ZE215E Operation Manual [PDF]

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ZE215E Operation Manual for Hydraulic Excavator



2019-07



II



ZE215E Operation Manual



To users Dear users, thank you for choosing "Zoomlion" hydraulic excavator. Before using this machine, please read and fully understand the contents of this manual and strictly abide by the relevant provisions. This Operation Manual introduces the safety information, important technical parameters, safety operation, and other aspects of the hydraulic excavator in detail to help you operate the track excavator safely and give full play to the efficiency of the machine in the operation process. Please keep this Operation Manual properly for reference at any time. Do not attempt to operate or repair the product without carefully reading and understanding the contents of it. In case of any questions or doubts, please call the local service engineer who will provide you with timely and effective technical support. We will not be responsible for any adverse consequences caused by not following this Manual. As the operation manual is an integral part of the product, please be sure to transfer this manual to the transferee when transferring the machine. Its contents have been protected by intellectual property rights. Please do not copy or use it for other purposes without permission. Due to the continuous improvement and upgrading of product design and different product specifications and models, the details of some pictures and texts in this Manual may be different from the products you own. In case of any questions, please call the local service engineer. We reserve the right to revise the contents of the Operation Manual without prior notice due to technical improvement. Please kindly understand. Thank you very much for your trust and support of "Zoomlion" products. Wish you all the best!



I



ZE215E Operation Manual



Safety information description The safety warning icons involved in the Operation Manual are as follows:



Danger



An emergency hazard that will result in death or serious injury if not



Warning



A potentially hazardous situation that will result in death or serious injury if



Attention



A potentially hazardous situation that may result in mild or moderate harm



Caution



II



avoided. not avoided. if not avoided. A risk not related to personal injury (such as property damage).



ZE215E Operation Manual



Table of content Chapter I Safety Criteria for Excavator ....................................................................................................1-1 1.1 Safety nameplate ...............................................................................................................................1-1 1.1.1 Location of safety nameplate .........................................................................................................1-1 1.1.2 Safety nameplate ...........................................................................................................................1-2 1.2 Safety instruction ............................................................................................................................1-14 1.2.1 Basic safety requirements ............................................................................................................1-14 1.2.2 Safety of work area ......................................................................................................................1-14 1.2.3 Safety in operation .......................................................................................................................1-14 1.2.4 Safe operation after work .............................................................................................................1-14 1.2.5 Keep the machine clean ...............................................................................................................1-15 1.2.6 Keep the cab clean .......................................................................................................................1-15 1.2.7 Avoid scalding injury ...................................................................................................................1-15 1.2.8 Fireproofing and anti-explosion ...................................................................................................1-15 1.2.9 Actions in case of fire ...................................................................................................................1-18 1.2.10 Prevent falling or flying objects .................................................................................................1-19 1.2.11 Stay away from high voltage cable ............................................................................................1-19 1.2.12 Ensure good visibility ................................................................................................................1-20 1.2.13 Ventilation of enclosed areas ......................................................................................................1-20 1.2.14 Signalman's signals and gestures ...............................................................................................1-20 1.2.15 Prevention of asbestos dust hazard ............................................................................................1-20 1.2.16 Safety rules for hydraulic oil ......................................................................................................1-21 1.2.17 Safe operation of high-pressure hoses .......................................................................................1-21 1.3 Unauthorized modifications ............................................................................................................1-21 1.4 Safety tool .......................................................................................................................................1-21 1.4.1 Work clothes and protective equipment .......................................................................................1-21 1.4.2 Fire extinguisher ..........................................................................................................................1-22 1.4.3 Handrails and pedals ....................................................................................................................1-22 1.4.4 Cab emergency exit ......................................................................................................................1-23



Chapter II Excavator Overview ..................................................................................................................2-1 2.1 Product introduction ..........................................................................................................................2-1 2.1.1 Purpose of excavator ......................................................................................................................2-1 2.1.2 Direction of excavator ....................................................................................................................2-2 2.2 Excavator profile ...............................................................................................................................2-3 2.3 Main technical parameters of excavator ..........................................................................................2-4



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ZE215E Operation Manual



Chapter III Basic operating technology of excavator ................................................................................3-1 3.1 General drawing of excavator operating equipment .........................................................................3-1 3.2 Excavator instrument operation ........................................................................................................3-2 3.2.1 Instrument operation ......................................................................................................................3-2 3.2.2 Instrument operation and setting ....................................................................................................3-3 3.3 Basic operating instructions ............................................................................................................3-19 3.3.1 Basic inspection items ..................................................................................................................3-19 3.3.2 Emergency shutdown project .......................................................................................................3-21 3.3.3 Basic operation of the switch .......................................................................................................3-22 3.3.4 Instructions for operating device .................................................................................................3-26 3.4 Instructions for attachment in the cab .............................................................................................3-28 3.4.1 Ash pan .........................................................................................................................................3-28 3.4.2 Air conditioner .............................................................................................................................3-29 3.4.3 Car radio .......................................................................................................................................3-31 3.4.4 Antenna ........................................................................................................................................3-33 3.4.5 Window and lock .........................................................................................................................3-33 3.5 Power supply and fuse ....................................................................................................................3-37 3.5.1 Precautions for fuse ......................................................................................................................3-37 3.5.2 Fuse capacity, circuit name, and relay name ................................................................................3-38 3.5.3 Fuse link .......................................................................................................................................3-39 3.6 Controller ........................................................................................................................................3-39



Chapter IV Safety operation procedure and operation technique of excavator .....................................4-1 4.1 Adjustment before the operation .......................................................................................................4-1 4.1.1 Driver seat adjustment ...................................................................................................................4-1 4.1.2 Rearview mirror adjustment ..........................................................................................................4-1 4.1.3 Safety belt ......................................................................................................................................4-2 4.2 Engine operation ...............................................................................................................................4-3 4.2.1 Engine check before startup ...........................................................................................................4-3 4.2.2 Operation confirmation before starting the engine ........................................................................4-8 4.2.3 Engine start ....................................................................................................................................4-9 4.2.4 Operation after engine start .......................................................................................................... 4-11 4.2.5 New machine running-in ..............................................................................................................4-13 4.2.6 Engine shutdown ..........................................................................................................................4-13 4.3 Safety operation rules for excavators ..............................................................................................4-14 4.3.1 Traveling of excavator .................................................................................................................4-14 4.3.2 Steering of excavator ...................................................................................................................4-15 4.3.3 Control and operation of the operating device .............................................................................4-17 4.3.4 Operation under different working modes ...................................................................................4-21 II



ZE215E Operation Manual



4.3.5 Prohibitions ..................................................................................................................................4-21 4.4 Safety operation technologies .........................................................................................................4-23 4.4.1 Safety traveling ...........................................................................................................................4-23 4.4.2 Allowable water depth .................................................................................................................4-24 4.4.3 Traveling on slopes ......................................................................................................................4-24 4.4.4 Escape from the mud ...................................................................................................................4-25 4.4.5 Machine parking ..........................................................................................................................4-26 4.4.6 Operation under special weather conditions ................................................................................4-27 4.4.7 Tasks after completion of above operations .................................................................................4-29



Chapter V Accessories and Options ............................................................................................................5-1 5.1 General precautions ..........................................................................................................................5-1 5.1.1 Safety precautions ..........................................................................................................................5-1 5.1.2 Precautions in disassembly & installation operations ....................................................................5-1 5.1.3 Precautions in the installation of accessories .................................................................................5-2 5.2 Operation instructions for accessories and options ...........................................................................5-3 5.2.1 Combination of the operating device .............................................................................................5-3 5.2.2 Selection of track shoes .................................................................................................................5-4 5.3 Operation for the recommended options ...........................................................................................5-5 5.3.1 Hydraulic breaker ...........................................................................................................................5-5



Chapter VI Transport and Storage of Excavator ......................................................................................6-1 6.1 Transport ...........................................................................................................................................6-1 6.1.1 Loading and unloading ..................................................................................................................6-1 6.1.2 Hoisting the machine .....................................................................................................................6-4 6.2 Storage ..............................................................................................................................................6-5 6.2.1 Precautions before storage .............................................................................................................6-5 6.2.2 Precautions during storage .............................................................................................................6-5 6.2.3 Precautions after storage ................................................................................................................6-6



III



ZE215E Operation Manual for Hydraulic Excavator Chapter I Safety Criteria for Excavator



ZE215E Operation Manual



Safety Criteria for Excavator



Chapter I Safety Criteria for Excavator 1.1 Safety nameplate 1.1.1 Location of safety nameplate The machine uses the following warning signs and safety nameplates (as shown in Fig. 1-1, note: The numbers in the illustration correspond to that of in ( ) in section 1.1.2 "Safety nameplate" in the text, for instance: 1→(1)). It shall be noted that: be sure that nameplates are in the correct position and are always kept clean so that the contents are clearly read. Do not use organic solvents or gasoline to clean nameplates, otherwise, they will peel off. If the nameplate is damaged, lost or cannot be read properly, it shall be replaced by a new one in time. For details of the part number of the nameplate, please refer to this Operation Manual or the actual nameplate, and order it from Zoomlion or Zoomlion distributor.



3



4



2



1



6 8



9 11



12



27



7



21



10



5



22



23



24



25 26



20 19



13



18



28



17



14



30



16



29



15



Fig. 1-1 1. Pay attention to the operating device 2. The complete machine hoisting figure 3. Nameplate of precautions for handling cable 4. Nameplate of engine warning 5. Nameplate of centre-of-gravity position 6. Nameplate of prohibiting lifting with this device 7. Precautions for adjusting the tensioning of track 8. Nameplate of binding position 9. Nameplate of escape way 10. Warning nameplate before leaving the machine 11. Warning nameplate before standing up from the driver seat 12. Warnings about operating and moving machines 13. Operational precautions 14. Warning before operation 15. Precautions for operation, maintenance, inspection, and transportation 16. Regular maintenance checklist 17. A warning to leave the driver seat 18. High voltage warning 19. A warning of falling off 20. Nameplate of locking the engine hood 21. Short circuit engine start forbidden 22. Nameplate of air filter maintenance 23. A warning to leave the driver seat 24. Rotation shall be stopped during testing and adjusting 25. Nameplate of disconnecting power supply cathode switch 26. Instruction of emergency exit 27. A warning to close the window 28. Nameplate of precautions for high-temperature coolant and hydraulic oil 29. Precautions for using accumulator 30. Nameplate of turning area forbidden



1-1



ZE215E Operation Manual



1.1.2 Safety nameplate Safety Criteria for Excavator



(1) Pay attention to the operating device, as shown in Fig. 1-2.



Attention 1. This nameplate indicates the risk of collision with the operating device of the machine; 2. Please keep a safe distance from the operating device of the machine.



Fig. 1-2 (2) Nameplate of complete machine hoisting figure, as shown in Fig. 1-3.



GRP



Fig. 1-3



(3) Nameplate of precautions for handling cable, as shown in Fig. 1-4.



Attention 1. It indicates the risk of electric shock when handling the cable. 2. Please read the instruction carefully and operate safely and correctly. Fig. 1-4



1-2



ZE215E Operation Manual



(4) Nameplate of engine warning, as shown in Fig. 1-5.



Safety Criteria for Excavator



Warning 1. This nameplate indicates that there is a risk of high temperature and injury by the fan blades after the machine is started or just closed.



Fig. 1-5



(5) Nameplate of center-of-gravity position, as shown in Fig. 1-6.



Attention 1. This nameplate is pasted to the center-of-gravity of the machine.



Fig. 1-6



(6) Nameplate of prohibiting lifting with this device, as shown in Fig. 1-7.



Danger 1. It indicates that lifting with this device is prohibited.



Fig. 1-7



1-3



ZE215E Operation Manual



(7) Precautions for adjusting the tensioning of the track, as shown



Safety Criteria for Excavator



in Fig. 1-8.



Attention 1. It indicates that the screw plug may fly off the track tensioning device and there is a risk of injury. 2. Please read the Manual to adjust the track correctly and



Fig. 1-8



safely.



(8) Nameplate of bundling position, as shown in Fig. 1-9.



Attention 1. It indicates that the bundling device can be installed here for fixing the machine and maintaining good stability to prevent the machine from shaking in transport. Fig. 1-9



(9) Nameplate of escape way, as shown in Fig. 1-10.



Attention 1. Please follow the nameplate to escape to ensure personal safety.



Fig. 1-10



1-4



ZE215E Operation Manual



(10) Warning nameplate before leaving the machine, as shown in



! WARNING



Safety Criteria for Excavator



Fig. 1-11.



Make sure that the safety locking lever is locked before leaving the machine.



Fig. 1-11



(11) Warning nameplate before standing up from the driver seat, as shown in Fig. 1-12.



! WARNING When operator stand and leave the seat to open or close the upper front window or skylight, or fix or unfix the lower front window, make sure to keep the safe-locking bar in the locked position. Otherwise, a touch to any joystick will cause machine’s sudden motion and accidents maybe happen.



Fig. 1-12



1-5



ZE215E Operation Manual



(12) Warnings about operating and moving machines, as shown



Safety Criteria for Excavator



in Fig. 1-13.



! WARNING To avoid accident that caused by malfunction, the operator should make sure of current working situation and working modes when it is operating, when doing it, operator should carefully notice the surroundings and operate slowly.



ISO



Fig. 1-13



(13) Operational precautions, as shown in Fig. 1-14.



!



CAUTION



1.For safe operation, please refer to the instruction about the standard operation and daily maintenance. 2.Please select the working mode that matches the work, so as to carry out easier and more efficient operation. 3.Starting and stopping of operation must be in accordance to instructions, sufficient idle operation is necessary. 4.When raising one side of machine body with the upper and lower arms supporting the ground, don’t work under the machine body. 5.When the vehicle is inclined and parked, make sure the bucket end is located at the ground and the track shoe is secured. 6.Don’t install or disassemble the machine with lifting jack theory. 7.Don’t crash the machine body while operating the upper, lower arms and bucket; be especially careful when working near the cab.



Fig. 1-14



1-6



ZE215E Operation Manual



(14) Warning before the operation, as shown in Fig. 1-15.



Safety Criteria for Excavator



!



WARNING



To avoid accidents, please notice following before operating machine:  An acoistic warning to alert bystanders.  Make sure that nobody within and/or around machine or its swing radius.  If necessary, swing upper structure to gain a full view.  In a poor view zone, watchers are needed. For the following items, observe the travel warning and install the reflector



Fig. 1-15



(15) Precautions for operation, maintenance, inspection, and transportation, as shown in Fig. 1-16.



Attention 1. Read the Manual before the operation, maintenance, inspection, and transportation.



