XCMG XE210C Hydraulic Excavator. Operating & Maintenance Manual (2011) - page 1
Preface
Welcome you to use our XE210C hydraulic excavators.
Before operating, maintaining and repairing these equipments, please read carefully and master this manual,
and learn how to correctly operate, maintain and repair your machines while paying more attention to related
safety warning. Otherwise, there will be the injury on person and damage on machines.
A standard machine is applicable in the working temperature between - 15℃~ 40℃, the altitude is below
2,000 meters.
If you need to use in other conditions except the above one, or modify the machine, please contact with our
company for confirmation.
This manual is the major 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 this book, especially those safety-concerned regulations, and try to operate according
to the requirement.
The following content is included in this book:
—— operation;
—— lubrication, maintenance and repair;
—— transportation, storage and protection;
—— specification of technology
We may change something any time about all the materials, the
charts and tables and the specifications in this manual before publishing
without informing you.
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Machine Number:
Please record all numbers correctly for future maintenance. In addition, your distributors also need this
information. If this manual is on the machine, please put the part of the machine numbers in the safe places
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:__________
Manufacturing No.:__________
Bucket
No.: ____________
Travel motor
No.:____________________
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Swing motor
No.:____________________
Hydraulic pump
No.:____________________
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Content
Preface
Machine Number
Safety
Instruction of safety and warning signs
7
Safety sign and other signs
9
Location of safety signs
9
Instruction of safety signs
10
Safety rules
17
Safety equipment
18
Safe operation of machine
26
Start the engine
26
Operation
27
Transportation
34
Battery
35
Traction
37
Lifting objects by the bucket
38
Optional components
39
Safety maintenance instructions
42
Name of parts
General drawing
48
Cab
49
Monitor
52
Displaying interface of main screen
54
Control panel of air conditioner
60
Radio
61
Seat
…62
Switches
…63
Operation general principle
…65
Operating 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 operating procedures
100
Lubrication, maintenance and repair
General principle
105
Lubrication of equipment
106
The Kinds of lubricant
106
Lubrication points
106
Lubrication period
110
Safety points for attention and precautionary measures
…111
Maintenance and repair
112
Safety rules
112
Maintenance
116
List of maintenance periods
130
Trouble shooting
131
Periodic replacement of parts
139
Transport, storage and protection
Transport
140
Caution of transport
140
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Road transport
141
Removal of trailer
141
Storage and protection
144
Daily and 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
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Safety
Instruction of safety and warning signs
This is the sign of “ATTENTION ON SAFETY”. When you notice
this warning ， you should read carefully the following
information and abide by it and inform other operators.
Understand the warning remarks on safety warning scutcheon.
On safety sign of this manual and machine, there are
“DANGER”, “WARNING” and “CAUTION”
separately used along with “ATTENTION ON SAFETY”, indicating 3 levels of danger due to dangerous or
unsafe operation. Whenever seeing the triangle sign of safety warning and whatever warning remark is
followed, you must read carefully the warning content.
Danger—— indicating the case with direct danger. Without avoidance, it will lead to the
death or serious injury. It can also warn the explosion or damage on
equipment due to improper operation or treatment.
Warning —— indicating the latent danger. Without avoidance, it will lead to the bad
injury or death. It can also warn and prevent the highly unsafe operation
from happening.
Caution—— indicating the latent danger. Without avoidance, it will lead to the slight or
medium-level injury. It can also be used to remind the prevention from
ordinary operating factors when working.
Sometimes some safety signs are also used on this machine; they are not followed with above signal
vocabulary.
In this book, “CAUTION” is used for the attention to safety indication.
Important——to avoid of the confusion between the 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
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 not recommended. Without
approval from our company, any modification made by operator will lead to the danger. So before correcting,
you should inquire our company or empowered franchiser. Otherwise, our company will not be responsible
for any bad result from unapproved renovation.
Our company will not be responsible for any equipment damage or unsafe running due to the following
reasons:
z
Carrying out modification on machine without any approval
z
The operation does not fit the normal mode
z
The equipment failure due to non-original product or unauthorized repair by company or individual
z
Beyond the usage range for the equipment
Our company will not compensate for any equipment damage or unsafe running due to the following reasons:
z
Improper operation
z
Insufficient maintenance
z
Using the fuel or lubricant beyond the recommendation
For the continuous improvement of product design and the difference of the customer’s demand on
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assignment, it is possible that the content, specification and icons etc. will 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.
