XCMG XE210C Operating & Maintenance Manual Download

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XE210C Hydraulic Excavator

Operating & Maintenance Manual

XUZHOU XUGONG EXCAVATOR

MACHINERY CO., LTD.

Summary of Contents for XE210C

Page 1: ...XE210C Hydraulic Excavator Operating Maintenance Manual XUZHOU XUGONG EXCAVATOR MACHINERY CO LTD ...

Page 2: ...r component of the equipment which provides the operator with necessary information on safety operation and maintenance It can also help the operator use and maintain purchased Xugong equipment properly and safely While selling the machine this manual is sure to be attached Before operating maintaining and repairing these equipments make sure to read carefully and have a good command of what is in...

Page 3: ...laces except the machine for filing in order to search the machine after missing The numbers listed in this group are the unique identification numbers serial numbers for each machine and the hydraulic parts please fill these identification numbers in the corresponding places for quick putting forward when required Machine Type ___________ Number of the complete machine Engine Type __________ Manu...

Page 4: ...XE210C Hydraulic Excavator Operating and Maintenance Manual 4 Swing motor No ____________________ Hydraulic pump No ____________________ ...

Page 5: ...g procedure 66 Operating environment 66 The preparation and operation of starting 70 The preparation and operation of starting 73 Operation of running 76 Operation of cutoff 81 Getting on and off the machine 83 Operating procedure 84 Operation under special conditions 93 Filling procedure of fuel hydraulic oil lubricant and anti freeze fluid 93 Safe operating procedure against fire 97 Other operat...

Page 6: ...nd short term storage and protection 144 Long term storage 144 Use preparation after storage 144 Technical specifications Product specification 145 Operation range 146 Hydraulic system schematic 147 Appendix Crawler type and application 148 Bucket type and application 149 Hammer style knapper Optional 150 Weight of work Load 153 Backcover ...

Page 7: ... indication of machine protection and person safety IMPORTANT this signal vocabulary is used to show the case probably leading to the damage on machine Attention additional introduction on certain information Since it is impossible to list all the latent dangers in all working conditions in advance the safety must be ensured for you and the others and the damage are avoided of if the operation is ...

Page 8: ... have some change at any time which will influence the maintenance and repair of machine The pictures in the book is only used to describe the concerning part vividly varying from the practical machine probably Our company reserves the rights to modify all materials drawings and specifications in this manual at anytime without any notice ...

Page 9: ... the loss damage of sign or dim characters or pictures please repair or replace them timely While the part with safety signs is needed for a replacement the new one must be ensured to have corresponding signs When cleaning the safety signs it is proper to use cloth water and soup solution other than those tools and detergent which will spoil the signs or any solvent gasoline and other pungent chem...

Page 10: ...0C Hydraulic Excavator Operating and Maintenance Manual 10 Instruction of safety signs 1 Warning on bucket lever away from operation scope 2 Picture of lubrication and maintenance 3 Operational instruction ...

Page 11: ... Manual 11 4 Warning signs in the manual 5 Sign for being away from the high voltage electricity 6 Sign for locking the doors and windows Attention To prevent the injury due to the fall of front window be sure to lock two sides of windows with lock pins ...

Page 12: ...ety exit sign 9 Sign for rotating 10 Anti falling sign Attention Before starting the engine or operator sound the horn and check that there is no people around the machine If the engine fails to start within 15 seconds return the key to the position of OFF and wait for 2 minutes to start again ...

Page 13: ... safety operation Before operation identify the relation between controlling mode of control lever and practical movement of machine Before starting or operating engine press horn and confirm nobody around the machine While leaving the operational location carry out the following i Lower the front parts like bucket on ground ii Stop the engine and withdraw the key iii Shift the cutoff lever of gui...

Page 14: ...n operation after stoppage The spring of adjuster bears great pressure and the pressure in oil cylinder is very high so an accident may caused by such high pressure when adjusting or dismantling A wrong operation is very dangerous when adjusting or dismantling Before adjusting the tension of crawler read carefully the operating manual and follow strictly the regulated order Warning ...

Page 15: ...afety sign for locked machine 20 Hydraulic oil sign Attention Before dismantling the hydraulic oil tank cap please shut off the engine first When the oil temperature is high do not dismantle the oil tank cap Before dismantling the oil tank cap it is necessary to dismantle the breather to release the internal pressure ...

Page 16: ...XE210C Hydraulic Excavator Operating and Maintenance Manual 16 21 No stepping sign 22 Sign to prevent scolding the arm ...

Page 17: ...o not operate the machine before removing the faulty Working suit and the protection articles for the operators Do not wear loose clothes and jewelries which are dangerous to be caught on the operating levers or other protruding parts If the hair is too long and extends outside the safety hamlets it is dangerous to wind into the machine so it is necessary to tie the hair before operation Wear the ...

Page 18: ...e sure to remove the mud and the oil contamination in the soles before entering the driver cab If the mud or oil contamination is adhered on the soles it is sliding when operating the pedals and possible to result in serious accidents Do not put the parts or tools around the driver cab Do not stick the plastic sorbent pad to the window glass because its magnifier role may cause fire When driving o...

Page 19: ...teps marked by the triangular arrows in the drawing To ensure the safety face the machine keep hold at the three points two feet and one hand or two hands and one foot tightly and step on the handrails and steps including the track shoes tightly When climbing up and down the machine do not hold the operating lever and do not walk on the engine without non slip mat or cover plate When climbing up a...

Page 20: ...t cooling liquid When discharging the cooling liquid to avoid the hot water or steam spraying and causing burning before starting to operate ensure to reduce the temperature of the radiator cap to that can be touched by the hands When dismantling the radiator cap loosen the cap slowly to reduce the internal pressure of the radiator Hot oil When checking or discharging the oil to prevent burning ca...

Page 21: ...ips paper scraps dust or other flammable materials piled or stuck in the engine exhaust pipe silencer accumulator cell and the engine cover Prevent the fire caused by the electrical wires Prevent the fire caused by the short circuit of the electrical system Keep the connections for the electrical wires clean and fixed firmly every day Check the electrical wires for looseness or damage timely tight...

Page 22: ...ing in the mine or quarry with the risk of falling stones install the falling object protection device and the front protection device and stick the transparent glass paper on the front glass Close the front window during the above operations Additionally ensure other personnel are not within the falling object area and keep a certain distance from the dangerous area The above contents are for the...