Fig. 1-16



1-7



ZE215E Operation Manual



(16) Regular maintenance checklist, as shown 1-17.



Safety Criteria for Excavator



25 19 20 21 22 23 24 26 27 28 29



Periodic maintenance and check table :Lubricate V :Check :Drain water and sediment :Change oil :Clean



:Replace filter core



☆ :Maintain when required



:Retighten, check and adjust



2 Engine



18



17 16 15 14 13 11 10 8 12 9



4 5



6 7



3



2



2



1



Maintenance period Inspection or maintenance area



First Each 100 day hours



1 Rotation bearing



∨



2 Operating device



○



3 Engine oil level



∨



Every 250 hours



First Every 500 500 hours hours



Every 1,000 hours



△



5 Travel speed reducer oil level



△



∨



6 Water and sediment in fuel tank



▲



7 Fuel level



∨



8 Hydraulic oil level



∨



9 Hydraulic oil



△



10 Return oil filter element of hydraulic tank



◎



◎



Suction oil filter element of hydraulic 11 tank



◎ (First) □



12 Air filter element for hydraulic tank



◎



◎



13 Engine oil and filter element



△◎



△◎



14 Turbocharger



∨□



15 Engine valve clearance



■



16 Engine fuel filter element



◎ ▲



◎ ◎ (Filter element)



18 Pilot filter element 19 Coolant level



◎ ∨



20 Air conditioner compressor belt



■



21 Battery condition



∨



22 Radiator fin



□



23 Air conditioner condenser



□



24 Starting motor



∨



25 Water pump



∨



26 Refrigerant level



☆



27 Air filter cleaner element 28 Air conditioner filter



◎ □



29 Swing/slewing reducer oil



△



Fig. 1-17 1-8



Every 4,000 Miscellaneous hours



○



4 Travel speed reducer oil



17 Oil-water separator



Every 2,000 hours



△



☆



ZE215E Operation Manual



(17) A warning to leave the driver seat, as shown in Fig. 1-18.



Safety Criteria for Excavator



Warning 1. It indicates the danger of being clamped or run over by the inactive machine due to its sudden movement; 2. Before leaving the machine, lower the operating device to the ground, turn the safety lever to the locked position, and remove the engine key.



Fig. 1-18



(18) High voltage warning, as shown in Fig. 1-19.



Warning 1. It indicates the risk of electric shock if the machine is too close to an electric wire. 2. Please keep a safe distance from the electric wire.



Fig. 1-19



1-9



ZE215E Operation Manual



(19) A warning of falling off, as shown in Fig. 1-20.



Safety Criteria for Excavator



Warning 1. It indicates that there is a danger of falling off; 2. Please keep a safe distance from the edge.



Fig. 1-20



(20) Nameplate of locking the engine hood, as shown in Fig. 1-21.



Attention 1. It indicates that after the engine hood is covered, please lift the handle to confirm that it is firmly locked. 2. Please read the operation manual and maintenance manual carefully, and follow the instructions.



Fig. 1-21



(21) Short circuit engine start forbidden, as shown in Fig. 1-22.



Danger 1. It indicates that the engine can only be started when you are in the driver seat; 2. Do not start the engine by short-circuiting the engine start circuit, which may cause serious personal injuries or fire.



1-10



Fig. 1-22



ZE215E Operation Manual



(22) Nameplate of air filter maintenance, as shown in Fig. 1-23.



Safety Criteria for Excavator



!



CAUTION



 Supplying oil into the air cleaner is strictly forbidden.  Clean the outer element core every 250 hours or when indicator lamp for blockage flashes.  Please replace the inner and outer element core simultaneously and don’t clean inner element core if warning of air cleaner element core, poor gas color, and powerless operation happen after the outer element core being cleaned.  Replace the inner and outer filter element cores if the outer element core has been cleaned 6 times or has been used for a full year.  If the element core is damaged or split with oil, replace it.  Replace and clean the element core according to the instructions.



Fig. 1-23 (23) A warning of falling off, as shown in Fig. 1-24.



Warning 1. It indicates that there is a danger of falling off; 2. Don't stand near this position.



STOP



Fig. 1-24



Fig. 1-25



(24) Rotation shall be stopped during testing and adjusting, as shown in Fig. 1-25.



Attention 1. It indicates there is a danger from rotating components, such as belts; 2. The machine can only be touched when all components of the machine are safely stopped.



1-11



ZE215E Operation Manual



(25) Nameplate of disconnecting power supply cathode switch,



Safety Criteria for Excavator



as shown in Fig. 1-26.



!



CAUTION



Attention 1. It indicates that if the machine is stored for a long time, please disconnect the cathode switch to prevent power loss of battery.



When the machine is not in use for a long time, please disconnect the negative switch.



Fig. 1-26



(26) Instruction of emergency exit, as shown in Fig. 1-27.



Attention



EMERGENCY EXIT Shatter the glass with sinker



Don’t cut yourself on the broken glass



1. It indicates that emergency hammer can be taken out under emergency situations to smash the rear window glass and escape, and pay attention not to be cut by the glass. Fig. 1-27



(27) A warning to close the window, as shown in Fig. 1-28.



Warning 1. It indicates that there is a risk of falling down for car windows; 2. Please insert the safety locking device after lifting the window,



Fig. 1-28 1-12



ZE215E Operation Manual



(28) Nameplate of precautions for scald prevention, as shown in



Safety Criteria for Excavator



Fig. 1-29.



Warning 1. It indicates that if the radiator or hydraulic tank cover is opened at high temperature, there is a risk of being scalded by hot water or hot oil. 2. The radiator or hydraulic tank shall be cooled before the cover is removed.



Fig. 1-29



(29) Precautions for using accumulator, as shown in Fig. 1-30.



Attention 1. It indicates the risk of explosion; 2. Do not drill, cut, hit or disassemble the accumulator



Fig. 1-30



and stay away from an open fire.



(30) Do not enter the rotating area, and please keep a safe distance from the rotating area of the machine, as shown in Fig. 1-31.



Attention 1. It indicates the danger of being squeezed by the superstructure of the machine;



Fig. 1-31



2. Please keep a safe distance from the rotating area of the machine.



1-13



ZE215E Operation Manual



1.2 Safety instruction Safety Criteria for Excavator



1.2.1 Basic safety requirements The driver shall obtain the required driving license or training certificate according to the laws and regulations of the place where the user is located, and only the trained and instructed personnel can operate the machine. All safety rules, precautions, and method of operation shall be observed when operating the machine. If the operator is affected by alcohol or drugs, its ability to safely operate or repair the machine will be seriously reduced to put oneself and others present in danger. When working with other operators or site traffic controllers, be sure that everyone understands the exact meaning of all hand signals used.



1.2.2 Safety of work area Check the work area thoroughly for abnormalities before starting operation (Fig. 1-32). There is a risk of fire when operating near combustible materials such as thatch roofs, dry leaves or hay, and attention shall be paid during operation. Inspect the topography and condition of the worksite and determine the safest method of operation. Do not operate in an area where there is a danger of landslide or falling rocks. Mark the locations of water pipes, air pipes or high-voltage electric wires buried under the worksite, if any, and contact the utility companies. Be careful not to break or damage any pipelines. Take necessary measures to prevent any unauthorized personnel from entering the work area. Check the depth and velocity of the water, and ground condition



Fig. 1-32



prior to operation when walking or operating in shallow water or on soft ground.



1.2.3 Safety in operation If any abnormality (noise, vibration, smell, smoke, oil leakage, or any abnormal indication of warning devices and instruments, etc.) is found during the operation process, it shall be reported to the supervisor and necessary measures shall be taken. Do not operate the machine before troubleshooting.



1.2.4 Safe operation after work a) Before the operator stands up from the seat (such as to open or close the window, remove or install the bottom window, or adjust the seat), the operating device shall be completely lowered to the ground, the joystick shall be locked, and then the engine shall be shut down; b) When leaving the machine, be sure to lower the operating device completely to the ground, lock the joystick and then shut down the engine. Lock all devices with the key, pull out the key and place it in the specified position, as shown in Fig. 1-33. Fig. 1-33



1-14



ZE215E Operation Manual



1.2.5 Keep the machine clean Safety Criteria for Excavator



a) If the electrical system is flooded, there is a risk of failure or malfunction. Do not flush electrical systems (sensors, connectors, etc.) with water or steam, as shown in Fig. 1-34; b) If the machine is inspected and maintained with mud or grease, there is a risk of slipping and falling or dirt getting in the eyes. Therefore, the machine shall be always kept clean.



1.2.6 Keep the cab clean a) Mud and oil shall be removed from the shoe soles when entering the cab. If you operate the pedal with mud or oil on the sole, your foot will slip, which may cause serious



Fig. 1-34



accidents. b) Do not leave parts or tools around the cab; c) Do not stick the sucking pad to the window glass. The sucking pad acts as a magnifying glass and many cause fire; d) Do not use a mobile phone in the cab while driving or operating the machine; e) Do not bring dangerous goods such as inflammable and explosive ones into the cab.



1.2.7 Avoid scalding injury 1.2.7.1 Hot coolant Do not operate until the water is cool enough to be able to touch the radiator cover by hand to prevent scalding by hot water or steam when checking or discharging the coolant. Slowly loosen the radiator cover to drain the internal pressure before removing it even if the coolant has been cooled.



1.2.7.2 Hot oil Do not operate until the oil is cool enough to be able to touch the cover or screw plug by hand to prevent scalding by the ejected oil or by touching hot parts when inspecting or draining the oil. Slowly loosen the radiator cover or the screw plug to drain the internal pressure before removing it even if the oil has been cooled.



1.2.8 Fireproofing and anti-explosion 1.2.8.1 Prevention of fire caused by fuel oil or engine oil Fuel oil, engine oil, anti-freezing solution, and window cleaning fluid are flammable and dangerous. To prevent fire, be sure to follow the following rules: a) Do not smoke or use any open flame near fuel oil or engine oil (as shown in Fig. 1-35). b) Turn off the engine before refuelling. c) Do not leave the machine when filling with fuel oil and engine oil; d) Tighten the fuel oil and oil tank cover firmly; e) Do not allow fuel oil to spill onto overheating surfaces or components of electrical systems; f) Refuel or store oil in a well-ventilated place. g) Keep the engine oil or fuel oil in a designated place, and no one shall enter without permission; h) Wipe off the overflowing oil after adding fuel oil or engine oil;



Fig. 1-35



i) Move all inflammable materials to a safe place before 1-15



ZE215E Operation Manual



polishing or welding work on the lower body starts.



Safety Criteria for Excavator



j) Adopt non-flammable engine oil to flush components. Do not adopt diesel and gasoline as they catch fire easily. Put the oily cloth or other inflammable materials into a safe container to ensure the safety of the workplace; k) Do not weld or cut piping containing inflammable liquids.



1.2.8.2 Prevention of fire caused by the accumulation of inflammable materials Remove dry blades, wood chips, scraps of paper, dust, and other inflammable that have accumulated or stuck around engines, exhaust pipes, mufflers, batteries or inside the hood.



1.2.8.3 Prevention of fire caused by electric wires Short circuit of the electrical system may cause fire, so: a) Keep electric wire connections clean and secure; b) Check for loose or damaged wires every day, tighten loose joints or electric wire clamps, and repair or replace damaged wires.



1.2.8.4 Prevention of fire caused by hydraulic piping Check whether all clamps of hoses and tubing, shields, and cushions are securely secured. If they are loose, hoses may be damaged and high-pressure oil may be ejected due to the friction with other components caused by vibration in the operation process, which might cause fire or serious injury.



1.2.8.5 Prevention of the explosion caused by lighting equipment Explosion-proof lighting equipment shall be used to check fuel oil, engine oil, battery electrolyte, window cleaning liquid or coolant, otherwise, there may be a risk of serious injury from the explosion. Follow the instructions in this manual when using the power source of the machine for lighting.



1.2.8.6 Accumulator 1.2.8.6.1 Precautions for accumulator operation The accumulator is charged with high-pressure nitrogen. Careless handling may cause an explosion and serious injury when operating the accumulator. Therefore, be sure to follow the following precautions (as shown in Fig.  1-36): a) Do not disassemble the accumulator; b) Do not keep the accumulator near the fire or expose it to the flame; c) Do not punch, weld or gas-cut the accumulator;



Fig. 1-36



d) Do not bump or roll the accumulator or subject it to any impact; e) Air must be vented when handling the accumulator.



1.2.8.6.2 Pressure relief steps for control piping of a machine equipped with an accumulator Lower the operating device to the ground and turn off the hydraulic hammer or other accessories. Turn off the engine.



1-16



ZE215E Operation Manual



Turn the key that activates the switch to the ON position again. to control the pedal to release pressure in the control pipelines. Adjust the safety lock joystick to the locked position.



1.2.8.7 Battery 1.2.8.7.1 Installation and removal of the battery The following rules shall be observed during installation and removal of battery wiring harness: a) Determine the positive (+) terminal and the negative (-) terminal during installation or disassembly; b) The dirt around the terminal is caused by the self-discharge of the battery. Therefore, adopt the sandpaper to polish the terminal to remove dirt and apply a thin coat of lubricating oil in the terminal before installing the wiring harness; c) Do not contact tools or other metal objects between the battery terminals; d) The positive terminal (+) shall be firstly installed, and the terminal on the grounding side shall be connected finally during wiring harness installation, as shown in Fig. 1-37(a). Check whether the wire harness is loose after it is installed, if it is, a re-installation shall be conducted. e) The wiring harness shall be disassembled in an order opposite to that of the installation, namely, the terminal on the grounding side (negative (-)) shall be disassembled first, as shown in Fig. 1-37(b). The battery is firmly fixed on the upper frame with the pressing plate during battery installation, and the tightening torque of the fixing bolt is 9 - 11N•m.



(a)



(b) Fig. 1-37



1.2.8.7.2 Battery charging When the battery is charged, there is a danger of the battery explosion if it is operated incorrectly (as shown in Fig. 1-38). Therefore, follow the instructions in "common malfunctions and troubleshooting" and the provided charger instruction manual, and follow the following precautions: a) Set the voltage of the charger to match that of the charging battery. If the voltage is chosen incorrectly, the charger will overheat and cause an explosion. b) Connect the positive (+) clamp of the charger to the positive (+)



Fig. 1-38



terminal of the battery. Then, connect the negative (-) clamp of the



1-17



Safety Criteria for Excavator



Set the safety locking joystick to the open position and then operate the full stroke operating device lever and accessories



ZE215E Operation Manual



charger to the negative (-) terminal of the battery. Be sure to fix the clamp firmly, as shown in Fig. 1-40;



Safety Criteria for Excavator



c) Adjust the charging current to 1/10 of the rated battery capacity (the rated capacity of the battery used in this model is 120AH). The recharging current shall be adjusted to be lower than the rated battery capacity during fast charging. If the recharging current is too high, the electrolyte will leak out or evaporate completely, which may cause fire and explosion of the battery. d) Do not charge the battery or start the engine with a different source if the battery electrolyte freezes, because there may be a danger of igniting the battery electrolyte and causing the explosion of the battery.



