XCMG XE210C Hydraulic Excavator. Operating & Maintenance Manual (2011)

Operating and Maintenance Manual 106

Lubrication of equipment

Attention: High-quality lubricant should be added according to appointed quantity. Excessive

lubricant or grease may lead to overheating and even speed up the abrasion.

The kinds of lubricant

List 2-1 List of lubricant varieties used for this machine

Lubricant

Brand/name

Used for

Capacity(L)

Remark

varieties

Pin shaft of working

0.3

equipments

2# highly pressured

Swing bearing

Grease

-20～40℃

lithium-based grease

Swing reducer

Rotation equipment oil-bath

Tension equipment

CF 15W/40 oil

Diesel engine

-15～40℃

Engine oil

CF 10W/30 oil

Diesel engine

-30～30℃

GL-4 SAE140 gear oil

Swing reducer

6.2

Lubricant

-20～40℃

GL-4 SAE90 gear oil

Travel reducer

2h6.8

Attention：If the excavator works in specially high or cold condition, special lubricant should be

used. You are suggested to contact with excavator dealer appointed by Xugong.

Attention：If the above requirements can’t be satisfied, please contact with Xugong excavator

agent or its after-market department.

Lubrication points

Fig.2-1 distribution of main grease points

List 2-2 list of illustrated signs

Operating and Maintenance Manual 110

Lubrication Period

Schematic of lubrication and maintenance

图 2-12

—Grease

—Engine oil

—Gear oil

—Engine oil filter

—Hydraulic oil filter

—Hydraulic oil

—Engine coolant

—Fuel filter

—Air filter

Table of lubrication periods:

Table 2-3 Lubrication Periods

Interval (hour)

Item

S/N

Maintenance point

Qty

100

250

500

1000

1500

2000

Work

Bucket and link pin

√

device

Others

√

Grease

Rotary bearing

√

Rotation reducer

√

Rotation device oil-bath

√

Check of engine oil level

√

Engine

Replacement of engine oil

√

oil

Replacement of engine oil filter

√

Check of oil

√

Traction reducer

level

Replacement

√

Gear oil

Check of oil

√

Rotary reducer

level

Replacement

√

Note: ƾ Maintenance shall be required only for the first check.

Operating and Maintenance Manual 111

Safety points for attention and precautionary measures

Summarize the working hours correctly to determine the lubrication time.

Stop in case of filling the grease, and don’t apply any lubrication work if not parked as per the

requirements of this manual.

Adopt the fire-prevention measures during the lubrication.

Prevent hot oil and harmful substances from harming the operators.

Avoid mixing the lubricating oils of different brands.

Clean the lubricated parts and vent hole, etc before filling; keep the tightness of seal ring after filling.

Clean or replace the filter at regular intervals, make a mark after draining the engine oil off, and don’t

start the filter without oil.

Remove the spilled lubricant.

Operating and Maintenance Manual 112

Maintenance and repair

Safety rules

Safety maintenance

In order to avoid any accident:

Learn of the maintenance regulations before the work.

Keep the work area clean and dry.

Don’t spray water or steam in the cab.

Fig.2-13

Don’t lubricate or maintain the machine with oil during the movement.

Prevent the hand, foot and clothes from contacting the rotating part.

Before maintaining the machine:

Park the machine on the level ground.

Fall the bucket to the ground.

Run the engine for 5 minutes at low speed and empty load.

Turn the key switch to OFF (off), and stop the engine.

Move the control lever several times to release the pressure in hydraulic system.

Remove the key from the key switch.

Hang up the nameplate “No Operation” on the control lever.

Pull the safety locking rod to LOCK (lock).

Cool the engine.

If the maintenance must be applied during the running of engine, a qualified driver must exist in the

cab.

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.

Check the parts at regular intervals, and repair or replace them as per the

Fig.2-14

demands.

Keep all the parts in good working state, and install them correctly.

Replace the worn or damaged parts in time, and remove any accumulated grease, oil or scrap.

