further work when cleaning with solvents was necessary.
Page 254 XGS40E Instruction Manual Check once a day the screw connections of the protective structures for tightness. Loose screw connections must be immediately retightened. Cleaning...
Page 255: Chapter 10 Technical Specifications/Performance Data
XGS40E Instruction Manual Chapter 10 Technical specifications/performance data 10.1 Operating limits 1. Carry out the comprehensive checking to the vehicle functions before the operation. 2. If the vehicle can’t work normally or hasn’t been correctly maintained, the corresponding operation shall be forbidden.
Page 256: Overall Dimensions
XGS40E Instruction Manual 10.2 Overall dimensions Figure 10-1 Machine overall dimension 10.3 Main technical specifications Table 10-1 Main technical data Machine Height Machine length 14.06 m Machine width 2.49/3.8 m Wheelbase 3.8 m Platform height 38.2 m Maximum carrying mass...
Page 257: Emission
XGS40E Instruction Manual Table 10-1 Main technical data(continued) Axle retracted: 6.8 m Axle full extended: 5.8 m Min. turning radius (2-wheel steering) Axle retracted: 10.8 m 8.2 m Axle full extended: Total weight of equipment 21460 Kg Turntable rotation 360°...
Page 258: Engine's Nameplate
XGS40E Instruction Manual 10.4.2 Engine’s nameplate Table 10-2 Engine’s nameplate 10.5 Vibration Vibration in the surrounding environment can cause problems such as resonance and impact of the mobile elevating work platform. Therefore, it is necessary to ensure that any vibration in the surrounding environ- ment does not affect the work of the mobile elevating work platform and the safety of personnel, otherwise the operation shall be avoided in a vibration environment.
Page 259: Hydraulic Schematics
XGS40E Instruction Manual 10.6 Hydraulic schematics Figure 10-2 Hydraulic schematics 1: Overview Technical specifications/performance data 10-5...
Page 260: Electric Schematics
XGS40E Instruction Manual 10.7 Electric schematics Figure 10-3 Electric schematics for model with Kubota engine 1 10-6 Technical specifications/performance data...
Page 261 XGS40E Instruction Manual Figure 10-4 Electric schematics for model with Kubota engine 2 Technical specifications/performance data 10-7...
Page 262 XGS40E Instruction Manual Figure 10-5 Electric schematics for model with Kubota engine 3 10-8 Technical specifications/performance data...
Page 263 X1:1 3/8B 3L 3L 6/1A X1:1 3/8B 4L 4L 6/1A 7/1E 1L K112:86 F111 F109 2.5mm K116 K112 K112 K115 6.7E 3.4D X104:N X101:S X104:3 Optional 2.5mm K114:85 X1:2 X101:R X103:R X103:G X103:J X201:R Hydraulic oil temp control SW X202:S +D1 θ...
Page 264 XGS40E Instruction Manual Figure 10-7 Electric schematics for model with Kubota engine 5 10-10 Technical specifications/performance data...
Page 265 XGS40E Instruction Manual Figure 10-8 Electric schematics for model with Kubota engine 6 Technical specifications/performance data 10-11...
Page 266 XGS40E Instruction Manual Figure 10-9 Electric schematics for model with Kubota engine 7 10-12 Technical specifications/performance data...
Page 267 2.5mm 2.5mm F112 20A F115 -X105:3 -X105:V 6/8A 4L 120Ω K117 .3B ECU power control F116 TOOL PORT EGR Valve ECU-KCR02 K117 6/8A 3L CAN1-H (with resistance) 105 POWER GND OIL-SW F114 POWER GND Connector A Oil SW CASE-GND Sedimenter SW -X105:F 18L 6/8B Sedimenter SW...
Page 268 XGS40E Instruction Manual Figure 10-11 Electric schematics for model with Deutz engine 1 10-14 Technical specifications/performance data...
Page 269 XGS40E Instruction Manual Figure 10-12 Electric schematics for model with Deutz engine 2 Technical specifications/performance data 10-15...
Page 270 E-stop on turntable 2.5mm S103 2.5mm 2.5mm 2.5mm X101:G 13L 7/1E X101:H 14L 7/1E S113 2L 7/1E Platform F101 K104 2L 6/1D X101:K Turntable 3L 4/1A X1:1 4L 4/1A X101:J 15L 7/1D F110 K115 4.3C 6L 5/1A Chassis power X105:1 K118 6.8E Manual resetting relay...
