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Shantui SE210 Hydraulic Excavator. Operation & Maintenance Manual - page 1

Introduction

SHANTUI

Summarize

Designed function

This machine is designed to work in normal situation. In special and dangerours

condition, operator should follow special reles and equipped special equipments.

Please contact dealer to get more information.

Engine

The engine is 6 cylinder, 4 stroke, direct injection, turbocharging, intercooling

and water-cooling, with 5.9 L output volume, the model is Cummins B5.9-C

Electronic system

This system consists engine, charging, monitoring, engine-pump control and air

condition sustem.

The speed is controlled by segmented increased continues button andautomatic

idling system. Idling and increased speed system would reduce engine’s revoling

speed after operation in 7 seconds, and increases the speed to the designed.

Hydraulic pump

Hydraulic pump component consists two variable cam-type pump connected by two

multiple keys and a quantitative gear pump, driven by engine.

HYDRAULIC EXCAVATOR

MODEL

SERIAL NO.

MASS

ENGINE

CAPACITY

POWER

Product identification Number

SHANTUI

SHANTU

I

2. Engine’s model and number and so on is on the plate where is on

theengine’s right sid (from fan).

Information and caution mark

The following is the caution and words which should be foune on machine.

1.Do not start engine

2. Safety lockout

Refer to “safety lockout system”

3.

Emergency exit

EMERGENCY EXIT

Please refer to “Escape in case of emergency”.

Hold the steel loop and draw

Press corners of the glass hard

out the rubber core

4. Operating options

Warning

To prevent personal injury or death resulting from incorrect operation, please

identify the operating condition of the machine and the operation mode

displayed when you operate the machine. When identifying the operating

condition of the machine, please pay attention to its peripheral portion while

operating slowly.

5. Accessories recommended table

Table of Recommended Accessories

Table of Recommended Accessories for SE210 Excavator

Location

Swing

Undercarriage

Antifreeze

Air

Engine

Fuel

Hydraulic oil

reduction

reduction

solution

conditioner

gear unit

gear unit

API CH-4/

Sulfur

Accessory

API GL-4

API GL-4

SJ SAE

content

ISO VG46

-45℃

R134a

requirement

SAE 90

SAE 85W-90

15W-40

<0.5%

Recommended

Premium

Special hydraulic

Special antifreeze for

-10# or -35#

Mobil GX

Mobil GX

-

variety

Blue

oil for SHANTUI

SHANTUI

Capacity:

Amount

20L

420 L

Capacity:25 L

4.4 L

2X5.4 L

0.9Kg

360L

Description:

The various types of accessories selected in the table are generally required at delivery. For cold northern and hot southern areas, you can adjust the

recommendations in accordance with the requirements of the Owner’s Manual depending on climate conditions.

6. High voltage

7. Maintaince

Service and maintenance

Engine 20L

Hydraulic system 500L

Swing reduction gear

unit 10.5L

Undercarriage reduction

gear unit 2X9.5 L

Routine lubrication point

Oil level check

Lubricant change

First lubricant change

Lubrication

Remark:

1.

Maintenance interval per owner’s manual

2.。 When servicing the excavator, park it on a

level ground, secure the work equipment,

and turn off the engine.

on a level ground, secure the work equipment,

and turn off the engine.

Lubriczation

schematic

8. Note

Caution

 Before operating the vehicle, you must

 If any hydraulic cylinder or a part of the

read the Owner’s Manual carefully.

circulating system is removed, be sure to

 Before starting the vehicle, check it.

follow the procedure below to bleed it

When any unsafe factor exists, do not

when reinstalling it.

start the vehicle.

1.

Idle the engine at low speed.

 The personnel must make clear the safe

2.

Extend and retract the cylinder piston for

distance to high-tension lines.

4-5 times at first and stop it at

100m

 Before leaving the driver’s seat, you must

before its stroke end.

observe the following:

3.

Then move piston of each cylinder to

Lower the work equipment to the ground.

respective stroke end for 3-4 times.

Lock control lever with safety lock, and

For details of track adjustment, refer to

stop the engine.

the Owner's Manual.

When jacking up the vehicle body using

 After a long-stay parking, you must

boom or stick, do not allow anyone to

follow the procedure below when starting

enter under the body.

the engine.

When parking on a slope, be sure to put

1.

Turn the starting switch of the engine to

stoppers under tracks.

the "ON" position.

When adjusting track tension, do not

2.

Start the engine.

slacken the valve for more than 1 turn.



Select engine oil according to ambient

When exceeded,

the

internal

temperature. Please refer to the Owner's

high-pressure grease may blow out.

Manual.

 When stopping the engine, idle it with

minimum throttle opening for 5 minutes

before stopping it.