1.2.8.7.3 Prevent the danger from the battery The battery electrolyte contains sulfuric acid, which produces inflammable and explosive hydrogen, and improper handling may lead to serious injury or fire. Therefore, the following precautions shall be followed (as shown in Fig. 1-39): a) Wear safety glasses and rubber gloves when operating the battery; b) Do not smoke or use open fire in the vicinity of the battery; c) Rinse your clothes or skin immediately with plenty of water when splashed with the sulfuric acid; d) Flush the eyes immediately with plenty of water and seek immediate medical attention if the sulfuric acid enters the eyes. e) Turn the start key switch to the OFF position before operating the battery.



Fig.1-39



Fig.1-40



Due to the risk of sparks, the following steps shall be followed (as shown in Fig. 1-40): a) Do not contact tools or other metal objects in the battery terminals, and do not put tools or other metal objects near the battery; b) As it will produce inflammable hydrogen when charging the battery, the battery shall be removed from the car to be put in a well-ventilated place with the battery cover being removed before charging; c) Firmly tighten the battery cover after charging.



1.2.9 Actions in case of fire Leave the machine quickly as follows in case of fire:



1-18



ZE215E Operation Manual



Turn the start switch to OFF to shut down the engine.



Safety Criteria for Excavator



Use handrails and stairs to leave the machine.



1.2.10 Prevent falling or flying objects In hazardous worksites where falling and flying objects may hit or enter the cab, operational conditions shall be taken into account and the necessary protective covers shall be installed to protect the operator (as shown in Fig. 1-41). Install the front shield and stick transparent cellophane on the front glass during removing or breaking operation. When working in mines or quarries where there is a risk of rockfall, FOPS (falling object protective device) and front shields shall be installed, and transparent cellophane shall be affixed to the front glass. The front window shall be closed when performing the above operation. In addition, be sure that other personnel are out of the danger zone, and maintain an appropriate safe distance.



Fig. 1-41



What is described above is used for typical working conditions, additional shields may be required depending on the site's operation conditions. Please contact Zoomlion or Zoomlion distributors in advance.



1.2.11 Stay away from high voltage cable Do not walk near the cable or operate the machine since there may be a risk of electric shock, serious injury or accident (as shown in Fig. 1-42). The following requirements shall be observed in the working area which may be close to the cable: a) Inform the local power company of the operation to be carried out and ask them to take necessary measures before starting work near the cable; b) Even if you don't go near a high voltage cable, you may get electric shocks that can cause severe burns and even death. Keep a safe distance between the machine and the cable



Fig. 1-42



(refer to table 1-1). Check with the local power company on safety practices prior to commencement of operation; c) Wear rubber shoes and rubber gloves to prepare for possible accidents. Put a rubber mat on the seat and make sure that the exposed part of the body does not touch the car body. d) If the machine is too close to the cable, a signalman shall be assigned to give warning; e) Do not allow anyone to stay near the machine when working near high voltage cable; f) If the machine is too close to or touches the cable, the operator shall not leave the cab until the cable is cut to prevent electric shocks.



1-19



ZE215E Operation Manual



Safety Criteria for Excavator



Table 1-1 Minimum safe distance between high- and low-pressure High voltage



High voltage



Minimum safe distance



Classification



V



m



100, 200



2



6,600



2



22,000



3



66,000



4



154,000



5



187,000



6



275,000



7



500,000



11



Low voltage



Extra-high voltage



1.2.12 Ensure good visibility Check the area around the machine for personnel or obstacles, and the conditions of the worksite to ensure safe operation or walking, as follows: Turn on the work light and headlight installed on the machine and set auxiliary lighting in the working area if necessary when working in a dark place. Stop operation in case of poor vision, such as fog, snow, rain or dust.



1.2.13 Ventilation of enclosed areas If the engine must be started in a closed area, or in the process of fuel handling, and oil or paint cleaning, doors and windows shall be opened to ensure ventilation to prevent gas poisoning.



1.2.14 Signalman's signals and gestures Place a sign on the road shoulder or loose ground, and assign a signalman if necessary in case of poor vision. The operator shall pay special attention to signs and follow the instructions of the signalman. Only one signalman can give the signal. Make sure all workers are aware of all signals and gestures before starting work.



1.2.15 Prevention of asbestos dust hazard Asbestos dust may cause lung disease if inhaled. There is a risk of asbestos inhalation when demolition operation or disposal of industrial waste are carried out in the workplace (as shown in Fig. 1-43). Therefore, the following rules must be observed: Water shall be sprayed during cleaning, and do not clean with compressed air. If there may be asbestos dust in the air, be sure to operate the



Fig. 1-43



machine in a high position and all personnel shall use qualified dust filter masks. No one is allowed to approach during the operation process. Workplace regulations, rules, and environmental standards shall be observed. This machine does not use asbestos, but counterfeit parts may contain asbestos, so be sure to use genuine Zoomlion parts and components. 1-20



ZE215E Operation Manual



1.2.16 Safety rules for hydraulic oil Safety Criteria for Excavator



There is always pressure inside the hydraulic system. Be sure to check that the pressure in the hydraulic oil line has been released when checking or replacing a pipeline or hose. If the oil circuit is still under pressure, serious injury or damage may be caused, so the following instructions shall be followed. Do not check or change work when there is pressure in the hydraulic system. If there is any leakage of the pipeline or hose and the surrounding area is wet, check the pipeline or hose for rupture and expansion. Goggles and leather gloves shall be worn during the examination (as



Fig. 1-44



shown in Fig. 1-44). High-pressure oil leaking through small holes can penetrate the skin, and there is a risk of blindness if it comes into direct contact with the eyes. Rinse the skin or eyes with plenty of clean water and seek immediate medical attention if it is injured by a high-pressure flow of oil.



1.2.17 Safe operation of high-pressure hoses The high-pressure hose leakage or penetration may cause fire or operation failure, which may lead to serious injury or damage. If the bolts are found to be loose, the operation shall be stopped and the bolts shall be tightened to the specified torque. If any damage is found to the hose, stop the operation immediately and contact Zoomlion or Zoomlion distributor. The hose shall be replaced in case of any following problems. a) Hydraulic pipe joint damaged or leaked; b) The outer layer is worn or broken, or the steel wire of the reinforcing layer exposed; c) Part of the outer layer swollen; d) Movable parts distorted or crushed; e) Impurities existed in the outer layer.



1.3 Unauthorized modifications Any modifications without Zoomlion's permission may be dangerous. Contact Zoomlion before modification. Zoomlion will not be liable for any injuries, accidents or product failures caused by modifications without Zoomlion's permission.



1.4 Safety tool 1.4.1 Work clothes and protective equipment a) Avoid loose clothing and accessories, as they may hook on the joystick or other protruding components; b) If the hair is too long and reaches out the helmet, there is a danger of getting tangled in the machine. Therefore, tie your hair up, and be careful not to let it get tangled in the machine; c) Always wear a helmet and safety shoes (as shown in Fig. 1-45). Wear safety glasses, face mask, gloves, earplugs, and safety belts if necessary when operating or maintaining the machine; d) All protective devices shall be checked before use.



Fig. 1-45



1-21



ZE215E Operation Manual



1.4.2 Fire extinguisher Safety Criteria for Excavator



In case of injury or fire, the following precautions shall be observed (as shown in Fig. 1-46) : a) Make sure you have a fire extinguisher and read the label to ensure that you know how to use it under emergency situations: b) Periodic inspection and maintenance shall be carried out to ensure that the fire extinguisher can be used at any time; c) Please record the emergency contact number of the operator. Fig. 1-46



1.4.3 Handrails and pedals The following requirements shall be followed to prevent personal injury caused by slipping or falling from the machine: a) Supporting parts like stairs, steps, and track shoes marked with arrows as shown in Fig. 1-48 shall be used when getting on and off the machine; b) In order to ensure safety, face the machine and keep three points (two feet and one hand or two hands and one foot) in contact with the handrail and pedal (including track shoe) to ensure self-support, as shown in Fig. 1-47; c) Do not grasp the joystick when getting on and off the machine;



Fig. 1-47



d) Do not climb on an engine hood or cover without skid pads; e) Check handrails and pedals (including track shoe) before getting on and off the machine. Oil, lubricating grease or mud on the handrails or pedals (including the track shoe) shall be wiped off immediately, if any, to keep these components clean. They shall be repaired in case of any damage, and the loose bolts shall be tightened; f) Do not get on and off the machine with the tools in your hand.



Fig. 1-48



1-22



ZE215E Operation Manual



1.4.4 Cab emergency exit be broken as an emergency exit. Follow these steps to escape (as shown in Fig. 1-49):



Safety Criteria for Excavator



If the cab door cannot be opened for some reason, the rear window can



1



a) Break the rear window glass with the escape hammer hanging in the right rear upper part of the cab (1); b) Climb out from the back window. Fig. 1-49



Attention 1. Do not break the rear window glass unless it is used as an emergency exit. Contact Zoomlion or Zoomlion distributor as soon as possible to replace the broken glass after breaking the glass.



1-23



ZE215E Operation Manual for Hydraulic Excavator Chapter II Excavator Overview



ZE215E Operation Manual



Chapter II Excavator Overview 2.1 Product introduction Zoomlion hydraulic excavators are mainly used for digging, levelling, ditching, loading, and dismantling operations.



2.1.1 Purpose of excavator a) Excavation operation The backhoe is suitable for excavation below the machine. the bucket cylinder and rocker, arm cylinder and arm are 90°, the maximum digging force of each cylinder can be obtained.



Excavator Overview



When the machine is in the state as shown in Fig. 2-1, i.e., when



90° 90°



Effective use of this angle during excavation can optimize work efficiency. The excavation range of the arm is 45° away from the machine to 30° towards the machine. It may vary depending on the depth of the excavation, but try to operate within the above range, and do not operate the cylinder to the end of its stroke.



30°



45°



Fig. 2-1



b) Ditching operation The ditching operation can be carried out effectively by installing a bucket matching the width of the ditch, and then adjusting the track to a position parallel to the excavated ditch, as shown in Fig. 2-2. First, dig out the two sides, and finally dig out the central part during ditching. Fig. 2-2



c) Loading operation In a place where the rotation angle is small, it is more efficient to park the dump truck where the operator can easily see it. If loading from the rear of the dump truck is more convenient and the loading capacity is larger than that from the side, the loading operation is shown in Fig. 2-3. In addition to the above purposes, the scope of use can be further increased by using various accessories and options.



Fig. 2-3



2-1



ZE215E Operation Manual



2.1.2 Direction of excavator The front, rear, left and right directions mentioned in this Manual (as shown in Fig. 2-4) refer to the directions seen by the driver in the seat when facing forward and the drive wheels are behind the machine.



Front



Excavator Overview



Operator’s seat



Left



Right



Sprocket



Rear



Fig. 2-4



2-2



ZE215E Operation Manual



2.2 Excavator profile The ZE215E hydraulic excavator introduced in this Manual has the same shape, as shown in Fig. 2-5.



6



7



5



8



4



9



10 11



2 12 13 14 1 Fig. 2-5 1. Bucket



2. Bucket cylinder



3. Arm



4. Arm cylinder



5. Boom



6. Boom cylinder



7. Hood



8. Counterweight



9. Upper frame



10. Traveling motor



11. Track shoe



12. Track frame



13. Idler



14. Cab



2-3



Excavator Overview



3



ZE215E Operation Manual



2.3 Main technical parameters of excavator Table 2-1 Main technical parameters Components Bucket



Excavator Overview



Engine



Item



Unit



ZE215E



m3



1.0



Model



-



6BTAA5.9-C(150hp)



Type



-



6-cylinder, 4-stroke water-cooling, turbocharged & intercooled



Rated power



kW/rpm



112/1950



Maximum torque



N·m/rpm



614/1500



Displacement



ml



5883



Starting motor



V



24



Amp



70



-



Awry plate type variable double-piston pump



L/min



2×206



pilot pump



-



Gear pump



Traveling motor



-



Double speed awry plate type plunger motor with automatic brake valve and parking brake



Rotation motor



-



Awry plate type plunger motor with automatic braking



MPa



34.3(37.3 in case of turbocharging)



Traveling hydraulic circuit



MPa



34.3



Rotation hydraulic loop



MPa



26



Pilot hydraulic circuit



MPa



3.9



mm



2-120×1315×85



mm



1-135×1540×95



mm



1-120×1120×85



Rotation motor



-



Awry plate type plunger motor



Reducing mechanism



-



Secondary planetary reducer



Slewing speed



rpm



11.5



Slewing braking



-



Wet-type multiple disc brake



Capacity



Generator Main pump type Maximum flow rate Hydraulic system



Operating device hydraulic circuit System pressure



Hydraulic oil Boom cylinder cylinder Number of Arm cylinder cylinderscylinder diameter × stroke × piston Bucket cylinder rod diameter



Rotary system



2-4



ZE215E Operation Manual



Table 2-1 (continued) Components



Item



ZE215E



Traveling motor



-



Awry plate type plunger motor



Reducing mechanism



-



Planetary reducer



Steering control



-



Operating rod with pedal



-



Wet-type multiple disc brake



kN



192



-



35°(70%)



km/h



5.3/3.1



Track frame



-



Box structure



Track pitch



Section/each side



46



Track roller



No. /each side



7



Carrier roller



No. /each side



2



Rail clamping device



No. /each side



1



Fuel tank (filling up)



L



350



Coolant (standard position)



L



30



Engine oil (standard position)



L



26



Rotation device (standard position)



L



3.4



Traveling device (standard position)



L



2×5.5



Hydraulic system (standard position)



L



300



Hydraulic tank (standard position)



L



180



kg



21300



Running system Parking brake Maximum traction Grade ability Traveling speed (high/low)



Underpan



Oil level capacity



Working weight Standard configuration



Excavator Overview



Unit



2-5



ZE215E Operation Manual



Table 2-2 Main dimension parameters (as shown in Fig. 2-6) ZE215E Item



Standard arm 2.925m



Short arm 2.4m



A (Total length)



mm



9555



9630



B (Total width)



mm



2800



2800



C Total height (to boom top)



mm



3085



3300



D (Tail rotation radius)



mm



2840



2840



E (Tail length)



mm



2800



2800



F (Height of counterweight above ground)



mm



1050



1050



G (Minimum ground clearance)



mm



440



440



H (Track ground length)



mm



3380



3380



J (Track length)



mm



4180



4180



K (Gauge)



mm



2200



2200



L (Track shoe width)



mm



600



600



M (track gear height)



mm



26



26



N total height (cab top)



mm



2990



2990



P (Upper frame width)



mm



2720



2720



A



D(E)



C F H J



P



N G



Excavator Overview



Unit



K B



Fig. 2-6 2-6



L



M



ZE215E Operation Manual



Table 2-3 Scope of work and digging force (as shown in Fig. 2-7) ZE215E Item



Standard arm 2.925m



Short arm 2.4m



A (Maximum digging distance)



mm



9830



9340



B (Maximum ground digging distance)



mm



9650



9165



C (Maximum digging depth)



mm



6610



6085



D (Maximum vertical digging depth)



mm



5580



5010



E (Maximum digging height)



mm



9615



9365



F (Maximum dumping height)



mm



6785



6525



G (Minimum swing radius)



mm



3290



3385



Maximum digging force of bucket



kN



157



158



Maximum digging force of arm



kN



110



142



Excavator Overview



Unit



A B G



E F



C D



Fig. 2-7



2-7



ZE215E Operation Manual for Hydraulic Excavator Chapter III Basic operating technology of excavator



ZE215E Operation Manual



Chapter III Basic operating technology of excavator 3.1 General drawing of excavator operating equipment The operating device of Zoomlion ZE215E hydraulic excavator is shown in Fig. 3-1.