Adopt inflammable cleaning oil, and prohibit to use the fuel or gasoline or other

easily flammable oil to clean the part or surface.

Disconnect the grounding cable (-) of battery before regulating the electric

Fig.2-15

system or welding on the machine.

Apply the sufficient illumination to the working places. In case of working under or inside the

machine, use the working lamps with shields always, otherwise the breakage of bulb may ignite the

spilled fuel, engine oil, anti-freezing fluid or washing fluid, etc.

Protection against separation of fragments

If the fragments are flied into the eye or bounced to any other part of body,

Fig.2-16

they will cause the severe injuries to body.

Operating and Maintenance Manual 113

Use the safety goggles or safety glasses to avoid the injuries of splashed metal pieces or fragments.

In case of hitting the object, prevent others from entering into the working place.

During the maintenance of machine, warn the others that any unexpected

machine movement will cause the severe injuries, and hang up the nameplate

“No Operation” on the control lever before maintaining the machine.

Correct supporting of machine

Don’t maintain and repair the machine before supporting the machine.

Fig.2-17

Fall the front-end working device always to the ground before maintaining and repairing the machine.

If the machine or front-end working device must be lifted for maintenance and repair, support the

machine or front-end working device. Don’t use the slag bricks, cord tires or racks to support the

machine, because they may be fallen-in under the continuous load. Don’t work under the machine

supported with single jack.

Far from the rotating parts

The entrapment of rotating part may cause the severe injuries.

In case of working beside the rotating part, don’t make the hand, foot, clothes,

jewellery or hair entrapped by the rotating part.

Fig.2-18

Avoiding the fly out of part

The 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:

Don’t remove the grease coupler or valve body.

The body and face must be far away from valve body because it may fly out.

The traction reducer has a certain pressure:

Due to the possible flyout of part, the body and face must be away from the air

bleed bolt to avoid any injury.

Fig. 2-19

The gear oil is hot, which may lead to scald injury. After cooling the gear oil,

loosen the air bleed plug gradually to release the pressure.

Safety storage of fittings

The stored fittings such as bucket, hydraulic hammer and grafter may fall, resulting in severe injuries.

Store the fittings and apparatus safety to avoid falling, so the children and other personnel should be

far away from the storage area.

Pay attention to high-temperature fluid.

Avoid the heat injury caused by the sprayed high-temperature fluid. After the operation, the cooling

water of engine is hot and has a certain pressure; there is hot water or steam in engine or radiator.

If the skin contacts the spilled hot water or steam, the severe skin burns will be caused.

Avoid the burning of hot water that may be sprayed out. Don’t open the cover of

radiator before cooling the engine. In case of opening the cover, turn the cover to bottom

slowly, and remove the cover after releasing the pressure fully.

Fig. 2-21

Operating and Maintenance Manual 114

Pressure exists in the hydraulic oil tank. Ensure the pressure is released before

removing the cover.

High-temperature fluid and surface. During the operation, engine oil, gear oil an

hydraulic oil may become hot; engine, hose, pipe and other parts will also beco

Fig. 2-22

After cooling the oil and parts, start to check or maintain them.

Periodic replacement of rubber hose

Due to ageing, fatigue and wear, the rubber hose containing flammable fluid may be broken under the

pressure. It’s difficult to judge the poorness of rubber hose due to its ageing and wear, and replace the

rubber hose at regular intervals.

Irregular replacement of rubber hose may cause the fire, the injection of fluid into skin or the knock of

front-end working device to persons around it will cause severe heat injury, dermal gangrene, other

injuries or death.

Pay attention to high-pressure fluid

If the fuel, hydraulic oil or other fluids injected under high pressure can penetrate the skin or rip into

the eyes, it will cause severe injury, blindness or death.

Fig. 2-23

Fig.2-24

Release the pressure before removing the hydraulic or other pipes to avoid this risk.

Tighten all the connections before pressurizing them.

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 eyes.