Page 23: ... immediately Modification without approval Any modification without approval from Xugong Excavator Mechanical Co Ltd is possible to cause danger Therefore before modifying please contact the distributor of Excavator Mechanical Co Ltd For any injuries accidents or product faults caused by modification without approval from Xugong Excavator Mechanical Co Ltd the company will not bear any responsibil...

Page 24: ...h So a safe distance must be kept between the machine and the cables shown as the table below Before starting to operate please formulate the related safety operating measures together with the local electric power company In order to prepare for the possible accidents wear the rubber shoes and rubber gloves lay a layer of rubber mat on the chair and note that the exposed part of the body not to c...

Page 25: ...e driver cab cannot be opened normally due to some certain reasons crush the rear window glass and escape from the dangerous place soon Prevention for the asbestos dust danger If too much asbestos dust in the air is breathed it is possible to suffer the lung cancer When dismantling or treating the industrial wastes in the work place there is a risk to breathe the asbestos the following rules shall...

Page 26: ...up the angle of the operating light and check up if the whole controlling lever lies in the central position Adjust the wing mirror to be convenient for seeing the rear of the machine on the driving seat Check up the upper side the lower side or the peripheral region of the machine to ensure that there is no person or barrier The safety rules for starting the engine Honk the horn as a warning when...

Page 27: ...es for changing the direction of the machine Before moving the upper structure should be located at the proper position to make the chain wheel located to the rear of the cab If the chain wheel is in front of the cab the operating direction is reversed for example going forward is changed into going backward and the left into right Before moving make sure again that there is no person or barrier i...

Page 28: ...if the machine is equipped with the automatic speed reducing device If the automatic is turned on the rotate speed of the engine is increased and the moving will be suddenly accelerated Avoid moving on the barrier as far as possible If the machine has to move on the barrier make the working device close to the ground and move slowly When moving or carrying out operation keep a certain safety dista...

Page 29: ... achieved When the machine moves on the slope the bottom of the bucket is 20 to 30 cm 8 to 12 in from the ground In an emergency the working device can rapidly drop down to stop the machine When the machine moves upslope the driving cab is adjusted to the direction of the upslope When the machine moves on the slop downwards the hardness of the ground surface in front of the machine must be examine...

Page 30: ...ke a turn and transverse on the slop The machine should change the position of the machine at the flat area and then go up to the slope Because the slipping of the machine on the slop of a small degree is dangerous the machine should walk on the slop at low speed In the engine misses when the machine is moving on the slop the operating lever must be shifted to the middle position to start the engi...

Page 31: ... The operation of making the working device turn will make the machine roll over If the machine must be used on the slope a platform must be piled up to maintain the balance of the machine Forbidden Operation Do not dig the working surface under the suspended part The operation will cause the danger of store falling or collapse of the suspended part and the danger of store falling on the machine D...

Page 32: ...impact of the working device is forbidden to avoid the injure or damage caused by flying objects Generally the working device on the side is easy to incline than the working device in the front or at the back When crushers or other heavy working device is used the machine has the danger of losing balance and tipping over When the machine operates on the flat area and slopes Do not suddenly drop ro...

Page 33: ... firm and flat ground The machine should park on the place free of falling rock or collapse Descend completely the working device to the ground When leaving the machine the safty locking lever is adjusted to the locking positions and then the engine is shut down In order to prevent people without permission from moving the machine the door of the driving cab needs to be locked and the key needs to...

Page 34: ...e obeyed According to the weight the width and the length of the machine the trailers are selected and the transportation route is determined On such an occasion user can contact with Xugong excavator dealer to carry out the equipment disassembling work When the machine passes through bridges or buildings the structural strength must be examined to judge that the structural strength can bear the w...

Page 35: ... sulfuric acid enters into the eyes the eyes must be washed by a large amount of water and the injured must go to hospital During the battery operation the battery maybe generates sparks and the key switch must be turned to the close position The operations must be carried out according to the following steps Do not make tools or other metal objects contact between the battery terminals Do not let...

Page 36: ...tart switches of normal machine and fault machine should be turned to off Otherwise when the power is supplied the machine may move When the auxiliary cable is installed positive must be firstly connected When the auxiliary cable is removed ground or negative cable grounding side must be firstly disconnected When the auxiliary cable is removed auxiliary cable clamps should not touch each other and...

Page 37: ...en the wire ropes are used leather gloves will be worn The wire ropes are fixed on a machine frame In the traction process persons should not stand between traction machine and machines which are pulled The machines should not be pulled on slopes The wire ropes with broken wires A diameter reduction B or bending C should not be used In the traction process the wire ropes may be broken easily and t...

Page 38: ...gs are around the peripheral region and the collision should be avoided Do not start turn or stop the movement of the machine to avoid object oscillation Do not lift objects at the side or towards the machine When the objects are lifted the operators should not leave seats Using the machine to lift the objects is dangerous which is prohibited in principle Warning The appropriate accessory devices ...

Page 39: ...surfaces excavating tunnels crushing cinders and crushing or cutting rocks Press tightly the drill rods onto the surface at a right angle as shown in figure When striking the drill rods will be pressed tightly on the surface and the machine frame is lifted above about 5 cm Never carry vehicle too high If the surface is repeatedly struck but not broken in 1 minute the hammer should be moved and bre...

Page 40: ...oil cylinder of the bucket must be rectified to ensure the direction alignment Matters needing attention of the hydraulic hammer In order to avoid void striking the drill rod should be pressed when needed When the oil cylinder is operated the rip end should not be reached and the distance is kept about 5 cm Do not swivel the hydraulic hammer when working on rocks concrete and so on ...

Page 41: ...tenance Manual 41 When striking do not move the drill rod Do not strike horizontally or upward When punching on the ground do not twist the drill rod When lifting the machines do not make the bucket oil cylinder to elongate to the maximum position ...

Page 42: ...e slip or drop and cause injury Top window which is made by organic glass polycarbonate should be cleaned with water and not with any alkaline solvent If benzene toluene methanol or other basic solvent are used chemical reaction will be caused like that glass is dissolved or decomposed and polycarbonate will age When persons work with others one header should be commanded When the machines are fix...

Page 43: ...ons must keep in communication with each other Pull the safety lock control rod to the locked position When operate near fan fan belt or other rotating parts the operator must pay special attention to prevent being coiled Prohibit touching any operating lever If necessary the operator needs to send signals to other persons to warn them moving to a safe place Never insert tools or other objects int...