1 2 3



16



9



4 5 6 15



7



10 11 Basic Operating Technology of Excavator



8



14



12 17



13 Fig. 3-1



1. Machine instrument



2. Powerful digging switch



5. Throttle control knob



6. Working light switch



3. Cigarette lighter



4. Start switch



7. Wiper switch



8. Window washer switch



9. Right side operating device lever



10. Travel lever



11. Left side operating device lever



12. Safety lock control



13. Traveling pedal



14. Air-conditioning control panel



15. Radio



16. Horn switch



17. Headlight switch



3-1



ZE215E Operation Manual



3.2 Excavator instrument operation 3.2.1 Instrument operation 1



2



00000.0h



3



4



5



6 1



AUTO



7 P



8



11:46:23



2019-06-12



9 20 10 19



18



Basic Operating Technology of Excavator



11 17



AUTO



16



15



14



13



12



Fig. 3-2



3-2



1. Working hourmeter



2. High/low-speed icon



3. Automatic idle icon



4. Safety belt icon



5. Buzzer icon



6. Gear



7. Operating mode



8. Time and date display area



9. Preheating icon



10. Boom icon



11. Cooling thermometer



12. Buzzer mute button



12. Buzzer mute button



13. Menu key



14. Automatic idle button



15. High and low speed switch button



16. Operating mode switch button



17. Hydraulic oil temperature



18. Amount of fuel



19. Bucket icon



20. Pilot icon



ZE215E Operation Manual



3.2.2 Instrument operation and setting 3.2.2.1 Normal startup and shutdown of instrument a) Instrument startup: Turn the key switch to the ON position to make the meter start initializing into the standard working interface, as shown in Fig. 3-3;



00000.0h



1



AUTO



P



11:46:23



2019-06-12



ZOOMLION



Fig. 3-3 b) Instrument shutdown: Turn the key switch to the OFF position to turn the meter to the OFF position, the instrument is in a blank screen due to outage, as shown in Fig. 3-4.



00000.0h



1



AUTO



P



11:46:23



2019-06-12



Power off ... Thanks for using Zoomlion device The system shutdown is in progress



AUTO



Fig. 3-4



3-3



Basic Operating Technology of Excavator



AUTO



ZE215E Operation Manual



3.2.2.2 Selection of working mode The customer can choose the suitable working mode based on the machine construction condition. There are five working modes: P, E, L, B1, and B2, and the default mode is E after power-up. P is the high-power quick digging mode, E is the standard economic working mode, L is the light digging and fine levelling operation mode, B1 is the attachment mode such as the hydraulic hammer, B2 is the attachment mode such as hydraulic shear (when no accessories are installed, no B mode is displayed). Press MODE button to switch working mode in a cycle. The interface of instrument switching is shown in Fig. 3-5.



00000.0h



1 B1



AUTO



00000.0h



11:46:23



2019-06-12



E Basic Operating Technology of Excavator



AUTO



1 P



AUTO



00000.0h



11:46:23



2019-06-12



11:46:23



L



AUTO



00000.0h



1 E



AUTO



2019-06-12



B1



1 L



AUTO



11:46:23



2019-06-12



P



AUTO



AUTO



Fig. 3-5



3.2.2.3 Selection of high and low speed running When it needs to switch between high and low speed running, press the



button on the instrument panel. Hi



means high speed and Lo means low speed, and the system is running at a low speed by default. When switching between high and low speed, the corresponding mode icon will be displayed on the LCD screen, and it will return to the standard operating interface after 2 seconds, as shown in Fig. 3-6.



3-4



ZE215E Operation Manual



00000.0h



1 P



AUTO



00000.0h



11:46:23



2019-06-12



1 P



AUTO



11:46:23



2019-06-12



Hi



L0



AUTO



AUTO



Fig. 3-6



Basic Operating Technology of Excavator



3.2.2.4 Pilot safety switch Lift the safety handle and the LCD screen displays the unlock status when operating, as shown in Fig. 3-7. When the construction work is finished, put down the safety handle, and the LCD screen displays a locked status, as shown in Fig. 3-8. 00000.0h



1



AUTO



P



11:46:23



2019-06-12



AUTO



Fig. 3-7



00000.0h



1



AUTO



P



11:46:23



2019-06-12



AUTO



Fig. 3-8



3.2.2.5 On and off of automatic idle function AUTO



Press



n/min



to turn on or off auto idle function. When the excavator is working normally, the gear is more than 7 gear,



and the excavator remains inactive, the gear shall be lowered to 1 gear after 2 seconds, and then to 1400rpm after 3 seconds, and then to gear 1 speed after 60 seconds. It is inactive in gear 4-7, 3 seconds later, it shall be reduced to 1400rpm, and 60 seconds later, it shall be reduced to the gear 1 rotational speed. When the excavator is active, the control system will increase the engine speed to the original speed within 1 second. It is allowed to select automatic idle permissible or automatic idle cancelled by botton for the automatic idle function. The interface is shown in Fig. 3-9 and 3-10.



3-5



ZE215E Operation Manual



00000.0h



1



AUTO n/min



00000.0h



P



P



11:46:23



2019-06-12



11:46:23



2019-06-12



1



AUTO n/min



AUTO



AUTO



Fig. 3-9



Fig. 3-10



Basic Operating Technology of Excavator



3.2.2.6 Powerful digging switch Only when the system power mode is in P and E, and the engine speed is above gear 6, the system can perform turbocharged function. The system will automatically raise the engine speed to the set speed when the button switch on the right handle is pressed, and the system digging force is increased to the maximum and lasts for 8 seconds, then the function will be turned off. Moreover, after each execution of this function, the second one can only be carried out at an interval of more than 3 seconds. If the current power mode is running in mode B, the system will automatically change the switch into the operating switch of the hydraulic hammer or other accessories. The powerful digging swtich button and interface are shown in Fig. 3-11. 00000.0h



1



1 P



AUTO



11:46:23



2019-06-12



AUTO



Fig. 3-11



3.2.2.7 Help/sound attenuation cancelling When the system alarm is ringing, the sound will be attenuated when the corresponding button is pressed, otherwise, it will go to view "help" information.



3-6



ZE215E Operation Manual



3.2.2.8 Time/alarm content prompt When there is no alarm state in the system, the current time will be displayed in this area. When there is an alarm signal in the system, the red alarm icon and text prompt will be displayed in the center of the screen. In case of failure, the interface is shown in Fig. 3-13. In case of no failure, it is shown in Fig. 3-14. Alarm icons for each parameter are shown in Fig. 3-15. 00000.0h



1 P



AUTO



00000.0h



11:46:23



2019-06-12



1



AUTO



P



11:46:23



2019-06-12



Basic Operating Technology of Excavator



Air filter is blocked, please check. AUTO



AUTO



Fig. 3-13



Fig. 3-14



Coolant temperature too high



Hydraulic oil temperature too high Oil return fiter core blocked



Coolant level too low



Charging abnormal



Maintenance prompt



Fuel level too low



Engine oil pressure too low



Pilot filter core blocked



Air filter core blocked



Preheating



Abnormal communication with controller Fig. 3-15



3.2.2.9 Staged hourmeter setting Press the menu button to enter the main interface to select the user interface, as shown in Fig. 3-16. Move through the arrow icon to enter the user setting, and select the staged hourmeter setting, as shown in Fig. 3-17 and 3-18, selecting for the staged timing work. Display the staged hourmeter. You can choose to display the working hourmeter or staged hourmeter on the main interface, as shown in Fig. 3-19.



3-7



ZE215E Operation Manual



00000.0h



1



AUTO



P



11:46:23



2019-06-12



1 P



00000.0h 2019-06-12



11:46:23



Work Interface



Work Info.



Video Set.



User Menu. Service Menu.



System Set. Display Set. AUTO



Fig. 3-16



00000.0h 2019-06-12



1 P 11:46:23



00000.0h 2019-06-12



Basic Operating Technology of Excavator



User Menu.



User Settings



Enable Selection



Language settings



Information Inquiry



Clock settings



User Settings



1 P 11:46:23



Brightness settings Throttle settings Sensor settings Time of returning to home page without operation Stage hour metering User Telephone Number settings



Fig.3-17



00000.0h 2019-06-12



Fig.3-18



1 P 11:46:23



00000.0h 2019-06-12



1 P 11:46:23



Stage hour metering



Stage hour metering



Display Stage Hourmeter Use Stage Hourmeter



Display Stage Hourmeter Default Display Power Hourmeter Default Display Stage Hourmeter Use Stage Hourmeter



Fig. 3-19



3-8



ZE215E Operation Manual



3.2.2.10 Language selection Press the menu button to enter the user interface, as shown in Fig. 3-16. Move the arrow icon to enter user settings as shown in Fig. 3-17 and 3-18. After entering the language setting, select the language through the Left & Right arrow keys, and press



1 P



00000.0h 2019-06-12



AUTO



11:46:23



key to confirm, the interface as shown in Fig. 3-20.



00000.0h 2019-06-12



Time setting



Language Setting



Chinese / Chinese English / English Français / French Pусский / Russian Español / Spanish



1 P 11:46:23



Date: 2019-06-12



Time 06:30



Português / Portuguese



Deutsch / German Italiano / Italian Türkçe / Turkish



Basic Operating Technology of Excavator



Fig. 3-20



Fig. 3-21



3.2.2.11 Clock adjustment Press the menu button to enter the user interface, as shown in Fig. 3-16. Move the arrow icon to enter user settings, as shown in Fig. 3-17 and 3-18. After entering the clock setting interface, enter the exact time through the Left & Right arrow keys, and press



to confirm, the interface as shown in Fig. 3-21.



3.2.2.12 Brightness control Press the menu button to enter the user interface, as shown in Fig. 3-16. Move the arrow icon to enter user settings as shown in Fig. 3-17 and 3-18. After entering the language setting, select the language through the Left & Right arrow keys, and press 00000.0h 2019-06-12



key to confirm, the interface as shown in Fig. 3-22. 1 P 11:46:23



Brightness setting



50%



Fig. 3-22:



3-9



ZE215E Operation Manual



3.2.2.13 Sensor setting When the sensor is replaced or its pressure value deviates greatly, the customer can reset it. Press the menu button to enter the user interface, as shown in Fig. 3-16. Move the arrow icon to enter user settings as shown in Fig. 3-17 and 3-18. After entering the language setting, select the language through the Left & Right arrow keys, and press



key to confirm,



the interface as shown in Fig. 3-23.



00000.0h 2019-06-12



1 P



00000.0h 2019-06-12



11:46:23



Sensor Settings



Sensor Settings



Start sensor setting, please press CONFIRM key to continue and RETURN key to return



Basic Operating Technology of Excavator



00000.0h 2019-06-12



During communication ······



1 P



00000.0h 2019-06-12



11:46:23



1 P 11:46:23



Sensor Settings



Sensor Settings



Completion percentage: 10%



Setting is completed Press back key to back



Fig. 3-23



3-10



1 P 11:46:23



ZE215E Operation Manual



3.2.2.14 Throttle setting When there is a large deviation between the engine speed of each gear and the set speed, the customer can reset the throttle. Press the menu button to enter the user interface, as shown in Fig. 3-16. Move the arrow icon to enter user settings as shown in Fig. 3-17 and 3-18. After entering the language setting, select the language through the Left & Right arrow keys, and press a) Confirm whether to enter the throttle setting, press 00000.0h 2019-06-12



1 P



key to confirm,



key to confirm, the interface as shown in Fig. 3-24; 00000.0h 2019-06-12



11:46:23



Throttle Settings



1 P 11:46:23



Throttle Settings



Start throttle setting, please press CONFIRM key to continue and RETURN key to return



Please start the engine



Basic Operating Technology of Excavator



Fig. 3-24 b) Set the throttle control knob to the high-order, press 00000.0h 2019-06-12



1 P 11:46:23



Throttle Settings



Please turn the throttle knob to the Max. Press confirm key to continue and back key to canel.



Fig. 3-25



c) Set the throttle control knob to the low-order, press



key to confirm, the interface as shown in Fig. 3-25; 00000.0h 2019-06-12



1 P 11:46:23



Throttle Settings



Please turn the throttle knob to the Min. Press confirm key to continue and back key to canel.



Fig. 3-26



key to confirm, the interface as shown in Fig. 3-26;



d) Please start the engine: skip it if started. The interface as shown in Fig. 3-27;



3-11



ZE215E Operation Manual



00000.0h 2019-06-12



1 P



00000.0h 2019-06-12



11:46:23



1 P 11:46:23



Throttle Settings



Throttle Settings



During communication ······



Please start the engine



Please wait！



Fig. 3-27



Basic Operating Technology of Excavator



e) The interface in the process of setting is shown in



00000.0h 2019-06-12



Fig. 3-28;



1 P 11:46:23



Throttle Settings



f) Setting result interface is shown in Fig. 3-29. Engine speed: 1024 Completion percentage: 10%



Fig. 3-28 00000.0h 2019-06-12



1 P



00000.0h 2019-06-12



11:46:23



Throttle Settings



Throttle Settings



Setting is failed



Setting is completed



Press back key to back



Press back key to back



Fig. 3-29



3-12



1 P 11:46:23



ZE215E Operation Manual



3.2.2.15 Menu return delay without operation



00000.0h 2019-06-12



1 P 11:46:23



Time of returning to home page without operation



Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the arrow icon to enter the user setting interface, as shown in Fig. 3-17 and 3-18. Enter the menu and return to the delay



Return Time : 89s



setting interface without operation, and revise it by moving the arrow key. Press



key to confirm, and the interface is as



shown in Fig. 3-30.