Fig. 2-25

In case of any accident, let the doctor who’s familiar with this type

of wound cure immediately.

Any fluid injected into skin must be removed through surgery within several hours, otherwise the

dermal gangrene will be caused.

Treatment of accumulator

The pilot control system is equipped with an accumulator filled with high-pressure nitrogen, so the

pressure of system must be relieved during the maintenance of pilot control system. It’s very

dangerous in case of incorrect operation.

Don’t drill on the accumulator, or don’t make it contact the flame, fire or heat source.

Don’t weld the accumulator, or don’t attach any article on it.

In case of removing, maintaining or treating the accumulator, the filled gas must be discharged.

Contact with our company or supplier.

Operating and Maintenance Manual 115

In case of treating the accumulator, wear the safety goggles and protective gloves. The high-pressure

hydraulic oil will stab the skin or cause the injury.

Safety maintaining air-conditioning system

The splash of refrigerant on skin will cause the frost injury.

During the maintenance of air-conditioning system, use Freon correctly as

per

the instructions for Freon container.

Fig.2-26

Adopt the recovery or recirculation system to prevent Freon from

discharging into the into the atmosphere.

Don’t make Freon fluid contact the skin.

Correct treatment of discards

Any improper 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.

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.

Don’t pour the waste liquid on the ground, into sewerage or any water source.

The air-conditioning refrigerant is leaked into the air, which will damage the

atmospheric layer of the earth. According to the government regulations, an

Fig.2-27

air-conditioning service center with desired certificates may be required to

recover and regenerate the air-conditioning refrigerant.

Inquire the correct recovering or treatment methods of discards from local environmental protection or

recovery center or your assigned dealer.

Operating and Maintenance Manual 116

Maintenance

Check and maintenance of hydraulic device

Note: during the operation, the parts of hydraulic system will become very hot, and

cool the machine before starting the check or maintenance.

During the maintenance of hydraulic device, ensure that the machine shall be placed on the flat or

hard ground.

Fall the bucket to the ground, and turn the engine off correctly.

Maintain the hydraulic device after cooling the machine part, hydraulic oil and lubricating oil fully,

because the residual heat and pressure will exist in the hydraulic device soon after finishing the

operation.

Drain the air in the hydraulic oil tank to release its inner pressure.

Cool the machine. Check and maintain the high-temperature or high-pressure parts, because they may

cause the sudden flyout or spray of parts or hydraulic oil and the personal injury.

In case of removing the plug, don’t make your body and face against them, because any hydraulic part

may still have a certain pressure even if the part has been cooled.

Don’t try to maintain or check the traction or rotary motor circuit on the slope, because they can have

high pressures due to their own weights.

During the connection to the hydraulic hose and pipe, 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:

Clean the inner face of hose, pipe or oil tank with cleaning fluid, and dry them thoroughly before

connecting them.

Use non-destructive or defective O rings, and don’t damage them during the assembling.

During the connection of hose, don’t make the high-pressure hose distorted, because the lifetime of

twisted hose will be greatly reduced.

Tighten the low-pressure hose clamp cautiously, and ensure they can’t be screwed too tight.

In case of filling the hydraulic oil, use the oil of the same brand always, and don’t mix the oils of

different brands. In case of wishing to use the oil listed in “Brands and Names of Recommended

Hydraulic Oils”, ensure that all the hydraulic oil in the system is fully replaced.

Don’t run the engine without oil in hydraulic oil tank.

Check of hydraulic oil level

Important: don’t run the engine without oil in

hydraulic oil tank.

Fig.2-28

Check the level of hydraulic oil every day.

Park the machine on the flat ground.

Retract the state positioner fully with a bucket rod hydraulic cylinder,

and stretch it out fully with a bucket hydraulic cylinder.

Stop the engine as per the shutdown steps of engine (P20).

Important: if the shutdown steps of engine are incorrect,

the turbo supercharger may be damaged.

Pull the safety locking rod to LOCK (Lock).