Page 44: ...to maintain or to repair the machine no one without training is allowed to enter the area Accessories Before removing or installing the accessories a header will be commanded The accessories which are removed from the machines should be put in a stable place where the accessories do not fall Measures should be taken to prevent unauthorized persons from entering storage area Working under the machi...

Page 45: ... hard metal parts such as pins bucket teeth blade or bearings fragments may scatter and cause harm and therefore goggles and gloves should be worn during operating When striking the pins or the bucket teeth the fragments may fly out the surrounding area must not have persons and then the injury is avoided If struck strongly the pins may fly out and cause damage to the surrounding persons Welding o...

Page 46: ...ion spring if the high tension spring is removed in a wrong way the spring will fly out which causes serious injury or death Relevant safety rules of high pressure oil The internal part of the hydraulic system always has pressure when checking or replacing pipes or hoses the pressure in the hydraulic oil pipe must be checked whether has been released or not If oil pipe still has the pressure serio...

Page 47: ... batteries it is necessary to comply with the laws and regulations Air Conditioner Maintenance If the air conditioner refrigerant gets into the eyes it may cause blindness if the refrigerant comes into contact with skin it can cause frostbite Compressed Air When cleaning with compressed air the particles flying out may cause injury on person or damage on machines When cleaning filter or radiator w...

Page 48: ...ic Excavator Operating and Maintenance Manual 48 Name of Parts General drawing Bucket lever Boom Bucket Cab Chassis Tool case Diesel tank Hydraulic oil tank Hydraulic system Engine Armrest Engine Case Counter weight ...

Page 49: ...ntrol lever 7 boosting switch above right operational lever 8 right control lever 9 monitor 10 key switch of engine 11 engine speed knob 12 switch for arm lamp 13 switch for working lamp 14 switch for wiper 15 switch for washer 16 button for emergency cutoff optional attachment 17 cigarette lighter 18 switch for radio 19 control button for air conditioner 20 safe locking lever Fig 1 27 layout of o...

Page 50: ...advancement and reversing of rightside crawler 7 Boosting switch on top of right operational lever After being pressed the max excavation force can be obtained in short time 8 Right control lever Control the rising and descending of moving arm as well as excavation and unload of bucket 9 Monitor Operation indication and warning for details see the latter introduction 10 Key switch of engine Start ...

Page 51: ...draulic Excavator Operating and Maintenance Manual 51 18 Switch for radio Control the radio 19 Control button for air conditioner Control the air conditioner 20 Safe locking lever Control hydraulic guidance oil ...

Page 52: ...rface List 1 3 List of illustrated signals Serial No Name Signal Function 1 Indication interface of screen Screen indication or main menu catalogue for details see the latter introduction 2 Alarm of hydraulic liquid temperature On for a high temperature 3 Air filter blockage alarm On for a blockage in the air filter ...

Page 53: ...d once after entering the main menu catalogue 11 Down button of decrease Being pressed cursor move downward once after entering the main menu catalogue 12 Button for choosing work mode When the machine is started mode S works Being pressed once circular options is made in order of S L B H S 13 Muffling identificating button Being pressed warning sound stops Confirm the cursor column after entering...

Page 54: ... Water thermometer 6 Automatic idle indicator 7 Time and information prompt 8 Instantaneous reinforcement indicator 9 Oil level display 10 Working mode indicator 11 System voltage indicator a When the key switch is turned to ON internal parameters initialization of the instrument is started and three seconds later it switches to the following interface Date time and information display area ...

Page 55: ...on can be chosen c Automatic idle speed button after the automatic idle speed button is pressed there will be at the lower left Three seconds later the controller pulls the pointer from the current throttle position to the idle speed position as follows after the automatic idle speed button is pressed again at the lower left disappears and the controller automatically pulls the pointer from the id...

Page 56: ... use only as operation demonstration which may be different from that of the machines a Button operation in the working interface When the menu key is pressed in the working interface the main menu interface is entered as follows Date time and information display area Date time and information display area Main menu Maintenance message Users setup System setup GPS installation Date time and inform...

Page 57: ...n as follows Choose in the use information menu and press the confirmation key host information is shown as follows Use information Host information Detail information Date time and information display area Power supply Normal Normal Date time and information display area Fuel quantity Coolant temperature Machine information Machine serial No Service type 1 Website 1 Machine type Date time and inf...

Page 58: ...g in the main menu and press the confirmation key the user setting menu is entered as follows Choose in the user setting menu and press the confirmation key the clock adjustment menu is entered as follows Choose in the user setting menu and press the confirmation key the clock adjustment menu is entered as follows User adjustment Clock adjustment Language setup Brightness control Date time and inf...

Page 59: ...he language setting menu is entered as follows Choose in the user setting menu and press the confirmation key system setting use menu is entered as follows Language setup Date time and information display area Brightness control Date time and information display area Password input Date time and information display area Chinese ...

Page 60: ... is pressed the fresh air motor of air conditioning unit is off while other motors are started and then the air inside the cab is transmitted to the inner of the unit through evaporator blower and then the air is transmitted into the cab by the evaporator blower to form ventilation 7 Cooling Switch When this button is pressed the cooling indicator is on and the air conditioning system is switched ...

Page 61: ... new stations available in the preset 4 Preset Button In FM mode press to select preset station and hold to store station In MP3 mode 1 PAUSE Pause play 2 SCN Scan normal play 3 RPT Repeat normal play 4 RDM Random normal play 6 DISP Display track number duration 5 Screen 6 VOL Volume Press VOL to turn up or down the volume 7 SEL Effect Time setting Press to display time and date on screen press wi...

Page 62: ...ble back and forth 2 Adjustable on weight 3 Adjustable back cushion 4 Adjustable armrests Warning The seat is designed for one person at a time Do not adjust the seat during digging actions Avoid moving objects Assembly and maintenance should be performed by qualified personnel ...

Page 63: ...ting or shutting down the engine OFF position The key can be plugged in and pulled out All of the switches of the electric system are closed The engine is stopped ON position When the engine is running keep the key of the starting switch in the ON position START position This is the starting position for the engine When starting the engine keep the key in this position After the engine is started ...