Fig. 3-30



Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the arrow icon to enter the user setting interface, as



00000.0h 2019-06-12



Basic Operating Technology of Excavator



3.2.2.16 User phone settings



1 P 11:46:23



User Telephone Number settings



shown in Fig. 3-17 and 3-18. Enter the user phone setting interface and change the phone number by moving the arrow key. Press key to confirm, and the interface is as shown in Fig. 3-31.



3.2.2.17 User password setting Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the arrow icon to enter the user setting interface, as



133 8903 1111



Fig. 3-31 00000.0h 2019-06-12



1 P 11:46:23



User Password settings



shown in Fig. 3-17 and 3-18. Enter the user password setting interface and change the password by moving the arrow key. Press key to confirm, and the interface is as shown in Fig. 3-32.



00000000



Please remember your code



Fig. 3-32



3-13



ZE215E Operation Manual



3.2.2.18 Operation information query Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the arrow icon to enter the information query as shown in Fig. 3-17. Select the interface of operation information query and operating condition parameter information setting through the Left & Right arrow keys. Press



key to confirm, and the interface is as shown in



Fig. 3-33. 00000.0h 2019-06-12



1 P



1 P



00000.0h 2019-06-12



11:46:23



11:46:23



Information Inquriry



Running Information Inquriry



Running Information Inquriry



Working Parameters Information



Alarm Information



Run time Information



Fault Record



TGU Parameters



Maintenance Information Inquriry



Temporary Unlocking



Maintenance Confirmation Service call QR code Equipment Information and Configuration



Basic Operating Technology of Excavator



Fig. 3-33



3.2.2.19 Operating parameter The user can directly press the menu button to enter the main interface, as shown in Fig. 3-16, and directly enter the query of operatiNG parameters as shown in Fig. 3-34. Or enter the user interface as shown in Fig. 3-17. Operate the information query interface through the Left & Right arrow keys, as shown in Fig. 3-33. Enter the operating condition information, as shown in the figure, to enter operating condition, as shown in the figure. Press the Up & Down arrow keys to query operating condition parameters, the interface as shown in 3-34.



3.2.2.20 Operation time information Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the arrow icon to enter the user interface as shown in Fig. 3-17. Select the information query interface through the Left & Right arrow keys as shown in Fig. 3-33 to enter the operation time information. Press the Up & Down arrow keys to inquire, and the interface is as shown in Fig. 3-35. 00000.0h 2019-06-12



1 P 11:46:23



1 P



AUTO



11:46:23



System Voltage



27.8V



Power-on Hour Metering



1.4 h



Cooling Water Temperature



25.5℃



Work Hour Metering



1 h



Engine RPM



1000RPM



Construction Hour Metering



2 h



Fuel Volume



50%



B1 Hour Metering



0 h



Hydraulic Oil Temperature



20℃



B2 Hour Metering



0 h



Front Pump Pressure



0MPA



Stage Hour Metering



2 h



Rear Pump Pressure



0MPA



Fig.  3-34 3-14



00000.0h 2019-06-12



Fig.  3-35



ZE215E Operation Manual



3.2.2.21 Temporary unlocking Press the menu button to enter the main interface when the vehicle is provided with a lock function, as shown in Fig. 3-16. Move the arrow icon to enter the user interface as shown in Fig. 3-17. Select the information query interface through the Left & Right arrow keys as shown in Fig. 3-33 to enter the temporary unlock. Press the Up & Down arrow keys to inquire, and the interface is as shown in Fig. 3-36. 00000.0h 2019-06-12



1 P 11:46:23



Temporary unlocking



Machine code: 0001 Random code: 123



Basic Operating Technology of Excavator



Fig. 3-36



3.2.2.22 Alarm information query Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the menu through the arrow icon to enter the user interface as shown in Fig. 3-17. Select the information query interface through the Left & Right arrow keys to enter the alarm information. Press the Up & Down arrow keys to inquire, and the interface is as shown in Fig. 3-37.



3.2.2.23 Fault record query Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the menu through the arrow icon to enter the user interface as shown in Fig. 3-17. Select the information query interface through the Left & Right arrow keys to select the fault record query. Press the Up & Down arrow keys to inquire, and the interface is as shown in Fig. 3-38.



00000.0h 2019-06-12



1 P



AUTO



11:46:23



V_520195_1



Short circuit to ground in P2 pump pressure sensor



V_520195_5



Open circuit in P2 pump pressure sensor



V_520195_6



Short circuit in P2 pump pressure sensor



Fig. 3-37



1 P 00000.0h 11:46:23 2019-06-12 VCU historical fault (01) AUTO



NO.



Code



01 V_520193_4



OC Time to send 4 2019-07-09 16:49



Fig. 3-38



3-15



ZE215E Operation Manual



3.2.2.24 Maintenance information query Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the menu through the arrow icon to enter the user interface as shown in Fig. 3-17. Select the information query interface through the Left & Right arrow keys to select the maintenance information query. Press the Up & Down arrow keys to inquire, and the interface is as shown in Fig. 3-39.



3.2.2.25 Maintenance confirmation Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the menu through the arrow icon to enter the user interface as shown in Fig. 3-17. Select the information query interface through the Left & Right arrow keys to select the maintenance confirmation. Press the 00000.0h 2019-06-12



00000.0h 2019-06-12



1 P 11:46:23



Maintenance Maintenance Last maintenance Countdown for time next maintenance cycle content



Engine oil filter



0



0



to confirm, and the interface is as shown in Fig. 3-40. 1 P 11:46:23



Maintenance setting



0



Filter element of the engine oil-water separator



Basic Operating Technology of Excavator



0



0



0



Primary fuel filter element of the engine



0



0



0



Already maintained



Secondary fuel filter element of the engine Engine oil



0



0



0



0



0



0



0



0



Engine coolant



0



Return oil filter element of hydraulic oil



0



0



0



Fig. 3-39



Fig. 3-40



3.2.2.26 Service call QR-code Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the menu through the arrow icon to enter the user interface as shown in Fig. 3-17. Select the information query interface through the Left & Right arrow keys to select the service call and QR-code query, and the interface is as shown in Fig. 3-41. 00000.0h 2019-06-12



1 P 11:46:23



00000.0h 2019-06-12



1 P 11:46:23



Equipment Information Machine PIN Number:



ZMTZE000V00000001



Service Call： 400-800-0157



Display Hardware:



YQ4.348.1467



Display Software:



YQ.282.1028_V02



Controller Hardware:



ZMTZE000V00000001 Controller Software:



00000000000 Engine Version:



00000000000



TGU ID Number:



000000000000000



SIM Card Number:



000000000000000



Fig. 3-41



3-16



Fig. 3-42



ZE215E Operation Manual



3.2.2.27 Equipment information and configuration sheet Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the menu through the arrow icon to enter the user interface as shown in Fig. 3-17. Select the information query interface through the Left & Right arrow keys to select the equipment information and configuration sheet, and the interface is as shown in Fig. 3-42.



3.2.2.28 Video interface switch (optional) When the vehicle is equipped with the camera, press the menu button to enter the main interface, as shown in Fig. 3-16. Select video function and open the video as shown in Fig. 3-44. Return to the main interface and enter the rear-view video screen as shown in Fig. 3-45. The camera position is shown in Fig. 3-43.



00000.0h 2019-06-12



1 P 11:46:23



Video setting



Enable the Video function



Basic Operating Technology of Excavator



Disable the Video function



2019-06-12 11:46:23 1 P AUTO



Camera



00000.0h AUTO



Fig. 3-43



Fig. 3-44



Fig. 3-45



3.2.2.29 Sound-light alarm setting (optional) When the vehicle is equipped with a sound-light alarm, press the menu button to enter the main interface, as shown in Fig. 3-16. Move the menu through the arrow icon to enter the user interface as shown in Fig. 3-17. Enter the selectable interface and select the auxiliary control function as shown in Fig. 3-46, and then select whether it works by using the Up & Down arrow keys. Press



key to confirm, and the interface is as



shown in Fig. 3-47. 00000.0h 2019-06-12



1 P 11:46:23



Function selection



00000.0h 2019-06-12



1 P 11:46:23



Auxiliary control function setting



Auto warm-up setting Boom semi-flow setting Boom priority setting Auxiliary control function setting



Fig. 3-46



Audible alarm for swing



Valid



Light alarm for swing



Valid



Audible alarm for traveling



Valid



Light alarm for traveling



Valid



Fig. 3-47 3-17



ZE215E Operation Manual



3.2.2.30 Setting of priority function of the boom (optional) When the vehicle is equipped with a boom-priority solenoid valve, press the menu button to enter the main interface, as shown in Fig. 3-16. Move the menu through the arrow icon to enter the user interface as shown in Fig. 3-17. Enter the selectable interface and select the boom-priority as shown in Fig. 3-46, and then select whether it works by using the Up & Down arrow keys. Press



key to confirm, and the interface is as



shown in Fig. 3-48. 00000.0h 2019-06-12



1 P 11:46:23



Boom priority setting Enable the boom priority



Valid



Basic Operating Technology of Excavator



Fig. 3-48



3.2.2.31 System heater setting Press the menu button to enter the main interface, as shown in Fig. 3-16. Move the menu through the arrow icon to enter the user interface as shown in Fig. 3-17. Enter the selectable interface and select the system heater setting as shown in Fig. 3-46, and then select whether it works by using the Up & Down arrow keys. Press



key to confirm, and the interface is as shown in Fig. 3-49. 1 P 00000.0h 2019-06-12 11:46:23 Auto Warm Settings



Auto Warm Settings（Engine） Invalid Valid Auto Warm Settings（Hydriol）



Fig. 3-49



3-18



ZE215E Operation Manual



3.2.2.32 Boom semi-streaming mode selection (optional) When the vehicle is equipped with a boom semi-streaming solenoid valve, press the menu button to enter the main interface, as shown in Fig. 3-16. Move the menu through the arrow icon to enter the user interface as shown in Fig. 3-17. Enter the selectable interface and select the boom semi-streaming as shown in Fig. 3-46, and then select whether it works by using the Up & Down arrow keys. Press



key to confirm, and the interface is as shown in Fig. 3-50. 1 P 00000.0h 2019-06-12 11:46:23 Boom semi-flow setting



Enable the boom semi-flow



Valid



Basic Operating Technology of Excavator



Fig. 3-50



3.2.2.33 Indicator a) Cooling water temperature analog indicator: Indicating the current temperature of the engine coolant. The display range is -40 - 120ºC. The yellow section is below 40ºC, the green section is 40 - 102ºC, and the red section is the alarm section. When the cooling water temperature of the engine T≥105ºC, the controller will automatically control the throttle of the engine to drop one gear for the protection. If the cooling water temperature of the engine T≤95ºC, the overheating protection function will automatically be canceled. b) Hydraulic oil temperature analog indicator: indicating the operating hydraulic oil temperature of the current system. The display range is 40～110ºC. The yellow section is below 40ºC, the green section is 40 - 95ºC, and the red section is the alarm section. c) Fuel level analog pointer table: a display range of 0 - 100%. The red segment is 0 to 10%.



3.3 Basic operating instructions 3.3.1 Basic inspection items



Warning 1. The instrument is not a guarantee of the machine. Check the parameters directly instead of simply rely on the instrument during the pre-start inspection (daily inspection). Check the two basic items, namely, low coolant level alarm and maintenance reminder before starting the engine. If there is any abnormality, the instrument related to the abnormal position will be on and the buzzer will ring at the same time.



3-19



ZE215E Operation Manual



a) Low coolant level alarm This meter will warn the operator that the liquid level in the water radiator has dropped. The indicator light is red if the liquid level of the radiator is low. Therefore, check the liquid level of the coolant radiator and secondary tank, and add coolant, as shown in Fig. 3-51. Fig. 3-51 b) Maintenance reminder When the maintenance reminder light is on, it is to warn the operator that the time set for the next maintenance has reached after the last maintenance, as shown in Fig. 3-52. This warning will stop 5 seconds later and it will return to normal operation. If the maintenance is completed, the "confirm" button on the screen can be pressed to indicate the completion of the maintenance. If you need to change the



Fig. 3-52



Basic Operating Technology of Excavator



setting of maintenance cycle, please contact Zoomlion or Zoomlion distributor.



c) Charge display It the battery voltage alarms, it is to warn the operator that the charging system is in abnormal situation in the operation of the engine. If the battery is not properly charged when the engine is running, the corresponding alarm icon will be accompanied by text prompts, as shown in Fig. 3-53.



Fig. 3-53



d) Low fuel level alarm When the alarm light is on, it is to warn the operator that the oil level in the fuel tank is at a low level. At the moment, the amount of fuel left can only keep the machine working for 1-2 hours at most. Therefore, refueling shall be done as soon as possible, as shown in Fig. 3-54.



Fig. 3-54



e) Air filter element blocking alarm When the alarm light is on, it is to warm the operator that the air filter cleaner is blocked, as shown in Fig. 3-55. Turn off engine to check and clean air filter cleaner.



Fig. 3-55



3-20



ZE215E Operation Manual



3.3.2 Emergency shutdown project



Warning 1. If there is an alarm, immediately shut down the engine or make it run at a low idle speed, then check the appropriate parts and take necessary measures. These items shall be followed when the engine is running. If there is an abnormality, the meter related to the abnormal part will become red and the buzzer will ring. Therefore, measures shall be taken immediately. a) Coolant temperature alarm Coolant temperature alarm warns that the coolant temperature is too high. If the engine coolant temperature becomes unusually high, the warning light turns red, the overheating control system starts automatically, and the Stop operation and run the engine at a low idle speed until the warning light is off if necessary.



Basic Operating Technology of Excavator



engine speed drops, as shown in Fig. 3-56. Fig. 3-56



b) Hydraulic oil temperature alarm Hydraulic oil temperature alarm warns the operator that the hydraulic oil temperature has risen. If the warning light is red during the operation process, the engine shall be run at a low idle speed or the engine shall be shut down until the oil temperature drops and the warning light is off, as shown in Fig. 3-57.