Fig.2-29

1－liquid-level meter

Operating and Maintenance Manual 117

Open the access door at the hydraulic pump, check the liquid-level meter on hydraulic oil tank.

The oil level must be between the marks on the level meter, otherwise add in the hydraulic oil.

Note: the hydraulic oil tank has a certain pressure. Release the pressure of oil tank

and remove the cover carefully before removing the oil tank cover.

Add in the hydraulic oil, and check the level meter again.

Attach the cover, and ensure the components of filter and hanger rod are correctly positioned.

Drain the dirt reserve tank of hydraulic oil tank

Important: don’t run the engine without oil in hydraulic oil tank.

Drain the dirt reserve tank of hydraulic oil tank once every 250 hours.

For the convenience of access, rotate the upper car by 90°, and park the machine on the flat ground.

Stop the engine as per the shutdown steps of engine (P20).

Important: if the shutdown steps of engine are incorrect, the

turbo supercharger may be damaged.

Pull the safety locking rod to LOCK (lock).

Note: the hydraulic oil tank has a certain pressure. Release the

pressure firstly, don’t loosen the drain plug before cooling the oil,

Fig.2-30

because the oil may be hot and cause the severe scald injury.

1－Dirt drain plug

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.

After draining the water and deposits, tighten the drain plug again.

Replacement of hydraulic oil or cleaning of oil suction filter

Note: the hydraulic oil may be hot, and the oil must be cooled before starting the

work.

Replace the hydraulic oil or clean the oil suction filter every 2000 hours.

For the convenience of access, rotate the upper car by 90°, and park

the machine on the flat ground.

Retract the state positioner fully with a bucket rod hydraulic cylinder,

Fig.2-31

and stretch it out fully with a bucket hydraulic cylinder.

1－Oil tank cover

Stop the engine as per the shutdown steps of engine (P20).

Important: if the shutdown steps of engine are incorrect, the turbo super charger

may be damaged.

Pull the safety locking rod to LOCK (lock).

Clean the top of hydraulic oil tank, and prevent the dirt from intruding

into the hydraulic system.

Note: the hydraulic oil tank has a certain pressure. Release

the pressure, and then remove the oil tank cover.

Remove the oil tank cover.

Fig.2-32

Draw off the hydraulic oil with a pump. The capacity of hydraulic oil in

2－Oil drain plug

Operating and Maintenance Manual 118

the tank:

XE210C:220L.

XE230,XE260C：240L.

Remove the drain plug to make the hydraulic oil discharged.

Take out the components of oil suction filter and hanger rod.

Clean inner sides of filter and oil tank. In case of replacing the filter,

attach a new filter to the hanger rod as shown in right figure.

Attach the components of filter and hanger rod, and ensure the filter

is correctly fixed on the outlet.

Replace the oil filter of hydraulic oil tank

(refer to

“List of

Maintenance Periods”).

Fig.2-33

Clean, attach and tighten the drain plug.

3－Components of oil suction filter

Fill the hydraulic oil up to its level between the marks of level meter.

and hanger rod

Attach the oil tank cover, and ensure the components of filter and

hanger rod are in correct positions.

Important: in case of starting the engine without oil in hydraulic pump, it will

damage the hydraulic pump.

Remove the air bleed plug from the top of hydraulic pump.

Fill up the hydraulic pump with hydraulic oil through the hole of air bleed

plug.

Attach the air bleed plug.

Start the engine and run it at low speed and empty load. Hang “No

Fig.2-34

Operation” nameplate to the safety locking rod, and ensure the safety

4－Air bleed plug

locking rod in LOCK (lock) position.

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.

Run the engine at low speed and empty load, and actuate the control lever slowly or stably for 15

minutes to discharge the air out of the hydraulic system.

Retract the state positioner fully with a bucket rod hydraulic cylinder, and stretch it out fully with a

bucket hydraulic cylinder.

Stop the engine as per the shutdown steps of engine (P20).

Pull the safety locking rod to LOCK (lock).