Page 64: ...p switch The button switch on the operating lever of the left working device is used to start the contact mode strength function As long as pressing the click switch the hydraulic system pressure can be increased which plays a role of increasing the power output of the excavator and the excavating force But the maximum time to use the maximum power is 8 seconds to prevent damaging the hydraulic sy...

Page 65: ...art of engine please refer to operating manual of diesel engine and this book When a refill is needed for the loss of hydraulic oil make sure to use the identified clean hydraulic oil Oil of different brand is forbidden Pay attention to the cleanliness of hydraulic oil at any time If it is aging bad or not clean enough be sure to replace it at once with the new oil Normally a replacement happens a...

Page 66: ...he machine will move in the reverse direction of moving forward and the heading direction of the reverse moving When using the operating lever check the track frame is towards the rear part or the front part If the chain wheel is in the rear part then the track frame is towards the front part When using the pedal for operating and moving special attention should be paid The operating levers 2 3 ar...

Page 67: ...dle position the movable arm and the scoop keep immovable Operation for the accumulator Warning The accumulator is filled with high pressure nitrogen wrong operation may cause explosion and result in serious injury or damage When operating the accumulator the following steps must be followed Control the pressure in the pipeline not to be discharged thoroughly and do not stand in the direction of t...

Page 68: ...ndles A heave outwards and pull upwards the front window can be opened 3 Put the window in the locking position after opening them Close the windows 1 Put the auxiliary devices on the ground and then shut down the engine 2 Hold two handles A heave outwards and pull downwards the front window can be closed 3 Install the windows firmly and use the key to lock them A ...

Page 69: ...ure the door of the driver cab is fixed on the lock C firmly Press the handle D in the driver cab of the operator release the door of the driver cab Fire extinguisher and emergency exit Fire extinguisher optional part The fire extinguisher is installed on the two bolts E in the right and rear side of the driver cab Use the fire extinguisher when fire alarming Emergency exit When emergency use the ...

Page 70: ...he case of bad health weariness due to the medicine or unease in the environment which will reduce your response towards the contingency and lead to the accident i While working with other driver or traffic keeper on the spot it is necessary to ensure the hand language and working environment are familiar to all the personnel j Please keep an eye on all the factors affecting safety at any time Tak...

Page 71: ... Fix the long hair avoid of wearing large clothes ornaments or other things which will hook on to control lever or other parts of the machine and cause the casualty c Don t wear clothes full of oil stains for it is flammable d Make sure to wear goggles head helmet safety shoes and gloves e While repairing the equipment don t use tool of weak strength because it is easy to be broken or slippery lea...

Page 72: ...PROTECTION SYSTEM is equipped in the cab f When the groundwork turns soft reinforcement on ground should be implemented before the work g While working on icy surface you should be alert specially for the going up of environment temperature will make the groundwork soft and slippery h When operating the machine beside some flammable things like dry grass pay more attention to the possibility of ca...

Page 73: ...ever the belt is safety it is better to be renewed once every 3 years Operating only when the operator is on the seat a Incorrect starting procedure of engine may cause a severe casualty b Start the engine only when the operator is on the seat c Make sure not to stand on crawler or ground to start the engine d Don t starts the engine through short circuit starting motor terminal e Before starting ...

Page 74: ...onitor while cleaning the monitor or switch it is advisable that cloth is used rather than sharp objects like screwdriver since they will spoil the screen of monitor Start the engine a Pull the safe locking lever to LOCK position b Turn the engine speed knob to low speed idle position c Press the horn to remind the surrounding people d Turn the key switch to START position Important prevent the da...

Page 75: ...in full stroke for 5 min with the interval of 30 seconds 3 When the hydraulic oil temperature reaches the required value warm up indicator will go out showing the completion of warming up the engine 4 After heating the hydraulic oil increase the engine speed and begin working Important operate the machine at lower load and speed until the engine and hydraulic system have a normal temperature Check...

Page 76: ...dyframe there is an arrow sign indicating the front direction of machine Prevent the machine from carrying the passengers a The passengers are easy to be wounded on the machine for example hit by foreign object or cast away by the machine b Only the driver rather than other passenger is allowed to be on the machine c Sometimes the passenger will block the view of driver leading to the operation of...

Page 77: ...icture the machine will be braked by treading brake d Turn right push forward the left treading control lever e Turn left push forward the right treading control lever f Rotate at the original position self rotation push forward one treading control lever while pull another one Switch of treading mode Caution since rolling over of the vehicle will result in the casualty so don t change the treadin...

Page 78: ...h the edge of bridge g When crossing the river the operator should measure the depth of river with bucket and cross the river slowly Don t cross the river when the water exceeds the top edge of supporting chain wheel h When treading on uneven ground engine speed should be decreased and the slow treading mode should be chosen to reduce the possibility of damage on the machine i Don t travel across ...

Page 79: ...e with towing rope equipped correctly refer to the following part of towing the machine in short distance Lift single side crawler with moving arm and bucket lever Caution the angle between the moving arm and bucket lever should be kept 90 110 and the arc part of bucket should be placed on ground Crawler should be lifted away from the ground by rotating the lower machine body by 90 and lowering do...

Page 80: ...r such condition you should check the position of machine frequently if necessary readjust it c Try to prevent water from submerging the rotary support small rotary gear and central connector d If the rotary support small rotary gear and central connector are submerged you should dismantle the drain plug to remove mud and water cleaning rotary area putting on the plug lubricating the small rotary ...

Page 81: ...the emergency cutoff button and stop the engine Important Normally being forbidden this mode is used to stop the engine only there is some big danger involving the person and equipment d Turn the key switch to OFF position and stop the engine e Withdraw the key from key switch f Pull the safe locking lever to LOCK position Prevent the machine from causing the injury If you try to climb on or block...

Page 82: ...d Without load run the engine 5 min at low idling speed to cool the engine e Stop the engine and withdraw the key from switch f Pull the safe locking lever to LOCK position g Shut the windows and cab door h Lock all the maintenance hatches and compartments Fig 1 62 ...

Page 83: ...e facing the machine a Before getting on or off the machine you should clean and dry the oil butter mud or sand on railing board or crawler immediately if they exist then keep these parts clean If some part is damaged you should repair it and tighten the loose screw b When getting on or off the machine don t grip the control lever c Don t jump on or off the machine especially those moving one for ...

Page 84: ...reading motor at the rear to maximize the machine stability and lifting ability On the machine there is a scutcheon indicating the control mode of control lever and treading pedal After being released the control lever will return to the middle position automatically followed by the stop of the machine List 1 8 List of illustrated signs Serial number Function 1 Bucket lever protrudes 2 Bucket leve...