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Safety sign and other signs
On many part of this machine, there are safety sign and other signs, so the operator should fully understand
the content and location of all signs and abide by the following requirements:
z
Maintain the safety signs clear, undamaged and existing; if there is the loss, damage of sign or dim
characters or pictures, please repair or replace them timely.
z
While the part with safety signs is needed for a replacement, the new one must be ensured to have
corresponding signs.
z
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 chemical
agent to avoid of the shedding of those signs.
z
The assignment of safety signs and other signs is shown as follows:
Location of safety signs
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Instruction of safety signs
（1） Warning on bucket lever away from operation scope
(2)
Picture of lubrication
and maintenance
(3)
Operational instruction
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(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.
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(7)
Machine starting 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.
(8)
Safety exit sign
(9)
Sign for rotating
(10)
Anti-falling sign
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(11)
Sign for being away from the
action radius
(12)
Battery sign
Dangerous
z being flammable, steam of battery fluid should
be far away from spark because the battery will
explode or lead to fire disaster if collided with.
Metal product like tool and flammable object
should not be placed together with battery.
z Being poisonous, vitriol in battery will erode
skin or clothes, even lead to blindness if
entering the eyes. The following treatment
should be carried out if vitriol splashes on body:
1. rinse skin with water
2. middle size acidity with soda or limewater
3. clean
the
eyes with water for
10-15min.,seek out immediate treatment
(13)
Sign to prevent the movable arm injury
Warning
● Avoid being bruised by boom.
● Do not extrude any part of your body out of the
window-sill or window frame. Otherwise, you may be
hurt by any accident bump or misoperation on boom
control lever.
● Prohibit taking down the window-sill. If the
window-sill is lost or damaged, please repair it.
(14)
Sign for the driver’ notes
Caution
z
Before operation, read operation manual to ensure safety
operation.
z
Before operation, identify the relation between controlling
mode of control lever and practical movement of machine.
z
Before starting or operating engine, press horn and confirm
nobody around the machine.
z
While leaving the operational location, carry out the following:
Lower the front parts like bucket on ground
Stop the engine and withdraw the key
Shift the cutoff lever of guidance control to “LOCK”
z
It is forbidden to stand under the machine lifted by front part
z
When reverse bucket placed in opposite position works as
obverse one, it may bump onto the cab, which should be
avoided.
z
If the machine is operated within bad visual field, signaler must
be present and his order must be followed.
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(15)
Warning on adjusting the crawler tension
Warning
z
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.
z
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.
(16)
Schematic drawing to start and close the safety handle.
(17)
Sign to abandon operation after stoppage
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(18)
Schematic drawing to lift the complete machine
(19)
Safety 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.
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(21)
No stepping sign
(22)
Sign to prevent scolding the arm
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Safety rules
z
Only the personnel trained and guided can operate and maintain the machine.
z
When operating and maintaining the machine, obey to all of the safety rules, notes and instructions.
z
No operating or repairing the machine after drinking when being sick to avoid injury to yourself or
others.
z
While working with other operators or site command personnel, be sure to use the gestures that all of
them can understand.
If abnormalities found
If any abnormality (noise, vibration, smell, abnormal display for the instruments, smoke, oil leakage or any
abnormal display on the alarming devices and the monitors) is found during operation or maintenance, report
to the responsible personnel and take proper measures. Do not operate the machine before removing the
faulty.
Working suit and the protection articles for the operators
z
Do not wear loose clothes and jewelries which are
dangerous to be caught on the operating levers or
other protruding parts.
z
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.
z
Wear the safety hamlet and safety shoes always.
When operating and maintaining the machine, wear
the safety glasses if necessary.
z
Check the functions of all of the protection devices
for normality.
Fire extinguisher and first-aid kit
In order to possible fire or injuries, attention must be paid to the following items:
z
Prepare the fire extinguisher and read the use
manual to ensure to know how to use when
emergences.
z
Check and maintain regularly to ensure the fire
extinguisher in a good condition at anytime.
z
Prepare the first-aid kit, check regularly, and add or
replace the drugs.
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Safety equipment
z
Ensure all shields and cover plates in the proper positions. If any damage for them, please repair
immediately.
z
Understand the use methods of the safety devices and use them correctly.
z
It is prohibited to dismantle any safety devices and keep them in a good working condition.
Keep the machine clean
z
If the water inflows into the electrical system, it will cause the instruments not to work and the
machine to be faulty. It is banned to use the water or steam to flush the electrical system
(such as the sensors and connectors, etc.).
z
If the machine brings with mud or oil contamination, it is dangerous to slide over and fall down while
checking or maintenance.
z
Please keep the machine clean always.