Check the level meter of hydraulic oil tank. If necessary, open the oil tank cover to add in the oil.

●

Drain the dirt reserve tank of fuel tank.

Drain the dirt reserve tank of fuel tank every day.

For the convenience of access, rotate the upper car by 90°, and park the

machine on flat ground.

Stop the engine as per the shutdown steps of engine (P19).

Fig.2-35

Important: if the shutdown steps of engine are incorrect, the turbo

1－Drain ball valve

2－Fuel ball valve

Operating and Maintenance Manual 119

supercharger may be damaged.

Pull the safety locking rod to LOCK (lock).

Open the drain ball valve in the bottom of fuel tank for several seconds to discharge the water and

deposits, and then close the ball valve.

Check of water separator

Check the water separator before the operation every day.

The water separator may mix the water in fuel. The water separator

contains a floating body that will float up during the accumulation of

water to ensure the water separator starts to drain when the floating

Fig. 2-36

body reaches the mark of “ Drain water ”on outer side of oil-water

1－Air bleed plug

separator.

2－plug

Important: if the fuel contains excessive water, shorten the check

3－Fuel prefilter

interval of water separator.

Drain steps

The water separator is located on fuel prefilter near to the hydraulic pump, open the right side shed

door, and fix the door with a fixing bar.

Close the fuel ball valve (Fig.2-35) in the bottom of fuel tank to stop the supply of fuel.

Loosen the air bleed plug on top of fuel prefilter, and anticlockwise loosen the drain plug in the

bottom of water separator to drain the water accumulated in water separator.

After draining the water, tighten the air bleed plug and drain plug. Turn the fuel ball valve to its

original position.

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 or abnormal starting of

engine. After draining the water and deposits in oil-water separator, replacing the fuel filter or

drying the fuel tank, ensure the air must be bleed out of hydraulic system.

Determine that the drain plug and air drain plug of oil-water separator are tightened. If the air bleed

plug is not tightened, the air in hydraulic system won’t be exhausted.

Ensure the fuel ball valve in the bottom of fuel tank has been opened.

Loosen the air bleed plug on the fuel filter.

Loosen the hand wheel on fuel supply pump, and move the plunger up and down until no air bubbles

are seen from the air bleed plug.

Tighten the air bleed plug, and

continue to move the plunger of

fuel supply pump up and down until

the load becomes heavier.

Push down the hand wheel of fuel

supply pump, and tighten it.

Start the engine, and run it at low

Fig. 2-37

speed and empty load.

1－Air bleed plug

2－Fuel supply pump

Operating and Maintenance Manual 120

Hang “No Operation” nameplate to the control lever.

Pull the safety locking rod to LOCK (lock).

Check the hydraulic system for leaks.

Replacement of fuel filter

Replace the fuel filter every 250 hours.

For the sake of safety and environmental protection, use the proper

containers always for draining the fuel oil. Don’t pour the fuel on the

ground, into the ditch, river, pond or lake, and treat the waste fuel

properly.

Fig.2-38

Remove the cartridge filter with a filter spanner.

1－Cartridge filter

Apply a thin layer of clean fuel to the gasket of new cartridge filter.

Tighten the cartridge filter by hands until the gasket contacts the seal face.

Turn the cartridge filter by ca. 2/3 circle with a filter spanner to tighten it, but it shall not be screwed

too tight.

After replacing the cartridge filter, bleed the air out of hydraulic system.

The above methods are for the replacement of second-class fuel filter on the engine side, and those of

first-class fuel filter on the pump chamber side are the 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

Fig.2-39

air filter

1－Outer filter element

2－Fixing clip

After six-time cleanings or one year, replace inner and

outer elements of air filter.

Park the machine on flat ground.

Stop the engine as per the shutdown steps of engine (P20).

Important: if the shutdown steps of engine are incorrect, the turbo supercharger

may be damaged.

Pull the safety locking rod to LOCK (lock).