Page 271 X1:1 3/8B 3L 3L 6/1A X1:1 3/8B 4L 4L 6/1A 7/1E 1L F111 F109 2.5mm K116 K112 K112 K115 6.7E 3.4D X104:N X101:S X104:3 选装 2.5mm K114:85 X1:2 X101:R Hydraulic oil temp control SW X103:R X103:G X103:J X201:R X202:S +D1 θ X104:4 2.5mm X202:T...
Page 272 XGS40E Instruction Manual Figure 10-15 Electric schematics for model with Deutz engine 5 10-18 Technical specifications/performance data...
Page 273 XGS40E Instruction Manual Figure 10-16 Electric schematics for model with Deutz engine 6 Technical specifications/performance data 10-19...
Page 274 XGS40E Instruction Manual Figure 10-17 Electric schematics for model with Deutz engine 7 10-20 Technical specifications/performance data...
Page 275 XGS40E Instruction Manual Figure 10-18 Electric schematics for model with Deutz engine 8 Technical specifications/performance data 10-21...
Page 276 XGS40E Instruction Manual 10-22 Technical specifications/performance data...
Page 277: Chapter 11 Decommissioning And Disposal
Improper disassembly increases the risk of accidents! • Contact your XCMG partner for proper disassembly of the machine. • Disassemble the machine into its individual parts according to the instructions of your XCMG partner NOTICE! Property and environmental hazards Safety and environmental protection should be in focus...
Page 278 XGS40E Instruction Manual Brake pads, brake bands, brake linings, clutch plates and some gaskets. The asbestos contained in these parts is bound or sealed with resin. bound or sealed. Normal handling is not dangerous as long as no asbes- tos dust is generated is produced that can become airborne.
Page 279 XGS40E Instruction Manual Index a safe way for transportation......................8-1 Agent ..............................3-1 air intake system ....................6-59, 6-62, 7-2 axle balance ............................5-2 Axle balance............................5-2 battery ...................... 4-36, 5-29, 5-31, 8-8 Battery ............................... 7-4 commissioning ......................2-8, 4-4 Commissioning ..........................
Page 280 XGS40E Instruction Manual Engine start ............................5-24 engine starting ......................4-19, 5-23 explosive ............................4-34 fuel system .......................3 -6, 6-56–6-57 fuel water separator.................4-19–4-20, 6-19, 8-8 Fuel water separator ..................6-23, 6-55–6-56 Fuel-water separator .......................... 7-5 greasing point ............................ 8-8 greasing points ........................... 8-8 hydraulic hose ..........................
Page 281 XGS40E Instruction Manual Maintenance Personnel ........................2-11 manufacturer ..2-5–2-6, 3-3, 3-5, 3-7–3-9, 3-11–3-12, 4-2–4-4, 4-19, 4-24, 4-28, 5-3, 6-14, 6- 63, 10-1 Manufacturer ....................... 1-3, 3-1 MEWP ..............3-3–3-12, 4-29–4-30, 5-29, 6-8, 9-3–9-4 operating personnel..........................3-5 operator .. 1-1, 1-3, 2-7–2-8, 2-12, 3-1–3-2, 3-4–3-5, 3-7, 3-9–3-11, 4-4–4-5, 4-24–4-25, 4-29, 5-11, 5-19, 6-1, 6-5, 6-7, 6-11–6-12, 10-3...
Page 282 XGS40E Instruction Manual safety label............................9-2 safety sign ............................1-2 service stuff......................4-34, 5-24 slewing bearing..................6-18, 6-21, 6-41–6-42 Slewing bearing ......................6-38, 6-40 slewing gear .....................6 -41–6-42, 7-8 slewing mechanism .....................6 -24, 7-6 slewing motor ..........................6-38 slewing reducer ..........................7-7 Slewing reducer ....................
Page 283: Copyright
– without before permission in writing from the manufacturer No reproduction or translation of this publication, in whole or part, without the written consent of XCMG Fire-Fighting Safety Equipment., LTD.
Page 286: All Rights Reserved
Manufacturer: XCMG Fire-Fighting Safety Equipment Co., Ltd. Address: No. 17 Zhujiang East Road, Hi-tech Industrial Development Zone, Xuzhou, Jiangsu, China. Post Code: 221100 Tel: 0516–87981118 Service Tel: 0516-87981166 Quality Assurance Tel: 0516-87986966 Spare parts Tel: 0516–87989292 Version No.: Version in September, 2022.

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