Fig. 3-57 c) Oil pressure alarm If the engine oil pressure falls below the normal level, the alarm light will turn red. At the moment, the engine shall be shut down and the oil level in the lubrication system and oil sump shall be checked, as shown in Fig. 3-58.



Attention



Fig. 3-58



1. When the start switch is in the ON position, this indicator light remains on. After the engine starts, this light will go out. 2. It is normal for the buzzer to ring temporarily when the engine is started.



3-21



ZE215E Operation Manual



3.3.3 Basic operation of the switch Switch positions are shown in Fig. 3-59:



1



10



9



2 3 4 5 6 7



8 Basic Operating Technology of Excavator



Fig. 3-59 1. Powerful digging switch



2. Cigarette lighter



3. Start switch



4. Throttle control knob



5. Working light switch



6. Wiper switch



7. Window washer switch



8. Headlight switch



9. Room light switch



10. Horn switch



3.3.3.1 Powerful digging switch The powerful digging switch on the top of the right operating device lever is shown in Fig. 3-59 (1), which is used to increase the digging force in a short time. The operation button is shown in Fig. 3-11(1).



3.3.3.2 Cigarette lighter Switch (2) in Fig. 3-59 shall be used during cigarette lighting up, as shown in Fig. 3-60. When the cigarette lighter is pushed in, after a few seconds, it will return to its original position, and it can be re-used after being pulled out. If the cigarette lighter is disassembled and used as a power supply, the maximum power of the load is 120W (24V×5A). Fig. 3-60



3-22



ZE215E Operation Manual



3.3.3.3 Start button Fig. 3-59 start switch (3) is used to start or shut down the



T OFF



HEA



engine, as shown in Fig. 3-61. OFF position: Keys can be inserted or removed.



ON



ON position: The electrical system is energized and the



START



starting switch key shall be kept in the ON position while the engine is running. START position: It is where the engine starts. Keep the key in this position when the engine is started. As soon as the engine Fig. 3-61



is started, the key shall be released and it will automatically return to the ON position.



HEAT position: When the engine is started in winter, the engine automatically detects the temperature of the cooling water. When the water temperature is less than -3℃, the preheating function is automatically turned on, and the instrument monitor light is on. The text indicates "preheating is in progress", and the text indicates "preheating is completed" when the preheating is over.



1. The safety lock lever must be locked before the engine is started. If the engine fails to be started after the start switch is in "START position" for 10 seconds, the engine shall be restarted wait 2 minutes later. If the engine is started continuously for more than 15 seconds, the starter motor may be burnt out.



3.3.3.4 Throttle control knob speed and power output as shown in Fig. 3-62.



b MAX



Control knob (4) in Fig. 3-59 is used to control the engine a) Low idle speed position: Turn the knob towards the left (counterclockwise) b) High idle speed position: Turn the knob towards the right (clockwise)



MIN



a



Fig. 3-62



3.3.3.5 Working light switch As shown in Fig. 3-63, switch (5) in Fig. 3-59 is used to control platform light and boom light. The switch has three positions: a) All lights are off b) The boom light is on c) Both the platform light and the boom light are on



Fig. 3-63 3-23



Basic Operating Technology of Excavator



Attention



ZE215E Operation Manual



3.3.3.6 Wiper switch Wiper switch (6) in Fig. 3-59 is used to control the opening and speed of the wiper, as shown in Fig. 3-64. The switch has three positions: a) The wiper is off b) The wiper works at a low speed c) The wiper works at a high speed



Fig. 3-64



3.3.3.7 Window washer switch Window washer switch (7) in Fig. 3-59 is used to control the opening of the window washer as shown in Fig. 3-65. The



Basic Operating Technology of Excavator



switch only has on and off positions.



Fig. 3-65



3.3.3.8 Emergency mode switch When the controller can not work normally, pull the emergency mode switch to make the machine in the emergency running state. During operation, turn the switch A in the transfer box behind the cab to the emergency position (as shown in Fig. 3-66).



3-24



ZE215E Operation Manual



K2



K6



预留 F16 10A F17 15A F18 5A



F10 20A F11 10A F12 10A



F4 5A F5 5A F6 5A



K12



预留



K11



预留



K10



K14



K5



K7



K9



K13



F1 30A F2 30A F3 10A



F19 20A F20 5A F21 10A



F13 10A F14 10A F15 20A



F7 10A F8 10A F9 10A



正 常



应 急



应急模式开关



A 正 常



A



应 急



先导控制切换开关



Basic Operating Technology of Excavator



Fig. 3-66



3.3.3.9 Headlight switch Switch (8) in Fig. 3-59 is used to turn on two headlights, The icon is consistent with the working light, as shown in Fig. 3-67.



Fig. 3-67



3.3.3.10 Room light switch Switch (9) in Fig. 3-59 is used to turn on the room light.



ON



ON position: Light on OFF position: Go out As shown in Fig. 3-68.



OFF



Fig. 3-68 3-25



ZE215E Operation Manual



3.3.3.11 Horn switch When the button switch (10) on the top of the left operating device lever is pressed, the horn will beep, as shown in Fig. 3-69.



运行



停止



Horn switch



Fig. 3-69



Fig. 3-70



3.3.3.12 Fuel pump control switch The oil pump starts to work when the operation button switch is pressed, and the fuel pump stops working when the stop



Basic Operating Technology of Excavator



button is pressed or the fuel level reaches 90%, as shown in Fig. 3-70.



Attention 1. It is forbidden to run the fuel pump without load, otherwise, the fuel pump shall be damaged.



ON



90°



3.3.3.13 Cathode switch



OFF



As shown in Fig. 3-71, the negative switch is used for switching on and off of the circuit of the finished machine. The switch key can



1



only be removed in the OFF position. ON position: The circuit is connected, the electrical circuit of the finished machine is live; Fig. 3-71



OFF position: The circuit is broken, and the power supply of the finished machine is cut off.



Attention 1. Be sure to put the negative switch in the OFF position and keep the switch key properly when repairing, welding



4



and long-term parking the machine.



3.3.4 Instructions for operating device The schematic diagram of each operating device is shown in Fig. 3-72:



3



2



(1) Safety lock joystick (2) LH lever (3) Traveling lever



1



(4) RH lever Fig. 3-72 3-26



ZE215E Operation Manual



3.3.4.1 Safety lock joystick



Warning 1. Be sure to place the safety lock joystick firmly in the lock position when leaving the cab, as shown in Fig. 3-73. If the safety lock joystick is in the open position instead of the lock position and other control handles are mistakenly touched, serious injuries will be caused. 2. If the safety lock joystick is not firmly placed in the



F



lock position, the safety lock joystick may move and



1



cause serious accident or injury. Be careful not to touch the operating device lever when pulling up or



L



down the safety lock joystick. Fig. 3-73



device, a turning, walking and accessory (if equipped) joystick. Push down the safety lock joystick to apply the lock.



Since it is a hydraulic lock, even if the safety lock is in a locked position, the operating device lever and traveling lever may move, but the operating device, traveling motor, and rotation motor will not work.



3.3.4.2 Use of lever 3.3.4.2.1 Operating device lever Automatic idle function of the engine changes is as follows:



d



a) When the traveling lever and operating device lever are in the neutral position, the engine speed will slow down to idle speed



a



N



b



even if the fuel control knob is above the intermediate speed. If



c



one of the levers is operated, the engine speed will rise to the speed set by the fuel control knob. b) If all the levers are in the neutral position, the engine speed drops to the automatic idle speed setting speed. c) Left side operating device lever (2) As shown in Fig. 3-72 and Fig. 3-74, used for operating the rotary action of the arm



Fig. 3-74



and upper part;



a: Arm unloading b: Arm digging c: Right slewing d: Left slewing N (neutral position): The superstructure and the arm are kept in place. d) The right operating device lever (4), as shown in Fig. 3-72 and



b



N



c a



d



3-75, is used to operate the boom and bucket.



a: Boom lifting



Fig. 3-75 3-27



Basic Operating Technology of Excavator



Safety lock control lever (1) in Fig. 3-62 is a locking operating



ZE215E Operation Manual



b: Boom lowering c: Bucket unloading d: Bucket digging N (neutral position): The boom and the bucket are kept in place.



3.3.4.2.2 Traveling lever



Warning 1. Do not put your foot on the pedal except when the



a



machine is traveling. If the foot is left on the pedal and mistakenly stepped on it, the machine will suddenly move and may cause a serious accident. 2. Check the front and rear side of the machine when using the traveling lever; (If the drive wheel is in the



Basic Operating Technology of Excavator



operate and walk. Traveling joystick (3) in Fig. 3-61 is used to change the travel direction of the machine, as shown in Fig. 3-76.



b



N



rear, the machine is facing forward.) 3. Special attention shall be paid when using pedals to



N



a



a



b



a b



b



(a) Forward: push forward the lever (pedal tilts forward) (b) Reverse: pull back the lever (pedal tilts backward)



Fig. 3-76



N (neutral position): The machine stops



3.4 Instructions for attachment in the cab



A



3.4.1 Ash pan The ash pan (A) is on the right front side of the cab. Be sure to put the cigarette in the ash pan (A) and close the lid, as shown in Fig. 3-77.



Fig. 3-77 3-28



ZE215E Operation Manual



3.4.2 Air conditioner 3.4.2.1 Precautions for air conditioner



Attention 1. Be sure to turn on the air conditioner when the engine is running at a low speed. Do not turn on the air conditioner when the engine is in high-speed operation, because it will cause air conditioning damage; 2. If the air conditioning control panel is flooded, it will cause accidental failure. Therefore, keep these components dry. In addition, do not allow open fire near these components. a) The cab shall be ventilated often when the refrigerator is used: Your eyes will be badly affected if you smoke when the cooler is on, so open the window for ventilation and conduct refrigeration for a short time to get rid of the smoke. When the air conditioner is in long-time running, it shall be ventilated and refrigerated every hour. b) When the window is foggy: air conditioner is used too much when the air is very humid, the outside of the window may become foggy. At the moment, the air conditioner shall be turned off to adjust the temperature in the cab.



Attention 1. Do not to keep the temperature of the cab too low. When the refrigerator is on, set the temperature to the recommended 22-26°C when entering the cab. This temperature is considered most suitable for the body, so attention shall be paid to properly regulate the temperature.



3.4.2.2 Button instruction The air conditioner control panel of the machine is shown in Fig. 3-78. The air conditioner must be off when the engine is started.



1



2



3



4



5



6



TEMP



Fig. 3-78



1. Mode switch



2. Temperature control switch 3. Air volume control switch



4. Fresh/cycle selector switch 5. ON/OFF switch



6. Air-conditioning refrigeration



switch



3-29



Basic Operating Technology of Excavator



On rainy or wet days, if the inside of the window is foggy, open the air conditioner to help keep the window clear. If the



ZE215E Operation Manual



a) Mode switch: The switch (1) is a set of air conversion, namely the air vent selector switch. Each air vent is shown in Fig. 3-79. There are four specific modes as follows:



A



: Represents the ventilation at the bottom, namely the air coming out of the vent C;



B



: Represents the bottom and the rear are ventilated at the same time, namely the ventilation of A and C Air comes out from the vents at the same time; : Represents the ventilation at the rear part, namely the air coming out of the vent A; : Represents that the air conditioner is in defrosting state and has both the bottom and front vents open. (A): Rear vents (4)



D1 D2



(B): Face vent (1)



C



(C): Bottom vent (1)



Basic Operating Technology of Excavator



(D1): Front window vent (1)



Fig. 3-79



(D2): Front window vent (1) Front window vent (D2) can be opened or closed by hand. b) Temperature control switch: Switch (2) is used to control the temperature in the cab. There are 12 levels of temperature adjustable, red for heating, blue for cooling. Tip: A/C is in off state and the corresponding button light is off during heating; A/C must be in on state and the corresponding button light is on during heating. Press  switch to increase the set temperature; Press  switch to increase the set temperature; c) Air volume control switch: Air volume adjustment switch (3) is used to adjust air volume. Air volume can be adjusted to 4 levels, namely low, medium 1, medium 2, and high. Press  switch to increase the set air volume; Press  switch to reduce the set air volume; d) Fresh/cycle selector switch: switch (4) for the conversion of air sources between the air recirculation inside the cab and the air intake from the outside. : Outside air enters the cab. Use this switch to absorb fresh air or demist; : The outside air is cut off, and the air only circulates inside the cab. Use this switch for rapid cab cooling or when the outside air is not clean. d) ON/OFF switch: Switch (5) control the on or off of the air conditioner. e) Air-conditioning refrigeration switch: Turning on the switch (6) means that it is in the state of refrigeration and the compressor is started. Turning off the switch means that it is in the heating state and the compressor stops working. General temperature regulating switches are used for refrigeration at the coldest and level 2-5, and for heating at the level 6-11 and at the hottest level.



3-30



ZE215E Operation Manual



3.4.2.3 Air conditioning operation instructions 3.4.2.3.1 Panel operation a) Press the air volume switch (3) and adjust the air volume to meet the requirements; b) Turn on the air conditioner switch (6) when cooling and turn off the air conditioner switch (6) when heating. Check whether the upper indicator light of the switch is on. c) Press the temperature control switch (2) to adjust the temperature in the driving room to the right level; d) Press Mode switch (1) to select the required ventilation mode. The corresponding upper indicator light will be on when the mode is selected; e) Press fresh/cycle selector switch (4): Select the air circulation inside the cab or take in fresh air from the outside; f) Press ON/OFF switch (5), the display of temperature setting and air volume setting and the indicator light above the air conditioner switch is off and the operation stops.



3.4.2.3.2 Defroster operation a) Press the air volume adjustment switch (3) and adjust the air volume; b) Press the defrosting Mode in Mode switch (1);



Basic Operating Technology of Excavator



c) Press fresh/cycle selector switch (4) and set it to take in the fresh air; d) Press the temperature control switch (2) and set the temperature to the hottest level; e) Adjust the vents ti make the air blow on the glass.