Page 85: ... LOCK position and stop the engine Then you can carry out a repair or contact with appointed dealer Engine s speed control According to this picture increase or decrease engine speed through engine speed knob on right control box a Increase engine speed by turning the engine speed knob clockwisely on the contrary decrease engine speed by turning the engine speed knob counter clockwisely b Before s...

Page 86: ...a Mode S standard excavating mode It can save fuel consumption best and should be adopted in normal work When it works mode S indicator shines b Mode L weak excavating mode and mode of leveling up ground In this mode engine speed may be reduced but excavation force remains the same with mode S although the output is little less than that of mode S but the fuel consumption and noise have been reduc...

Page 87: ...digging in one angle bucket teeth should be avoided to collide with the crawler 4 when digging a deep ditch you should prevent the moving arm or hose of bucket s hydraulic cylinder from knocking on the ground Operation to level up the ground Important don t push the soil with bucket while treading When you need to level up the earth put the bucket Lever a litter further from the vertical position ...

Page 88: ...y to extend the bucket lever fully and abandon the bucket don t penetrate the ground with bucket teeth to dig out the stone which will lead to serious damage on machine f When the machine is driven out of the water the incline angle of machine should is less than 15 Don t submerge the machine into water whose surface is over permitted depth normal water depth should not exceed the upper edge of su...

Page 89: ...d to work on soft land the ground should be fully hardened in advance a When working on the machine you must wear tight clothes and other safety products like safety helmet which are suitable for work b Let other person go out of the moving range of the operation and the machine clean all the obstruction During the operation you should pay attention to the surrounding all the time and don t let th...

Page 90: ...on not to knock down the people around Before moving turning or operating the machine identify the position of those people Always keep the treading annunciator and horn in working state if there are When the machine begins to move they can warn the surrounding people When the machine is treading rotating or being operated the signaler should be employed and coordinate the hand signs with others b...

Page 91: ...the lower machine body vertical to the ditch side to place the machine When the groundwork begins to collapse and the machine can t be withdrawn don t get nervous Instead you should fix the machine by lowering down the working equipments Avoid turning over the vehicle Don t try to jump out of tipping machine or you will be suffered from serious or fatal crush since the inclining speed of machine i...

Page 92: ...sion or fire causing a severe casualty a Before the excavation check the position of electric cables gas pipes and water pipes b Keep a legal min distance with electric cables gas pipes and water pipes c If optical fiber cable is cut off due to the accident Don t look at the end of cable which otherwise may lead to serious wound in your eyes d Please contact directly with local related department ...

Page 93: ...rounding people should be far away from working area Drive the machine prudently Important in cold weather you must park your machine on hard ground to avoid the crawler frozen with ground Remove the oddments on crawlers and chassis bodyframe If the crawler has been frozen with ground lift the crawler with moving arm and bucket lever and move the machine with care to avoid destroying the driving w...

Page 94: ... everyday Be careful not to splash the fuel on machine or ground While refilling regulated capacity should not be exceeded 8 After the refill replace the oil inlet cap on fuel tank to avoid losing or damage Hydraulic system a Recommended hydraulic brand and name List 1 12 brand and name list of hydraulic oil Supplier 20 15 10 40 Xugong Special hydraulic oil used for Xugong excavator 32 Special hyd...

Page 95: ...LX2 6 2L XE210C 6 8LX2 6 2L Cooling system a Recommended cooling fluid List 1 17 Capacity list Supplier 20 30 10 40 Xugong Special coolant used for Xugong excavator 30 Special coolant used for Xugong excavator 45 Shell OTA 30 OTA 45 b Capacity of cooling liquid List 1 18 Capacity list Parameter Machine type Anti freeze fluid Antirust fluid XE210C 23 L 0 46 L XE210C3Ⅶ 23 L 0 46 L XE210C2 23 L 0 46 ...

Page 96: ...16 1 l1 30 6 9 16 1 15 35 8 1 14 9 20 40 9 2 13 8 25 45 10 4 12 6 30 50 11 5 11 5 Attention 1 Anti freeze fluid is poisonous If taken in it will result in a severe casualty accident Once drinking it by mistake the patient should be channeled off to vomit and obtain an immediate emergent treatment 2 While storing anti freeze fluid make sure to store it in a container with sealing cap and remarkable...

Page 97: ...t may lead to a fire disaster 1 Check the loss or loose of pipe clamps the distortion of hoses mutual friction between pipes and hoses the damage on fuel cooler and the loose of flange screw of fuel cooler to avoid the leakage 2 Tighten repair or change any pipe clamp pipe hose fuel cooler and flange screw of fuel cooler which have been lost flexible or damaged 3 Don t bend or knock high pressure ...

Page 98: ...rating the machine Withdraw when catching a fire a If catching a fire leave from the machine according to the following method 1 If time is permitted turn the key switch to OFF and stop the engine 2 If time is permitted use fire extinguisher 3 Leave from the machine b At the emergency if the cab door and front window can t be opened smash front or rear window glass with emergency hammer and then w...

Page 99: ...a Prevent the happening of latent poisonous gas and dust b Carry out removing paint work outdoors or in drafty place dispose the paint and solvent correctly c Remove the paint before the welding or heating 1 If the sand paper or grinding wheel is to get rid of paint pay attention not to suck in dust by wearing qualified respirator 2 If using the solvent or removing paint agent you should get rid o...

Page 100: ...ing to lift or raise originally rated weight When the exterior area of the cargo is relatively big watch out any kinds of gust a Bind the sling or chain tightly on the load supposed to be lifted When binding the sling or chain make sure to wear gloves b Turn the bucket and withdraw the bucket lever connect the sling or chain with bucket ring Before starting hand signs must be coordinated with the ...

Page 101: ...per is heavier than bucket so the stability of machine may be reduced 2 When using hammer style knapper the machine is easier to incline and the flying or bouncing object may bounce into cab or other part of machine Please abide by the following and other necessary notices to avoid the happening of accident and damage on machine a Avoid using hammer style knapper to bump into other object Since th...

Page 102: ...r lever fully d If there is abnormal jumpiness in hydraulic hose of knapper please stop the operation at once the pressure change inside the battery of knapper or damaged battery will lead to abnormal hose jumpiness and even cause the damage on knapper and or machine e Don t operate the knapper in water which may make it rusted even damage the seal and components in hydraulic system f Don t use kn...