9. Keep distance

Working area, keep in distance！

10. Travel direction

11. Fuse parameters

12. Swing location

13.Warning！Banned trample, prevent slip

14. Keep distance

In swing radius, keep in distance！

15. Warning! Cooling liquid is with high heat and pressure, be careful of scald.

16. Warning! Turnng, keep in distance

17. Caution! Hydraulic oil is with high heat and pressure, be careful of scald.

CAUTION

1.

Be sure to turn off the engine before

opening its hood.

2.

Do not open the hood when oil temperature

is too high.

3.

Open the hydraulic oil tank cap slowly to

release its internal pressure completely.

4.

Do not loosen the drain plug when oil

temperature is too high.

18.

Dangerous! Inflammable and explosive! Keep

fire away!

DANGER

Fuel

Diesel oil

When refueling, be sure to stop the

engine and keep safe distances from all

lights and open flames.

19. Lifting and fixed position.

Repair and maintenance

Overview

In order to reduce the cost of using the machine as much as possible, you must do

the machine with good maintenance and repair. Repair and maintenance intervals

apply to normal environmental and working conditions of the machine, the operator

can do the maintenance work described in the "Manual", further adjustments and

Do not operate the machine, before you are familiar to the position,

function and usage of the control instrumentation and control

system, you must carefully read and be familiar with this part. You

should view the displayed information at any time, and take

appropriate measures to avoid damage to the machine.

V3.0-13C Excavator monitor is equipped with a wide selection of type, 160 X128 dot matrix

LCD display, vibration, good anti-interference ability, especially suitable for outdoor light

environment; System is displayed in Chinese / English, with text and symbols displaying a

variety of working conditions and a variety of fault alarm information. Various control functions

are came true by centralized key control, monitoring of working conditions at any time, having

the advantage of controlling display modern, reliable, simple operation and easy.

一.Description of the instrument panel

Start key switch

The start key switch has 3 (4) positions: HEATER (optional), OFF, ON, and START.

When the machine is operating normally, the monitor will display the following: (main frame)

SHANTUI

Operating state

Waiting to start

Fuel

Coolant

temperature

They can be divided into 6 areas:

Fuel level display

Operating state display

Coolant temperature

SHANTUI

display

Operating state

Waiting to start

Clock/calendar

disaplay

Time and date

Set speed display

Coolant

Fuel

temperature

Expressed as follows:

1. Status display area

Displays the current engine operating state, such as the [start waiting] , [waiting for

operations], [normal operation], [delay] and so on standby.

Monitoring system monitors the situation of engine lubrication system, cooling

system, intake system, power generation systems, and hydraulic system at the same

time.

If the system gets problem, it will display the following fault alarm information in

the status area:

Level 1 alarms

1.1. It displays [Coolant level] and flashes to indicate that the engine coolant level is below the

normal value. At the same time, the buzzer sounds.

1.2. It displays [Coolant temperature too high] and flashes to indicate that the engine coolant

temperature is above the normal value. At the same time, the buzzer sounds.

1.3. It displays [Oil lubrication] and flashes to indicate that the engine oil pressure is below the

normal value. At the same time, the buzzer sounds.

1.4. It displays [System pressure] and flashes to indicate that the line pressure of the hydraulic

system is above the normal set value. At the same time, the buzzer sounds.

1.5. It displays [Voltage too low] and flashes to indicate that the battery voltage is below 22V.

At the same time, the buzzer sounds.

1.6. It displays [Voltage too high] and flashes to indicate that the battery voltage is above 32V.

At the same time, the buzzer sounds.

1.7. It displays [Speed sensing] and flashes to indicate speed sensor signal abnormality. At the

same time, the buzzer sounds.

Level 2 alarms:

1.8.

It displays [Please refuel] and flashes to indicate that the remaining fuel in the fuel tank is

inadequate and that refueling is needed.

1.9. It displays [Air cleaner dirty] and flashes to indicate that the air cleaner is dirty and that

you need to clean up or replace the intake filter screen.

2. Fuel display area

An analog bar is used to display percentage of fuel in the fuel tank. When fuel level is below 20%,

it will display a “

” in the Time & Date position and flashes; at the same time, the status

display area will display a prompt [Please refuel].

3. Coolant temperature display area

An analog bar is used to display engine coolant temperature (℃). When the temperature is above

100℃, it will display a “

” in the Time & Date position and flashes; at the same time, the

status display area will display a prompt [Coolant temperature too high] and the buzzer will sound.

4. Calendar and clock display area

4.1. This area displays current date and time.

4.2. In case of malfunction alarm, an alarm prompt will be displayed in this position. (Alarm

messages are highlighted.)