3.4.3 Car radio 3.4.3.1 Function control and indication: The radio control panel of this machine is shown in Fig. 3-80:



4



1 PAU



VOL



3



2



1



SOURCE/OFF FM/AM



+



2 SCN



APS



3 RPT



4 RDM



5



6



5



6



SEL CLK



MUTE LOUD



USB



7



8



9



Fig. 3-80 1. Power supply/sound source control key



2. Automatic save & band selection key



3. LED display screen



4. Volume control key



5. Radio preset broadcasting station/MP3 play control function keys (Note: PAU- Pause, SCN- Scan, RPT- Repeat, RDM- Random) 6. Manual channel selection key



7. Clock & sound settings selection key



8. Muting&Loudness



9. USB interface



3.4.3.2 Precautions for use a) Set the volume in an appropriate position to avoid traffic and work accidents; b) The radio is easy to be damaged by water. Be careful not to spray water on the radio when washing your car. c) The preset button settings are eliminated during the replacement of the battery, and a re-set shall be conducted. 3-31



ZE215E Operation Manual



3.4.3.3 Radio operating instructions a) Power on/off Press "1" to turn on the radio power, long press the key to cut off the radio power. b) Automatic search and storage of the station Long press the "2" button to start an automatic channel search from the lowest frequency. The searched stations will be stored in the preset stations 1 to 6. Shortly press "2" to switch between FM and AM in the band. c) Volume control Press "4+" key to make the volume gradually increase; Press "4 -" key to make the volume gradually decrease. d) Select the preset station Press any number key in the "5" key to select the corresponding preset radio to play; Long press any number key in the "6" key to store the current frequency to the corresponding preset station in the process of play. e) Band selection key Press "6" for forward/backward station searching, for both automatic and manual searching.



Basic Operating Technology of Excavator



Automatic station searching: shortly press "6→/6←" key to forward/backward search station, the search stops and plays when a station is found. Manual search: long press "6→/6←" key to enter the manual search state. Press and hold the key, then the frequency will jump forward/backward rapidly. When the key is released, the frequency will stop beating. In this case, you can still shortly press "6→/6←" button to gradually adjust the frequency. Exit the manual search mode and return to the automatic search mode if no button is pressed within 2 seconds. f) Sound settings Shortly press "7" button to display the clock. Press the button again in 2 seconds to enter the sound setting selection state. No matter when the clock is displayed or when the sound setting is selected, exit the clock display and return to the radio display frequency if no button is pressed within 2 seconds. Long press the "7" button to enter the clock adjustment when the clock is displayed. Select the sound effect setting, and for each press, you can select VOL->BAS->TRE->BAL->VOL..., then press "4+/4 -" key to adjust the volume accordingly: bass, treble, left and right balance..... Note: VOL- Volume



BAS- Bass



TRE- Treble



BAL- Balance.



g) Muting and loudness control Shortly press the "8" key to mute the radio, and press again to make it sound. There is a corresponding mute symbol on the LCD screen. It will sound again by adjusting the volume in the mute state. Long press "8" key to turn on the loudness, press again to turn off it. Display the corresponding "LOUD" symbol on the LCD screen.



3.4.3.4MP3 operation steps a) Shortly press key to play MP3 when receiving the radio signal. b) First, read the USB disk for playing If there is NO USB disk, it displays "NO DISC". If there is a USB disk, but NO MP3 file on it, it will display "NO SONG". c) First, display the total number of tracks, and then began to play after reading the USB disk. d) Breakpoint memory play function In case that it is turned off or transferred to the radio in the process of playing MP3, when it is transferred to the MP3 player again, it will start playing from the last played place if the last played USB disk remains unchanged. If the device is unplugged in the process of playing when the USB disk is inserted, it will start playing from the previous place when the device is inserted again if the above MP3 song remain unchanged.



3-32



ZE215E Operation Manual



e) The LCD screen displays the track number and the playing time of the current one in the process of playing. f) Pause Press key in the process of playing to pause. At the moment, the LCD screen displays the track number and playing time and it is flashing. Press it again to continue the playing. g) Track selection Press "6→/6←" key to select the track forward/backward. h) Fast track selection Press and hold "6→/6←" key to fast increase/decrease the track number, and press it again to adjust the track number individually after releasing the key. If there is no button pressed within 1 second, it will skip to the last selected track to play. i) Repeated, random, and browse play Press one of the , , and keys to select the corresponding play mode. Press the corresponding key again to return to play in order mode. j) Support MP3 song types MPEG 1/2/2.5 Layer 3 Audio Sampling frequency: 8k, 11.025k, 12k, 16k, 22.05k, 24k, 32k, 44.1k, 48k



Basic Operating Technology of Excavator



Code rate: 32Kbps－320Kbps, support VBR For the number of MP3 files on the USB disk, the system only supports up to 511 MP3 files for each device, the system will not play the excessive ones.



Attention 1. Be sure to turn off the radio power source when you leave



A



the machine!



3.4.4 Antenna The antenna should be rotated to be flat to prevent any interference before the conveyor or it is placed inside the building. The antenna position is shown in Fig. 3-81 (A).



3.4.5 Window and lock



Fig. 3-81



3.4.5.1 Skylight



Warning 1. When leaving the driver seat, the safety lock joystick shall be firmly placed in the locking position, as shown in Fig. 3-73. 2. If the safety lock joystick is not locked and other levers are touched, it will cause a serious accident. a) Open the window Pull the lock knob (1) on both sides of the skylight and pull it up. The skylight is automatically open upwards under the action of two air springs (2) on both sides, as shown in Fig. 3-82.



3-33



ZE215E Operation Manual



b) Close the window Hold the handle (3) to pull the skylight downward and lock the skylight with the lock knob (1). Open the skylight again to make sure that it is successfully closed if it is not well locked.



2



3 2 1 Fig. 3-82



Basic Operating Technology of Excavator



3.4.5.2 Front



window



Warning 1. When the front or bottom window is open or closed, the safety lock joystick shall be placed in the lock position. 2. If the lever is not locked and it is accidentally touched, it will cause a serious accident. 3. Before the front window in front of the cab is open or closed, the machine shall be parked on the horizontal ground, the operating device shall be completely lowered to the ground, and the engine shall be shut down; 4. Hold the handle firmly with both hands to pull upward and do not let go until the automatic latch locks when opening the front window; 5. Hold the handle firmly with both hands as the window will move fast under its own weight when the front window is closed.



3.4.5.2.1 Opening steps The front window can be placed on the top of the cab as shown in Fig. 3-83. The opening steps are as follows: a) Place the machine on the ground and turn off the engine; b) Firmly lock the safety lock joystick; c) Check whether the wiper blade is placed in the fixed plate on the right side of the front window of the cab. d) Hold the handles (A) on the left and right side of the front window with both hands and pull the lock handle (B) to loosen the lock. At the moment, the front window can move as shown in Fig. 3-84. e) Hold the lower handle (C) of the front window of the cab with the left hand, and grasp the top handle (D) to pull it upward with the right hand until the front window is at the top of the cab. f) Check whether the lock handle (B) is firmly in the lock position. 3-34



Fig. 3-83



ZE215E Operation Manual



A



D B



C



Basic Operating Technology of Excavator



Fig. 3-84



F



Conduct a visual check. If the arrow on the lock case (F) corresponds to the arrow on the lock handle (B) as shown in Fig. 3-85, it indicates that the lock is in place. If the arrow on the lock case (F) does not correspond to the arrow on the lock handle (B), it indicates that the lock is not well secured. Repeat step e to lock it.



B Fig. 3-85



3.4.5.2.2 Closing steps



Warning 1. Slowly lower the front window when closing the front window to prevent from clamping the hand. The closing steps are as follows: a) Place the machine on the ground and turn off the engine; b) Firmly lock the safety lock control joystick; c) Hold the handle on the left and right sides (A) to pull the lock handle (B) to loosen the lock, as shown in Fig. 3-86; d) Hold the bottom handle (C) of the front window with your left hand, and hold the top handle (D) with your right hand to push forward and slowly drop; e) Push the bottom of the window forward to lock the lock handle when the bottom of the window is close to the top of the bottom window. f) Check whether the lock handle (B) is firmly in the lock position. Conduct a visual check. If the arrow on the lock case (F) corresponds to the arrow on the lock handle (B) as shown in Fig. 3-87, it indicates that the lock is in place. If the arrow on the lock case (F) does not correspond to the arrow on the lock handle (B), it indicates that the lock is not well secured. Repeat step e to lock it.



3-35



ZE215E Operation Manual



B



A



C



G



D



F



Basic Operating Technology of Excavator



B



Fig. 3-86



Fig. 3-87



3.4.5.3 Lock 3.4.5.3.1 Door lock As shown in Fig. 3-88, fix the door lock (1) at (3) after opening the door. The steps are as follows: a) Push the door towards the lock pin (3) to secure the door in place;



3 1



b) Press the handle (2) downward on the left side of the driver seat to open the lock pin when closing the door. c) Firmly fix the lock to the lock pin when fixing the door.



3.4.5.3.2 Cover and hood with a lock



2 Fig. 3-88



Locks are provided for: Fuel tank filling port, hydraulic tank filling port, cab door, hood, battery case cover, the door on the left side of the machine, and the door on the right side of the machine. Open or close these covers, doors, and hoods with a key. Insert the key to the end and then turn it. The key may be broken if it is not put to the end and turned. Steps to open and close the lock cover: a) Opening: 1) Insert the key into the key slot; 2) Turn the key counterclockwise, align the key slot with the mark on the lid and then open it. b）Closing:



3-36



ZE215E Operation Manual



1) Screw the lid on and insert the key into the key slot; 2) Turn the key clockwise as shown in Fig. 3-89, and then take off the key.



Lock



Open



Shoulder



Match mark on the cap



45°



Lock



180°



Lock



Basic Operating Technology of Excavator



Open



Open



Fig. 3-89



3.5 Power supply and fuse



Attention 1. Do not use the 24V power supply to power the 12V electrical device as it may cause electrical damage; 2. If the cigarette lighter is removed and used as a power supply, the maximum power of the load is 120W (24V×5A).



3.5.1 Precautions for fuse



Attention 1. Be sure to close the start switch before replacing the fuse; 2. The fuse is in the connecting box behind the cab. 3. The fuse is used to protect electrical equipment and electric wires from being burnt out; 4. Replace the fuse if it is corroded, or white powder is visible, or it is loose in the fuse holder. 5. Replace it with the fuse having the same capacity.



3-37



ZE215E Operation Manual



3.5.2 Fuse capacity, circuit name, and relay name Fuse capacity, circuit name, and relay name are shown in Fig. 3-90, and the position is located in the access hole behind the cab as shown in Fig. 3-66.



F9-10A



F7-10A F8-10A



F6-5A



F15-20A



F14-10A



收音机 RADIO 点烟器 CIGAR LIGHTER 雨刮器 WIPER 洗涤器 WASHER



F18-5A



F19-20A F20-5A



GPS



加油泵 FUEL FILLING PUMP 室内灯 ROOM LIGHTS 停油保持



CUT-OFF VALVE HOLD



F21-10A



F17-15A 钥匙开关 KEY SWITCH



RESERVED



预留 RESERVED



K9



K10



K11



K12



驾驶室顶灯 CAB HEAD LAMP



动臂灯



平台灯



BOOM LAMP



FRAME LAMP



电喇叭 SPEAKER



预留 RESERVED



预留 RESERVED



K13



K14



空调 AIR CONDITIONER



应急先导 EMERGENCY PILOT



Fig. 3-90



3-38



F12-10A F13-10A



F5-5A



F10-10A F11-10A



CUT-OFF VALVE PULL



F16-10A



停油保持 CUT-OFF VALVE HOLD



控制器 ECU 驾驶室顶灯 CAB HEAD LAMP 动臂灯 BOOM LAMP 平台灯 FRAME LAMP 喇叭 SPEAKER 空调 AIR CONDITIONER



停油快吸



K7 先导安全 PILOT



F4-5A



F3-10A



F2-30A



K6



备用



Basic Operating Technology of Excavator



K4



仪表 DISPLARY 诊断接头 DIAGNOSTIC TERMINAL 先导安全 DIAGNOSTIC TERMINAL



START PROTECT



CUT-OFF VALVE PULL



启动保护



启动继电器 START RELAY 停油快吸



K2(12V)



F1-30A



继电器保险 RELAY&FUSE



ZE215E Operation Manual



3.5.3 Fuse link Fuse links are components that are installed in large current areas of the circuit to protect electrical components and electric wires from being burnt. When the start switch is turned to the ON position, if the complete machine is out of power, it may be caused by a melted fuse link A (as shown in Fig. 3-91). Therefore, open the electric control cabinet of the machine to check the fuse link, and replace it if necessary.



A Fig. 3-91



Basic Operating Technology of Excavator



3.6 Controller The controller is mounted on the diaphragm in front side of the air filter, as shown in Fig. 3-92 (A).



Attention 1. Do not splash water and mud on the controller, or it may cause failure;



A



2. Do not disassemble the controller by yourself if the controller is abnormal. Please contact Zoomlion or Zoomlion distributor for repair.



Fig. 3-92



3-39



ZE215E Operation Manual for Hydraulic Excavator Chapter IV Safety operation procedure and operation technique of excavator



ZE215E Operation Manual



Chapter IV Safety operation procedure and operation technique of excavator 4.1 Adjustment before the operation 4.1.1 Driver seat adjustment



B



Adjust the seat as shown in Fig. 4-1 to make the operator operate the lever and switch freely and conveniently against the seat. The seat shall be adjusted as follows: a) Afterward and backward adjustment of seat Release the lever when using drawing rod 4 to move the seat to the desired position. Adjustable distance: 110mm (10mm



1



per stage). b) Backrest adjustment



D



Pull up the handle (1) and release it when the backrest is in



C



the best position for easy operation.



4



When adjusting the slant of the backrest, be careful not to interfere with the rear air conditioner cover plate, and not to let the armrest touch the lever. c) Seat height adjustment



A



F 3



E 2



Lift the seat up, and a 30mm has been raised when you hear a "click" sound, and another 30mm has been raised when



Fig. 4-1



to the lowest position again when you continue to lift it up. Maximum adjustment: 60mm (30mm per stage). d) Armrest angle adjustment The armrest can be lifted up for 100°, and it can be adjusted 40° continuously (10° above the horizontal level, 30° below the horizontal level). e) Integrated forward and backward adjustment of the seat and the lever Pull up the handle (2) to place the seat in the desired position and then release the handle. In this case, the driver seat, LH-RH lever, and the safety lock lever will all move together. Forward and backward adjustable range: 160mm. f) Seat suspension adjustment Adjust the rotating knob (3) to soften or harden the suspension so that the weight display (kg) in the transparent part of the knob is consistent with the weight of the operator. Adjustable range: 50-130kg. g) Headrest height adjustment Lift or press the headrest to make it be the most appropriate height.