Page 103: ... which may lead to the excessive vibration of hydraulic cylinder of bucket lever and even the oil leakage j Press down the knapper and place the hammer head axial center vertically on object and push it in k Don t operate the knapper continuously for over 1 min which may cause the excessive abrasion of hammer s head If the object can t be shattered in 1 min place the hammer s head to other positio...

Page 104: ... pressing down the knapper to prop up the lower machine body Though it is permitted to prop up the front edge of lower body within 150mm but normally this method is not necessary You mustn t prop up the front edge of lower body for over 150mm only relying on pressing down the knapper Fig 1 115 Pressing down Propping up 100mm 150 mm ...

Page 105: ...hich is included in the documents along with the excavator While carrying out maintenance or repair for this machine the related record should be made and saved For the excavator it is important to maintain and ensure its normal function So the machine should be kept clean so that any failure such as leakage looseness of screw or connection will be spotted Pay attention to environmental protection...

Page 106: ...s 0 3 20 40 Swing bearing 2 Swing reducer 1 Rotation equipment oil bath 12 Tension equipment 2 Engine oil CF 15W 40 oil Diesel engine 25 15 40 CF 10W 30 oil Diesel engine 25 30 30 Lubricant GL 4 SAE140 gear oil Swing reducer 6 2 20 40 GL 4 SAE90 gear oil Travel reducer 2 6 8 Attention If the excavator works in specially high or cold condition special lubricant should be used You are suggested to c...

Page 107: ... of connection rod 9 Others 11 2 Swing reducer 1 3 Swing bearing 2 Rotation device oil bath 1 4 Tension device 2 Connection points of working equipments a Bucket bucket lever and pin of connection rod b Pin at the root of moving arm c Connection pin between moving arm and bucket lever hydraulic cylinder piston and bottom pins of bucket lever Fig 2 2 Fig 2 4 Fig 2 3 ...

Page 108: ...f moving arm hydraulic cylinder e Pin of moving arm hydraulic cylinder and bottom pin of bucket lever hydraulic cylinder Rotary support area 2 lubrication points for rotary support Rotation device oil bath Engine Fig 2 5 Fig 2 6 Fig 2 7 Fig 2 8 Fig 2 9 Oil gauge Oil inlet cap ...

Page 109: ...Operating and Maintenance Manual 109 Travel reducer Rotary speed reducer Fig 2 11 Oil filling cover Oil gauge Specified range Fig 2 10 2 lubrication points for treading gearbox Oil inlet plug Oil level inspection plug Drain plug ...

Page 110: ... Periods Item S N Maintenance point Qty Interval hour 8 50 100 250 500 1000 1500 2000 Grease 1 Work device Bucket and link pin 9 Others 1 2 Rotary bearing 2 3 Rotation reducer 1 4 Rotation device oil bath 1 Engine oil 1 Check of engine oil level 1 2 Replacement of engine oil 3 Replacement of engine oil filter 1 Gear oil 1 Traction reducer Check of oil level 2 Replacement 2 2 Rotary reducer Check o...

Page 111: ...the requirements of this manual c Adopt the fire prevention measures during the lubrication d Prevent hot oil and harmful substances from harming the operators e Avoid mixing the lubricating oils of different brands f Clean the lubricated parts and vent hole etc before filling keep the tightness of seal ring after filling g Clean or replace the filter at regular intervals make a mark after drainin...

Page 112: ...e cab d If the machine must be lifted during the maintenance maintain the angle between the movable arm and bucket arm within 90 to 110 support any lifted part of machine firmly and don t work under the machine lifted by the movable arm e Check the parts at regular intervals and repair or replace them as per the demands f Keep all the parts in good working state and install them correctly g Replac...

Page 113: ... grease in track tension device is under a high pressure In case of not obeying the following matters severe injury blindness or death may be caused 1 Don t remove the grease coupler or valve body 2 The body and face must be far away from valve body because it may fly out b The traction reducer has a certain pressure 1 Due to the possible flyout of part the body and face must be away from the air ...

Page 114: ... penetrate the skin or rip into the eyes it will cause severe injury blindness or death a Release the pressure before removing the hydraulic or other pipes to avoid this risk b Tighten all the connections before pressurizing them c Check the leaks with a paper board and protect your hands and body to avoid the contacts with high pressure fluid Wear the face mask or safety goggles to protect your e...

Page 115: ...r treatment of discards will harm the environment and ecology and the potential harmful discards include hydraulic oil fuel engine oil coolant filter and battery etc a In case of discharging the fluid use the leak proof container Don t use the food or drink vessel because it may cause the wrong drinking b Don t pour the waste liquid on the ground into sewerage or any water source c The air conditi...

Page 116: ...ipe pay special attention to the seal surfaces to ensure no dirt exists on them and avoid the damages to them Please remember the following points for attention 1 Clean the inner face of hose pipe or oil tank with cleaning fluid and dry them thoroughly before connecting them 2 Use non destructive or defective O rings and don t damage them during the assembling 3 During the connection of hose don t...

Page 117: ...ause the oil may be hot and cause the severe scald injury e After cooling the oil loosen the drain plug in the bottom of hydraulic oil tank and drain the water and deposits Don t remove the plug fully and you d better loosen it enough to drain the water and deposits f After draining the water and deposits tighten the drain plug again Replacement of hydraulic oil or cleaning of oil suction filter N...

Page 118: ...rt the engine and run it at low speed and empty load Hang No Operation nameplate to the safety locking rod and ensure the safety locking rod in LOCK lock position u Loosen the air bleed plug slowly to discharge the accumulated air When the flow of air stops and the oil is discharged out of the plug hole tighten the plug v Run the engine at low speed and empty load and actuate the control lever slo...

Page 119: ...fter draining the water tighten the air bleed plug and drain plug Turn the fuel ball valve to its original position e Start the engine and check whether there is leakage or not of the plug and air bleed plug Note ensure that the air is bleed out of the hydraulic system after drawing the water Bleed the water out of hydraulic system Important the air in fuel system may cause the starting difficulty...

Page 120: ...same as the above methods Cleaning of outer element of air filter Clean the outer element of air filter every 250 hours or when the warning lamp of air filter element brightens clean the outer element of air filter Replacement of inner and outer elements of air filter After six time cleanings or one year replace inner and outer elements of air filter a Park the machine on flat ground b Stop the en...