4.2.1. It displays

and flashes to indicate too low engine coolant level.

4.2.2. It displays

and flashes to indicate too high engine coolant temperature.

4.2.3. It displays

and flashes to indicate too low engine oil pressure.

4.2.4. It displays

and flashes to indicate too high line pressure in the hydraulic system.

4.2.5. It displays

and flashes to indicate inadequate remaining fuel.

4.2.6. It displays

and flashes to indicate abnormal battery voltage.

4.2.7. It displays

and flashes to indicate dirty air cleaner.

4.2.8. It displays

and flashes to indicate abnormal speed sensor signal.

5. Hour meter

Then the engine start to timing meter start to working, the engine stop the timing meter will

stop too. Every time restart engine, the timing meter working base on the total time. The

picture will display the total time from the newest time.

6. Set speed display

Displaying the engine set speed of the current operating mode.

II. Description of key board

Monitor operating key board screen, as shown

Menu button

1.

is enter button, press this key to confirm that the contents of the prompt or

enter the options menu;

2.

is Page Down key, the contents of the key is corresponding to the

operation with the top of the screen.

In normal display mode, in addition to 【F】 mode, pressing this button can follow

50RPM / set times to reduce the engine speed.

3.

is Page Up key, the contents of the key is corresponding to the operation

with the top of the screen.

In normal display mode, in addition to 【F】 mode, pressing this button can follow

50RPM / set times to increase the engine speed.

Working Mode key

5.

is【F】 mode control keys; System is working in fine (slow) mode;

6.

is

【L】mode control keys; The system is working in Light-load mode;

7.

is

【M】mode control keys; The system is working in Standard operating

mode;

8.

is

【H】mode control keys; Strong power mode system.

Control key

9.

is working lights switch, press once to turn on the lights, and press again

will turn off the light.

10.

is brush key, press this key ,the L light will on means the brush in the

interval working situation , press again , the H lamp will light means brush in the

continue working situation, press the third time , the brush will stop working.

11.

is the double walk speed key , press this key , the above L lamp will light

means walking in the low speed, press again the H lamp light , means walking in

high speed situation. Press again the walking situation will back to low speed.

12.

is air conditioner key , press this key the refer lamp will light , means the

air conditioner have turn on

, when press again the lamp will off and the

air-conditioner will not working .

13.

is mute control buttons, press this key to keep the buzzer silent;

14.

is the brush water spray key, press this key, the lamp will light, the spray

pump will out of water, same time the brush will working. Leave this key the lamp

will off, and spray stopping and the brush stop too.

15.

(Optional) is Micro-mode control keys;

16.

is idle speed key, the lamp light time the situation are automatic to come back idle

speed and so operation leader, the engine automatic to back default speed to working , operation

leader in middle position stop more than 1 second, and start to delay, delay 7 seconds , the engine

automatic back to idle speed. The lamp off and the working will be manual work, now engine are

working on the default situation.

III.

Operating instructions

Make sure the safety lock lever is in the locked (raised up) position.

1.

After the start key is turned ON, the system will perform self check and initialization first. After

finishing initialization, the system will enter the main working interface automatically. If no

alarm signal appears on the display screen, the status display area should show [Waiting to start].

2. Turn the start key clockwise to the START position to start the engine. After the engine is started,

release the key rapidly to allow the engine to run automatically in idle state. Then the status

display area will show [Waiting to operate].

3.

Select operating mode according to operational need. (At engine start, the default mode is

[F].)

[H] mode: maximum power output. It is suitable for heavy-load operation.

[M] mode: 90% power output. It is suitable for operation in standard condition.

[L] mode: 70% power output. It is suitable for light-load operation.

[F] mode: 30% power output. It is suitable for occasions where fine movements are

required.

Generally [M] mode is recommended because it can significantly improve working condition,

reduce fuel consumption, noise, temperature rise and wear, and prolong life of the engine. In

auto idle state, set down the safety lock lever and operate the left and right levers or the travel

lever, then the engine will automatically run in the selected operating mode and the status

display bar will show [Running normally].

4.

To change engine speed in the operation process, you can press

or

key to

decrease or increase the working speed of the engine. Each press can rev down (up) the

engine by 50prm. The speed adjustment is valid only in this on/off period. At restart after

the system is turned off, the engine will return to the default set speed.

5.

Once an alarm signal, such as [Oil lubrication], [Coolant level] or [Coolant temperature too

high] message, appears in the status display area, stop immediate and check (refer to latter

fault handling section for details). Otherwise, the system will rev down the engine to idle

speed and record down time after 1 minute automatically. No record will be kept when

the engine is out of operation.

6.