Loosen the fixing clip, and remove the end cover.

Remove the outer filter element.

Air clogging switch

Flap outer filter element lightly by hands, and don’t on any hard

Shield

object.

cover

In case of cleaning outer filter element with compressed air, blow

outward from inner side of outer filter element.

Valve

Note: adopt low-pressure air (less than 0.2MPa) to

Fig.2-40

clean, have the personnel in the adjacent area away,

1－Outer filter element

protect against the splashed fragments, and wear the

2－Fixing clip

personal protection equipment, including safety goggles

3－Inner filter element

Operating and Maintenance Manual 121

or safety glasses.

Attach the outer filter element.

Attach the end cover, and tighten the fixing clip.

Start the engine, and run it at low speed and empty load.

Check the warning indicator of air filter element on the monitor. If the indicator goes on, stop the

engine immediately and replace the outer filter element.

In case of replacing the element of air filter, replace inner and outer filter elements together. Remove

the outer filter element; clean inner sides of filter before removing the inner filter element; remove the

inner filter element; install the inner filter element, and then install the outer filter element.

Check of coolant level

Full

Low

Fig.2-41

Fig.2-42

1－Radiator cap

2－Cooling water tank

Note: unless the system has been cooled, don’t loosen the radiator cap. Release the

whole pressure before removing the cover, and then screw it off slowly.

Check the level 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 radiator cap before cooling the engine. Release the whole

pressure before removing the cover, and then screw it off slowly.

Fig. 2-43

1－Radiator drain cock

Fig. 2-44

2－Engine drain cock

During the replacement of coolant, clean the inner side of radiator.

Remove the radiator cap, open the drain cocks of radiator and engine body to empty the coolant.

Close the drain cock, add fresh water and radiator cleaner into the radiator, start the engine, and run it

at the speed higher than low idle speed. When the pointer of cooling water thermometer enters into

the green area, continue to run the engine for ca. over ten minutes.

Operating and Maintenance Manual 122

Close the engine, open the drain cock, and flush the cooling system with fresh water until the drained

water becomes clean so as to remove the dirt and deposits.

Close the drain cock, add the fresh water, and add the antirust agent and antifreeze agent into the

radiator as per the specified mixing ratio. In order to prevent the air bubble from mixing into the

system, add in the coolant slowly.

Run the engine to bleed the air of cooling system fully.

After adding in the coolant, make the engine running for several minutes. Check the level of coolant

again, and add in the coolant again according to the demands.

Electric control system

Important: the installation of improper radio communicators and accessories will

influence the electronic elements of machine and cause the unexpected movement of

machine. The installation of improper electric devices may also cause the fault or

accidental fire. During the installation of radio communicators or additional

electric components or replacement of these components, be sure 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 expl

approaching the battery.

This machine adopts the maintenance-free battery,

so it’s unnecessary to add in the water frequently.

position of battery

Check the capacity of battery frequently to increase

Fig.2-45 Position of battery

lifetime.

Check of battery

Check the capacity of battery at least once every month.

Park the machine on flat ground.

Stop the engine as per the shutdown steps of engine (P20).

Check the capacity of battery. Observe the densimeter from

the upper part of battery.

If the following circles are seen from round porthole:

Green circle──indicate the normality of battery

Fig.2-46

Black circle──indicate the low capacity of battery that

1－Level meter

2－Porthole

needs to be charged

White circle──indicate the discarding of battery that needs to be replaced.

Keep the terminal of battery clean always to avoid the discharge of battery. Check the terminals for

loosening or rusting, and apply the grease or Vaseline to avoid the corrosion.

Replacement of battery

Operating and Maintenance Manual 123

There are two negative (-) grounded 12V batteries on the machine. If one battery of 24V system fails

but the other is still good, replace the failed battery with the battery of the same type. For example,

replace the failed and maintenance-free battery with new battery. The charging speeds of batteries in

different forms may be different, which may make one of these batteries fail due to overload.