Keep the driver’ cab clean
z
Be 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.
z
Do not put the parts or tools around the driver’ cab.
z
Do not stick the plastic sorbent pad to the window glass because its magnifier role may cause fire.
z
When driving or operating the machine, do not use wireless telephone in the driver’ cab.
z
It is banned to bring dangerous goods (such as the flammable and exposable goods) into the driver’
cab.
Leave the operator’s chair after locking the working devices
z
Before leaving the chair (e.g. when opening or closing the front window or the roof window,
dismantling or installing the bottom window and adjusting the chair), lower the working devices
down to the ground completely and then shut down the engine to avoid touching the operating lever
and make the machine move suddenly to cause serious injury or damage the machine.
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z
When leaving the machine, be sure to lower the
working devices down to the ground completely and
then shut down the engine. Lock all equipment, take
off the keys and put them in the safe places.
Handrails and steps
To avoid injury for the personnel climbing up and down the
machine, the following requirements must be followed:
z
When climbing up and down the machine, use the handrails and steps 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.
z
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.
z
When climbing up and down the machine, check the handrails and steps (including the track shoes)
for oil contamination, lubrication grease or mud. If there are these materials there, wipe off
immediately.
z
It is banned to climb up and down the machine with tools in the hand.
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Installation and dismantlement
z
Do not jump up and off the machine.
z
Do not climb up and down the machine when the machine is moving.
z
If the machine moves suddenly without manual operations, it is banned to jump up the machine and
attempt to stop the machine.
No persons allowed on the accessories
It is banned for any one to sit on the scoop, grab or other accessories, because it is dangerous to fall down or
cause serious injury.
Prevent scolding
Hot cooling liquid
z
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
z
When checking or discharging the oil, to prevent burning
caused by the oil sprayed or touching the hot parts, before
operating, be sure to cool the temperature to the degree
that the cap or the screw plugs of the oil tank can be
touched by hands. Before dismantling the oil tank cap or
the screw plugs, loosen the cap or screw plugs slowly to
reduce the internal pressure.
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Fire protection and explosion proof
Prevent fire caused by the fuel oil or engine oil
The fuel oil, engine oil, antifreeze and window washing are very
flammable dangerous goods. To prevent the fire, the follow
regulations must be followed:
z
Do not smoke or use any open fire near the fuel oil or engine
oil.
z
Before oil filling, shut down the engine.
z
When filling the fuel oil and the engine oil, do not leave the
machine.
z
Tighten the caps of the fuel oil tank and the engine oil tank.
z
Prevent the fuel oil overflow to the overheat surface or the
parts of the electrical system.
z
Ensure good ventilation in the oil filling or storage places.
z
The fuel oil or engine oil shall be kept in the designated
places, and no entrance without permission.
z
After filling the fuel oil or engine oil, wipe off the fuel oil or
engine oil overflowed.
z
When grinding or welding on the lower part of the machine,
transfer all the flammable materials to the safe places.
z
When flushing the parts with the engine oil, use the
inflammable engine oil. It is banned to use the diesel and
gasoline to flush the parts to avoid fire.
z
Put the towel sticking with oil or other flammable materials into the safe vessel.
z
Do not weld or use the cutting torch to cut the pipe with flammable liquid.
Prevent the fire caused by the piling of the flammable materials
z
Remove the leaves, weeds, dry wood chips, 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
z
Prevent the fire caused by the short circuit of the electrical system.
z
Keep the connections for the electrical wires clean and fixed firmly every day.
z
Check the electrical wires for looseness or damage, timely tighten the loose connections or wire
clamps, repair or replace the damaged electrical wires immediately.
Prevent the fire caused by the hydraulic pipelines
z
Check all of the clamps, shields and the buffer pads of the hoses and pipes for fixedness, during
operating, if the parts of the hydraulic pipelines are loose, they will rub with other parts to cause
damage for the hoses, result in the high pressure oil spraying and cause fire.
Prevent explosion caused by the lighting equipment
z
When checking the fuel oil, engine oil, battery electrolyte, window cleaning solution and the cooling
liquid, use the lighting equipment with explosion proof performances, if not to use such equipment, it
is dangerous to cause serious injury by the explosion.
z
When using the power supply of the machine for lighting, the related regulations in this manual shall
be followed.
Activities when there is a fire
If there is a fire, leave the machine soon according to the following requirements::
z
Turn the starting switch to OFF and shut down the engine.
z
Leave the machine with the handrails and the steps.
Cleaning solution for the windscreen
Use the Ethanol based cleaning solution. (Suggest not to use the harmful methanol based cleaning solution)
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