After finishing work, do not turn off the engine immediately. Instead, let the engine rev

down to idle speed automatically and run 3-5 minutes before shutdown, otherwise the

service life of the engine will be affected.

CAUTION: All keys are touch keys (each press corresponds to an operation) except that

the wiper spray key must be pressed and held to complete an operation.

IV. Fault handling and troubleshooting

In addition to displaying operating states, the monitor can also supervise operating states of the

lubrication system, cooling system, intake system, and generator system of the engine. If any of

above systems is out of order, the following prompts will appear in the Time & Date position on

the screen respectively:

Level 1 alarms

1.

[Oil lubrication] prompt: low pressure in lubrication system. Troubleshooting should

be carried out mainly in the following 3 aspects.

 Check engine oil line for clogging.

 Check engine oil pump for proper operation.

 Check for lack of engine oil.

2.

[Coolant temperature too high] prompt: It indicates that coolant temperature is above

100℃. In case of coolant temperature alarm, check the cooling system immediately.

Check the water tank for too high actual temperature and heavy coolant leak.

3.

[Coolant level too low] prompt: It indicates that the coolant level in the radiator or

surge tank is below the safe value. Then a troubleshooting is required:

 Check surge tank and water radiator for lack of coolant and seals of water radiator and

adapters for leakage.

 Check if coolant level in surge tank is below LOW mark.

 Check coolant level sensor which is mounted in two ways and falls into two types:

A. Mounted on water radiator: To check it in case of alarm, disconnect the sensor

connector and short it. If the alarm disappears, poor contact of the connector, sensor

bubbles or sensor damage may occur; if the alarm remains, perform troubleshooting

forward in turn to check for poor contact of connector.

B. Mounted on surge tank: To check it incase of alarm, disconnect the liquid level sensor

of the surge tank. If the alarm disappears, you need to replace the coolant level sensor;

if the alarm remains, perform troubleshooting forward in turn to observe signal wires

for short circuit.

4.

[System pressure] prompt: The pressure in the main pump of the hydraulic system is

above the set value.



·Check the constant pressure valve on the main valve for normal operation.

 If none of above occurs, please contact the nearest agent for help.

CAUTION: Once such alarm signal is displayed, stop immediately and check. Otherwise,

the system will rev down the engine to idle speed and record down time after 1 minute

automatically.

Please see the figure below:

Failure time

Low oil alarm

Min

Low coolant alarm

Min

High temperature alarm

Min

Clear record Options

Back

Level 2 alarms:

5.

[Voltage too low] prompt: It indicates that the battery voltage is below 22V. Then

you should try to start the engine once and judge the fault according to the response:

 If the engine can start and the alarm will disappear after the former has run for 10

minutes, then minor power loss occurs. You can troubleshoot the problem by running

the engine for an extended period of time. You can troubleshoot the problem by

running the engine for an extended period of time.

 If the engine can start but the alarm remains after the former has run for 10 minutes,

then you should check the generator for normal power generation and the battery for

damage.

 If the engine can not start, then serious battery power loss occurs or the battery has

been damaged and you should service or replace the battery.

6.

[Vol tage too high] prompt: It indicates that the battery voltage is above 32V. When

the engine is running properly, its working voltage should be 26V-31V. At this point, you

should measure the actual voltage of the battery.



·If the voltage is greater than 31.5V when the engine is running properly, then the

generator regulator is out of order and you should service or replace the generator.

7.

[Air cleaner dirty] prompt: It indicates that the air cleaner element is dirty. Then you

should clean up or replace the element.

8.

[Please refuel] prompt: It indicates that the actual fuel level in the fuel tank is less than

20%. Then you should check fuel level in the fuel tank and refuel in a timely manner.

9.

[Speed sensing] prompt: It indicates that no speed signal comes from the speed sensor

on the flywheel housing of the engine. Then you should check the engine speed sensor and

corresponding lines.

Other operations

After entering the main interface, you can press [OK] key to open System Setup and Log frame:

System Setup and Log options

01 Troubleshooting

02 Speed and Power

03 Time Setting

04 Failure Logging

05 System Help

Clear Record

Options

Back

After entering the main interface, you can press [OK] key to open System Setup and Log frame:

General settings include Troubleshooting, Time Setting, and System Help. Speed and Power

Settings, Working Hourmeter Setting, and Failure Logging are advanced settings which will not

be described here. (Only service personnel of or persons authorized by the company have access

to advanced settings.)

1. Troubleshooting

Press Page Up/Down key to move the black box in the figure up/down, and select “01”. Then

press [OK] key to open Troubleshooting frame.

Circuit Fault Display

Temperature Sensor Circuit

Fuel Sensor Circuit

Speed Sensor Circuit

Troubleshooting

Back

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