Page 121: ...el of coolant every day The level of coolant must be between the marks FULL and LOW on coolant tank The water tank shall be located behind the radiator shed door If the coolant level is below LOW mark add the coolant into the water tank If the water tank is empty add the coolant into the water tank after adding the coolant into the radiator Cleaning of radiator inner side Note don t loosen the rad...

Page 122: ...ure to consult with the assigned dealer Don t attempt to disassemble or modify any electric or electronic component If it s necessary to replace or modify these components please contact with the assigned dealer Battery Note the gas of battery can cause the explosion prevent the spark and flame from approaching the battery a This machine adopts the maintenance free battery so it s unnecessary to a...

Page 123: ...rent F4 Horn 10A F5 Headlamp arm lamp switch 10A F12 Radio 10A F9 Wiper and washer 10A F14 Controller 5A F13 Excitation Preheating Protection 10A F16 Safety Handle 5A F15 Monitor 10A F19 Air conditioner Controller 10A F18 Traction and booster 10A F23 Rotary Brake 5A F20 Traction and booster ring 10A F17 Pump Controller 5A Spare Fuse 10A Spare Fuse 10A Spare Fuse 20A F1 Shutdown of engine 10A F3 Ke...

Page 124: ...ucket is disturbed Don t use any disturbed machine If any disturbance deal with it in time Adjustment of bucket joint gap There is a regulation system of bucket connection gap capable of eliminating the connection slashing When the connection slashing is increased remove or attach the tab as described below a Park the machine on flat ground fall the bucket to ground with its plane down to avoid ro...

Page 125: ...ways good and replace it if necessary to ensure its good performance Check the safety belt lock latch and connector thoroughly before the operation If the safety belt or its part is damaged or worn replace it before the operation We suggest that the safety belt shall be replaced once every three years regardless of its conditions Check of crawler sag Check the crawler sag every day As shown in Fig...

Page 126: ...crawler rotate the valve body slowly anticlockwise with a deep socket wrench and the grease will drain out of its outlet 2 Rotate the valve body by 1 to 1 5 circles enough to loosen the crawler 3 If the grease can t be smoothly drained lift the crawler away from the ground and rotate the crawler slowly 4 After reaching the proper crawler sag tighten the valve body clockwise c Tighten the crawler N...

Page 127: ...eck it once every 250 hours If loose tighten the bolt up to the torque shown in Tightening of Bolt In case of replacement replace it with the same or higher class bolt and nut For the bolt and nut outside Tightening of Bolt refer to Tightening Torques Important check or tighten the bolt and nut with a torque wrench a Tightening Torques of Bolt Table 2 4 Tightening of Bolt S N Item Bolt diameter mm...

Page 128: ...ening torque is expressed in Nm For example in case of tightening the bolt or nut with a 1m long wrench turn the tail end of wrench by a force of 120N and create the following torques 1m X120 N 120 Nm In case of creating the same torque with a 0 25m wrench 0 25m 120Nm The desired force shall be 120 0 25 480 N Maintenance of hammer crusher The operation of hydraulic hammer crusher will accelerate t...

Page 129: ...liances clean them at regular intervals especially the terminals of AC generator and starting motor Frosty weather Fuel adopt the appropriate low temperature high quality fuel Lubricant adopt the high quality low viscosity hydraulic oil and engine oil Engine coolant be sure to adopt the anti freezing agent Battery charge the battery up at short regular intervals In case of not charging the battery...

Page 130: ... of coolant level 1 2 Check or adjustment of fan belt tension 1 3 Replacement of coolant anti freeze fluid Twice per year 4 Cleaning of radiator and oil cooler core or intercooler Inner 1 If required Outer 1 When replacing the cooling water 5 Cleaning of front mesh enclosure of oil cooler 1 If required 6 Cleaning of air conditioner condenser 1 If required Others 1 Check the bucket teeth for wears ...

Page 131: ...the machine in shorter interval in case of running the machine under the bad conditions 3 Make a periodic check and adjustment of lubrication or maintenance as per the readings of periodic maintenance meter on the inner side of tool box cover 4 When the hours of hour meter reach the replacement time of recommended lubricant and filter element or during the periodic check every day or every month r...

Page 132: ...r Blockage of fuel tank cover vent hole Clean or attach a new cover Dirt or trouble of fuel nozzle Contact with the assigned dealer of XEM excavator Adjustment required for injection pump linkage Contact with the assigned dealer of XEM excavator Wrong fuel Adopt the correct fuel Wrong engine oil Adopt the correct engine oil Trouble of turbo charger Contact with the assigned dealer of XEM excavator...

Page 133: ...Empty the oil tank and adopt the correct fuel Blockage or dirt of air suction or discharge system Clean the air suction or discharge system Off time of injection pump Contact with the assigned dealer of XEM excavator Dirty fuel nozzle or its incorrect operation Contact with the assigned dealer of XEM excavator Trouble of engine body Contact with the assigned dealer of XEM excavator Failure of engi...

Page 134: ...r Large noise or vibration of turbo charger Bearing is not lubricated Insufficient oil pressure check the blocked oil pipe of turbo charger Worn bearing Contact with your assigned dealer Air leaks of engine suction or drain pipe Check or repair Improper gap between the turbine and turbine case Contact with the assigned dealer of XEM excavator Breakage of turbine blade Remove the exhaust elbow and ...

Page 135: ...trip starting motor or AC generator corrosion of electric connection Check clean or tighten the electric connection Low voltage of battery Charge or replace the battery AC generator trouble Contact with the assigned dealer of XEM excavator Trouble of monitor Contact with the assigned dealer of XEM excavator Fracas of AC generator Worn driving belt Replace the belt Worn belt pulley Replace the belt...

Page 136: ...ontact with the assigned dealer of XEM excavator Three times Pause of motor action Contact with the assigned dealer of XEM excavator Four times Motor poor in the range of action Contact with the assigned dealer of XEM excavator Five times Broken circuit or short circuit of built in potentiometer of motor Contact with the assigned dealer of XEM excavator Six times Set broken circuit or short circui...

Page 137: ...ealer of XEM excavator Reduction of set pressure of main safety valve of control valve Contact with the assigned dealer of XEM excavator Low level of hydraulic oil Fill up the hydraulic oil Damage of oil suction pipeline or hose Contact with the assigned dealer of XEM excavator Blockage of suction filter and air sucked in oil suction Clean the filter system The hydraulic cylinder acts but it can t...