Replacement of fuse

If the electric device doesn’t work, check the fuse at first. The fuse box is located behind the seat,

open the fuse box cover up, and the spare fuse is located under the cover.

Important: avoid the damages to electric device due to overload, and install the fuse with

correct amperage.

Fuse box cap

Headlamp/ arm lamp

Horn 10A

switch 10A

Radio 10A

Wiper and washer 10A

Excitation/Preheating

Controller 5A

Protection 10A

Fuse box

Safety handle 5A

Monitor 10A

Air conditioner

Traction and booster

controller 10A

10A

Feed pump controller

Traveling booster ring

10A

Spare fuse 10A

Spare Fuse 20A

Shutdown of engine

Key switch 20A

10A

Indoor lamp 5A

Working lamp/arm

lamp 20A

Air conditioner

Controller 5A

compressor 20A

Cigar lighter 10A

Feeding pump 30A

24 Schematic of fuse box layout

Schematic

Name

Rated Current

Name

Rated Current

Code

Horn

10A

Headlamp/ arm lamp switch

10A

F12

Radio

10A

Wiper and washer

10A

F13

Excitation/Preheating

10A

F14

Controller

Protection

F16

Safety Handle

F15

Monitor

10A

Air-conditioner

10A

F18

10A

F19

Traction and booster

Controller

F23

Rotary Brake

F20

Traction and booster ring

10A

F17

Pump Controller

Spare Fuse

10A

Spare Fuse

10A

Spare Fuse

20A

Shutdown of engine

10A

Key switch

20A

Indoor lamp

Arm lamp and working lamp

20A

Air-conditioner

20A

F22

Controller 2

compressor

F11

Cigar lighter

20A

F10

Pump

30A

Operating and Maintenance Manual 124

Replace the bucket

e: avoid the injury caused by the flyout of metal filling or fragments in case of hitting out or

Movement of O-ring

in the connecting pin, and wear the safety goggles or safety

glasses and safety appliances applicable for operation.

Park the machine on flat ground. Fall the bucket to ground, fix its plane

on the ground, and ensure the pin shaft can’t be rolled after removing the

Bucket sleeve

pin shaft.

Fig.2-48

Side O-ring out as shown in Fig. 2-48.

Remove bucket pin shafts A and B, separate the bucket rod bucket, clean

pin shaft and pin hole, and apply enough lubricating oil to pin shaft and pin hole.

Align the bucket rod and new bucket, and ensure the bucket can’t roll.

Attach the bucket pin shafts A and B.

Attach the lock pin and retaining ring to pin shafts A and B.

Adjust connecting clearance of bucket at pin shaft A (see “Adjust

Link rod

connecting clearance of bucket”).

Apply the grease to pin shafts A and B.

Start the engine, and run it at low idle speed. Turn the bucket slowly in bo

directions to check if the rotation of bucket is disturbed. Don’t use any disturbed

Fig.2-49

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.

Park the machine on flat ground,

Bucket

Bucket lever

fall the bucket to ground with its

Bucket

shaft

plane down to avoid rolling the

Clearance

bucket.

adjusting part

Run the engine at low idle speed,

turn the bucket clockwise on the

ground until left boss top of bucket

Fig.2-50

contacts the bucket rod.

1-Bolt

2-Adjusting shim 3-Pressure plate 4-Cam

Stop the engine. Pull the safety

locking rod to LOCK (lock).

Note: in case of removing the tab, don’t remove the bolt (Item 1 shown in Fig.2-51). The tab is half

round, so it’s easy to push them out with a screwdriver after loosening the bolt.

Loosen the bolt slightly with a spanner. Push out all the tabs in the clearance c between the pressure

plate and bucket.

Push the bolt to one side of bucket rod, and eliminate the whole clearance a between bucket rod and

cam. Push the cam onto the bucket rod to increase the clearance b, and measure the clearance b with a

Operating and Maintenance Manual 125

feeler gauge, which shall not be adjusted below 0.5mm.

Attach the adjusting shims as much as possible in the clearance b.

Note: be sure to the residual adjusting shims in the clearance c to avoid the damages to bucket rod tail

end face or bolt.

Attach the residual tabs in the clearance c, and tighten the bolt.

Note: the total number of tabs is 12 (6 pairs).

If the measured value d is below 5mm, replace the cam.

Removal of traction control lever

If necessary, remove the traction control lever.

Fig.2-51

Fall the bucket to ground.

1, 2－Bolt

3, 4－Traction control lever

Stop the engine as per its shutdown steps (P20).

Pull the safety locking rod to LOCK (lock).

Remove the bolts 1 and 2, and remove the traction control levers 3

and 4 from the control valve.

Check and replacement of safety belt

Check the safety belt every day; replace the safety belt every 3

years.

Keep the safety belt always good, and replace it if necessary to

ensure its good performance.

Fig.2-52

Check the safety belt; lock latch and connector thoroughly before

1－Safety belt

2－Lock latch

the operation.

3－Connector

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

Fig.2-53

Check the crawler sag every day.

As shown in Fig.2-53, rotate the upper car by 90°, and then fall the bucket to lift the crawler away

from the ground, keep the angle between the movable arm and bucket rod within 90° to 110°, place

the arc part of bucket on the ground, place the cushion block under the frame of chassis to support the

machine, rotate the crawler back by two circles, rotate it forward by two circles, and measure the

distance A between frame bottom and track plate back from middle part of chassis frame.

Requirements of crawler sag:

XE210C, XE230, XE260C: A=300 to 335mm.

Note: check the slag of crawler after removing the soil on the track plate.

Operating and Maintenance Manual 126

●

Adjust the sag of crawler.

Points for attention for adjusting the crawler sag

If the crawler sag is not within the desired range, loosen or tighten the crawler as per the steps below.

During the adjustment of crawler sag, fall the bucket to ground, and jack the crawler on one side.

Apply the same methods to the crawler on the other side. Place the cushion block under the frame

every time to support the machine.

After adjusting the crawler sag on both sides, move the machine forward and backward several times.

Check the sag of crawler again. If the crawler sag can’t reach the specified value, continue to adjust it

until it’s satisfactory.

Loosen the crawler.

Note:

Don’t loosen the valve body rapidly or

Excessively, otherwise the grease in the tensioner

will spray. Loosen the valve body carefully, and

don’t make the body and face against it.

Grease outlet

Don’t loosen the grease coupler.

Fig.2-54

Important: if the crushed stones or soils are clipped

1－Valve body

2－Grease coupler

between the driving wheel and crawler, remove

them after loosening the crawler.

In case of loosening the crawler, rotate the valve body slowly anticlockwise with a deep socket

wrench, and the grease will drain out of its outlet.

Rotate the valve body by 1 to 1.5 circles enough to loosen the crawler.

If the grease can’t be smoothly drained, lift the crawler away from the ground, and rotate the crawler

slowly.

After reaching the proper crawler sag, tighten the valve body clockwise.

Tighten the crawler.

Note: if the crawler is still too tight after tightening the valve body anticlockwise, or it is still loose

after applying the grease into the grease coupler, this is abnormal. At this time, don’t try to remove

the crawler or track-tension device, because the high-pressure grease of track-tension device is

dangerous. Therefore, overhaul it or contact with your assigned dealer.

If it’s necessary to tighten the crawler, connect the grease gun to grease coupler, add in the grease

until the crawler sag reaches the specified value.

Check of air conditioner

Deflection

Oil leaks

Fan belt pulley

Press

Generator belt pulley

Press

Crankshaft belt pulley

Fig.2-55

Compressor belt pulley

1－Liquid reservoir

2－Interface

Fig.2-56

Check the air conditioner every day.

Check the cooling gas at the connections of pipe for leaks (as shown in above figure). If the oil leaks

XCMG XE210C Hydraulic Excavator. Operating & Maintenance Manual (2011) - page 6