Page 138: ...the assigned dealer of XEM excavator Trouble of pilot valve Contact with the assigned dealer of XEM excavator Damage of pilot pipeline Repair or replace Unstable travel Adjustment required for crawler Adjust the crawler sag Damage of crawler guide wheel supporting wheel or carrying wheel Contact with the assigned dealer of XEM excavator Bend of chassis frame Contact with the assigned dealer of XEM...

Page 139: ...tions breakage or damages and replace them according to the demands Be sure to check all the following hoses at regular intervals and replace or tighten any poor part as per the demands Table 2 12 Periodic Replacement of Key Parts Part replaced at regular intervals Replacement interval Engine Fuel hose from fuel tank to filter Every two years Fuel hose from fuel tank to injection pump Every two ye...

Page 140: ...slow speed mode with a travel mode toggle to avoid high speed e The steering on the slope is very dangerous and avoids the steering when going up or down the slope If the steering is required transport the machine back to the ground or trailer platform and drive it on the slope after rectifying the direction f In case of driving up or down the slope don t use any other control lever other than the...

Page 141: ...idth length and strength to make the inclination angle of slope or the gradient of platform below 15 Loading a The direction of machine is down with front end working device move the working device forward with it placed on front body without front end working device travel in reverse direction as shown in above figure b The centerline of machine shall be on the centerline of trailer c Drive the m...

Page 142: ...e the bucket on the ground before the machine starts to incline forward c During the forward movement of machine lift the movable arm and stretch the bucket rod until the machine drives fully under the slope or platform Lifting method of machine Note 1 Lifting steel rope and other lifting tools may be broken which results in the serious injury of person Don t use any damaged or aged steel rope or ...

Page 143: ...and remove the key from key switch c Adopt the steel rope and supporting rod with enough length make them not contact the machine during the lifting Wrap some protective material around the steel rope or supporting rod as per the demands to avoid the damages to machine d Drive the crane in proper lifting position e As shown in Fig 3 7 make the steel rope pass under the chassis frame on both sides ...

Page 144: ...toring it outdoor adopt the water shield Long term storage Storage place a Commonly store in the ventilated and dry warehouse b If the device is stored in open air park it on the concrete ground easy to drain the water cover and fix the canvas or hood and store it at the place that can t be invaded by natural disaster and without corrosive or harmful substance or gas Storage a Use the hydraulic fu...

Page 145: ...0 9550 9500 9550 B Total width transport mm 2800 3000 2800 3000 2800 3000 2800 3000 C Cab height transport mm 2950 3100 2950 3100 2950 3100 2950 3100 D Minimum ground clearance mm 460 500 460 500 460 500 460 500 E Crawler track mm 2180 2400 2180 2400 2180 2400 2180 2400 F Get on ground clearance mm 1030 1085 1030 1085 1030 1085 1030 1085 G Height of engine cover mm 2200 2300 2200 2300 2200 2300 22...

Page 146: ...2 XE210C2Ⅶ 2 53m Bucket Lever 2 91m Bucket Lever H1 maximum digging radius mm 9680 9925 H2 maximum digging depth mm 6280 6655 H3 maximum digging height mm 9745 9640 H4 maximum unloading height mm 6860 6800 H5 transport height mm 2985 2985 H6 total transport length mm 9520 9520 H7 minimum rotary radius mm 3530 3530 ...

Page 147: ...XE210C Hydraulic Excavator Operating and Maintenance Manual 147 Hydraulic System Schematic ...

Page 148: ... cobble down tree and rough ground using the low speed to travel B Common earth and soft ground Only can use the high speed and medium speed on the level ground if passing the obstacles can not be avoided slow down the machine and use the half speed of the low speed to travel can not be used on the rough ground with cobble and down tree C Extra soft ground marshland ground Only use this type when ...

Page 149: ...f the symbols on the above table Light load digging Heavy load digging Can not be used Application type Heavy load digging digging or loading mountain gravel explosion stone hard clay soft stone and so on Common digging digging or loading sand gravel clay and common earth Light load digging digging or loading dry and incompact earth sand mud and so on Their volume density is required below 1600kg ...

Page 150: ...op of scoop lever and the plug should be put on the hose end of the knapper to prevent the dirts into the system While standby lid and plug must be contained in toolkit for the convenience of usage 3 after the connection check the sealing of connection to see if there is any oil leakage or flexibility of pipe connectors Weight of hammer style knapper a When the components other than the standard b...

Page 151: ...wing list shows some hammer style knapper which can be fixed on Xugong excavator Before the adoption please inquire the dealer of hammer style knapper in earnest When using the parts other than the standard bucket the load on machine body normally is bigger than that with the bucket in use If the operation is unsuited it will damage the parts even the machine body So please read all this book to p...

Page 152: ...er Producer Korea Shuishan Korea Gongbing Japan Dongkong Japan Guhe Germany KRUPP Type of Knapper SB81 GB220E TNB 150LU F20 HM960CS Weight kg 1740 1620 1678 1430 1500 Oil Capacity L min 120 150 125 150 160 200 125 150 130 170 Operational Pressure MPa 15 7 17 7 15 7 17 7 12 7 16 7 15 7 17 7 11 8 13 7 Designed Pressure of Valve MPa 17 7 17 7 17 7 17 7 16 7 ...

Page 153: ...e coal 900 Dry ball clay 1000 Wet clay of raw subgrade 1750 Dry particles of common concrete 1500 Dolomite fragments 1500 Dry or soft soil 1200 Firm and dry soil 1500 Wet muddy soil 1750 Burned lime paste hot powder 960 3 crushed lime paste 1500 Overstacked dry gravel fragments 1800 Overstacked wet gravel fragments 1900 At least 2 class limestone 1300 Crushed limestone 1500 Good limestone 1600 Roc...

Page 154: ...AVATOR MACHINERY CO LTD ADD No 28 Donghuan Industrial Area Xuzhou Economic Development Zone Jiangsu China Postcode 221004 Sale tel 0516 87870116 Fax 0516 87870118 Service tel 0516 87870111 Fax 0516 87870117 Spare parts tel 0516 87870133 http www xcmg com First version in 2011 ...

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XCMG XE210C, Operating & Maintenance Manual

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