4.1.2 Rearview mirror adjustment



Warning 1. Be sure to adjust the rearview mirror before starting work. You may be hurt or hurt others due to poor vision without right adjustment. The adjustment method of the rearview mirror (as shown in Fig. 4-2) is as follows:



4-1



Safe Operation of Excavator Procedures and Operational Techniques



you hear another "click" sound. However, the seat goes back



ZE215E Operation Manual



A



V



B



C



D



W



W Fig. 4-2 a) Adjust the angle of the mirror (A) to ensure that persons of the left rear view can be seen; b) Adjust the angles of mirrors (B), (C), and (D) to ensure that persons within 1m of the right rear side and the counterweight back end (W) are seen. Adjust the mirrors (C) and (D) to ensure that the minimum clearance (V) between the rearview mirror and its supporting rod is greater than 10mm; c) If the mirror cannot be moved smoothly during adjustment, the mirror fixing screw and support rod fixing screw can be released for the adjustment.



4.1.3 Safety belt



Warning Safe Operation of Excavator Procedures and Operational Techniques



1. Check the safety belt bracket or installation for abnormalities before using the safety belt. Replace it if the safety belt is worn or damaged. 2. It shall be replaced every 3 years even if there is no abnormality visible. The production date of the safety belt is shown on the back of the safety belt; 3. Do not twist the seat belt when you fasten it. This safety comes with a winding device, so there is no need to



1



2



3



4



adjust the length. Refer to Fig. 4-3 for seat belt adjustment. The adjustment method is as follows: a) Fixed the seat safety belt Hold the safety belt clip (2) and pull the safety belt out of the winding device (1). Check the safety belt for distortion and insert the tongue (3) firmly into the buckle (4). At the moment, gently pull the seat belt to check whether it is locked correctly. b) Unfasten the safety belt



Fig. 4-3



Press the button (5) on the bucket (4) and remove the tongue (3) from the bucket (4). As the safety belt will automatically retract, hold the safety belt clip (2) and slowly make the safety belt return to the winding device.



Attention 1. The seat belt of this machine is optional. Users can order from Zoomlion or Zoomlion distributor as required. 4-2



5



ZE215E Operation Manual



4.2 Engine operation 4.2.1 Engine check before startup 4.2.1.1 Basic check



Warning 1. Inspect the machine and surrounding area before starting the engine. Check for loose bolts or nuts, leaks of oil, fuel or coolant, and check operating devices and hydraulic systems. Also, check if the conductor is loose near the high temperature, and whether there is dust accumulation; 2. Remove battery, engine muffler and other high-temperature engine components around the inflammable. A leak of fuel or oil can cause a fire on the machine. The following items shall be checked every day before starting the engine: a) Check operating device, cylinder, connecting rod, and hose for damage, abrasion or clearance. Check operating device, cylinder, connecting rod, and hose for cracks, excessive abrasion or clearance. It shall be repaired and replaced in case of any abnormality; b) Remove dust and dirt around the engine, batteries, and radiators. Check whether dust and dirt are accumulated around the engine or radiator. Check also if any inflammable material (dead leaves, twigs, grass, etc.) has accumulated around the battery or high-temperature components, such as the engine muffler or pressurizer. All dirt and inflammable shall be removed; c) Check for water and oil leaks around the engine. Check the engine for an oil leak and the cooling system for a water leak. It shall be repaired in case of any abnormality; abnormality; e) Check the lower body (track, drive wheel, guide wheel, thrust wheel, support chain wheel) for any damage, abrasion, loose bolts or oil leakage at the thrust wheel; f) Check armrest for damage and bolts for looseness. Repair damage and tighten loose bolts; g) Check the instrument for damage, and the bolt for loose. Components shall be replaced and dirt on their surface shall be cleaned in case of any abnormality; h) Clean the rearview mirror and check for damage. It shall be replaced if it is damaged. The mirror shall be cleaned and adjusted so that the rear view can be seen from the driver seat. i) Check seat safety belts and fasteners for abnormalities. Replace it with a new one if there is any damage.



4.2.1.2 Coolant inspection



Warning Do not open the radiator cover unless it is necessary. Check the auxiliary tank after the engine has cooled when checking the coolant. After the engine is shut down, the coolant is at a high temperature and the radiator has a higher internal pressure. If the radiator cover is removed in this case to remove the coolant, there is a risk of scalding. Slowly turn the radiator cover to release pressure before removing the cover when it is cooled down.



4-3



Safe Operation of Excavator Procedures and Operational Techniques



d) Check hydraulic device, hydraulic tank, hose, joint for oil leakage. The oil leak shall be repaired in case of any



ZE215E Operation Manual



Checking steps: a) Open the door at the left rear of the machine and check the auxiliary water tank (1) as shown in Fig. 4-4; b) Whether the coolant in the auxiliary tank is between LOW and FULL marks, as shown in Fig. 4-5. If the cooling liquid level is low, the coolant shall be added to the FULL level through the filling port of the auxiliary water tank; c) Tighten the cover firmly after adding coolant; d) If the auxiliary water tank is empty, there may be a leak; e) It shall be repaired immediately after inspection. Check the liquid level in the radiator if there is no abnormality. If the liquid level is low, add coolant to the radiator and then add coolant to the auxiliary tank (1).



FULL LOW



1 Fig. 4-4



Fig. 4-5



Safe Operation of Excavator Procedures and Operational Techniques



4.2.1.3 Check engine sump oil level



Warning 1. Parts and oil remain at high temperatures when the engine is shut down, which may cause severe scalding. Do not operate until the oil temperature drops. The inspection steps are as follows: a) Open the engine hood on the machine; b) Remove the oil gauge (F) and wipe off the oil with a piece of cloth; c) Insert the oil gauge (F) completely into the filler and pull it out; d) The oil level shall be between the H and L marks on the oil gauge (F). If the oil level is below the L mark, refueling shall be done through the filler (G), as shown in Fig. 4-6. If the oil level is above the H line, open the drain valve (P) at the bottom of the engine oil sump to drain the surplus oil and check the oil level again. If the oil level is suitable, tighten the filler cover and close the engine hood.



Warning 1. When checking the oil level after the engine is operated, shut down the engine and wait for at least 15 minutes before inspection; 2. If the machine is inclined, park the machine horizontally before the inspection.



4-4



ZE215E Operation Manual



G



F



H L P Fig. 4-6



4.2.1.4 Fuel level inspection, fuel charge



Warning Do not allow the fuel to overflow during refueling or it may cause a fire. Wipe it thoroughly if oil spills. As fuel oil is inflammable and dangerous, no firework is allowed near the fuel oil; 3. Do not start the fuel filling pump when the engine is running normally. Safe Operation of Excavator Procedures and Operational Techniques



F F



50mm （2in）



G



Fig. 4-7



Fig. 4-8



Inspection steps when no fuel oil filling pump is equipped: a) Open the filler cap (F) on the fuel tank (as shown in Fig. 4-7); b) As shown in Fig. 4-8, when the cap of the filler cap is opened, the level gauge (G) will be raised according to the fuel level. Check whether the fuel tank is full by looking into the tank and checking through the float gauge (G). If the oil tank is not full, refuel it through the filler until the float gauge (G) is raised to the highest position. (When the oil tank is fully filled, the top of the float gauge (G) is about 50mm (2in) from the upper-end surface of the oil port); c) Press down the float gauge (G) with the filler cap (F) after refueling. Be careful not to let the float gauge (G) get stuck on the lug of the filler cap (F) and tighten the filler cap (F) firmly.



4-5



ZE215E Operation Manual



Attention 1. If the air vent on the cap is blocked, the pressure in the tank will drop and the fuel will not flow. Air vents shall be cleaned regularly. Inspection steps when equipping with fuel oil filling pump: a) As shown in Fig. 4-8, open the filling cap (F) on the fuel tank and the float gauge (G) will rise according to the fuel level. Check whether the fuel tank is full by looking into the tank and checking through the float gauge (G). If the oil tank is not full, insert the fuel filling pump suction pipe into the oil tank (as shown in Fig. 4-9) and turn on the power through the start switch; Fuel injection pump and control box



STOP



Valve



ON



Fig. 4-10



Fig. 4-9



Safe Operation of Excavator Procedures and Operational Techniques



b) Open the ball valve switch next to the oil outlet, and open the switch on the upper part of the pump body. Press the green "Run" button of the refueling control box (as shown in Fig. 4-10). At the moment, the refueling pump will enter the automatic refueling control state. When the fuel tank is filled, the fuel pump will automatically be cut off, and the entire refueling process ends. c) In case of any accident occurs during refueling, press the red "stop" button on the refueling control box, and the fuel pump will stop running immediately. Press the "run" button again when it needs to be refueled. d) When the fuel pump automatically stops due to unexpected circumstances (for example, when the fuel foam is generated during refueling, the controller may mistakenly judge that the oil tank is full). If it is confirmed that the tank is not full, click the "Run" button. With a click, the pump will only run once (to avoid oil spills). Press the "Run" switch repeatedly until the tank is full.



4.2.1.5 Drain water and sediment from the fuel tank a) The water and sediment in the fuel tank are discharged directly through the drain valve installed at the bottom of the tank. Put a container under the drain valve (1) to collect the discharged fuel oil; b) Open the drain valve (1) at the bottom of the fuel tank to drain the accumulated sediment and water along with the fuel oil; c) When the clean fuel is discharged, close the drain valve (1) as shown in Fig. 4-11.



4-6



1 Fig. 4-11



ZE215E Operation Manual



4.2.1.6 Inspection of oil and water separator a) Open the door at the right rear of the machine; b) Find the oil and water separator as shown in Fig. 4-12 (A). Put a container under the oil and water separator to collect the discharged oil. c) Release drain valve (1) at bottom of oil and water separator to drain water and sediment.



Attention 1. It is recommended to discharge the sediment from the oil and water separator once after the machine operates each working day.



1



A Fig. 4-12



4.2.1.7 Hydraulic oil level inspection



Warning 1. Oil may be ejected when the cap is removed. Therefore, the cap shall be slowly turned to release the internal pressure before being removed. Safe Operation of Excavator Procedures and Operational Techniques



a) If the operating device is not in the state shown in Fig. 4-13, start the engine and make it operate at a low speed. Take back the arm and the bucket cylinder, then drop the boom, adjust the bucket teeth to make it contact with the ground, and shut down the engine; b) Within 15 seconds after the engine is turned off, turn the start switch to the ON position and operate the lever (operating



Fig. 4-13



device, traveling) in each direction to release the internal pressure. c) Open the right rear door of the machine and observe the oil level gauge (G). The oil level shall be between the H line and L line, as shown in Fig. 4-14. d) If the oil level is below the L line, conduct refueling through the filler (F) at the top of the hydraulic tank.



Attention 1. Do not add oil above the H line since it will damage the hydraulic oil line or cause oil injection. If the oil has been above the H level, the engine shall be shut down and surplus oil shall be discharged from the screw plug (P) after the hydraulic oil is cooled. Note: The oil level will change with the oil temperature, as shown in Fig. 4-14: a) Before the operation: the oil level is between H and L (oil temperature is from 10°C to 30°C); b) Normal operation: the oil level is close to H (oil temperature is from 50°C to 80°C).



4-7



ZE215E Operation Manual



F



G



H L



P Fig. 4-14



4.2.1.8 Electrical wire inspection



Warning 1. If the fuse is burnt out frequently or there are signs of the short circuit in the circuit, it shall be checked immediately to find out the cause and it shall be repaired or contact Zoomlion distributor for repair; 2. The upper surface of the battery shall be kept clean, check the air vent on the battery cover. If the air vent is blocked by dirt or dust, the battery cover shall be cleaned for cleaning the air vent. Inspection contents: Safe Operation of Excavator Procedures and Operational Techniques



a) Check whether the fuse is damaged, check whether the circuit is broken or shows the short circuit signs. Moreover, check whether the terminal is loose and tighten any loose parts; b) Special attention shall be paid to the inspection of "battery", "starting motor", and "AC generator" lines; c) When conducting patrol inspection or pre-start inspection, be sure to check around the battery whether there is inflammable accumulation, and remove them in case of any.



4.2.1.9 Horn function inspection a) Turn the start switch to the ON position; b) Make sure that the horn will immediately beep when the horn button is pressed. Repair it immediately if the horn doesn't sound.



4.2.2 Operation confirmation before starting the engine



Warning 1. Check whether the safety lock joystick is in the locked position as shown in Fig. 4-15 when starting the engine. If the safety lock control joystick is not locked, the operating device will suddenly move when the operating handle is accidentally touched during the engine starting, which may cause a serious accident. 2. When the operator stands up from the seat, be sure to set the safety lock joystick in the lock position, regardless of whether the engine is rotating or not. Check whether the safety lock joystick (1) is in the lock position. Check the position of each control handle. Adjust the control handle to the neutral position.



4-8



ZE215E Operation Manual



HEAT



OFF ON



F



START



1 L Fig. 4-15



Fig. 4-16



Operation confirmation steps before starting the engine: a) Do not touch the button switch when starting the engine; b) Insert the key into the starting switch as shown in Fig. 4-16, turn the key to the ON position, and then perform the following check; c) The starting switch is switched from OFF to ON, and the electrical system is switched on. The instrument will be started automatically, and it will be started successfully about 10 seconds later; d) If the starting switch stays in ON gear and the engine is not started, "oil pressure alarm" and "battery voltage alarm" may occur. It is normal if these alarm items disappear when the engine Safe Operation of Excavator Procedures and Operational Techniques



starts; e) When starting up, the initial state of each operating parameter is as follows: It runs at a low speed. Automatic idle state Working mode symbol: E mode Warm-up symbol: uncertain, depending on the current coolant temperature and system settings. Safety lock symbol: locked state. f) Press the headlight switch as shown in Fig. 4-17 to check whether the



Fig. 4-17



headlight is on. If the headlights do not work, the bulb may be burnt out or broken.



4.2.3 Engine start 4.2.3.1 Normal start



Warning 1. Check the surrounding area for people or obstacles, then sound the horn and start the engine; 2. The gases emitted by the engine are harmful and special attention shall be paid to ensuring good ventilation when starting the engine in a closed space.



4-9



ZE215E Operation Manual



Attention 1. Check whether the fuel control knob is in a low idle speed (MIN) position before starting the engine; 2. Do not run the starting motor continuously for more than 15 seconds; 3. If the engine fails to be started, wait at least 2 minutes before restarting. 4. If the fuel control knob is in the MAX position, the engine will accelerate suddenly, causing damage to engine components. Therefore, adjust the control knob to the intermediate or low speed. 5. The machine must idle for 5 minutes after being started up before it can work properly. The normal starting steps of the engine are as follows: a) Check whether the safety lock joystick is in the lock position as shown in Fig. 4-15. If the safety lock joystick is in the open position, the engine will not be started. b) Set the fuel control knob to the low idle speed (MIN) position as shown in Fig. 4-18. Turn the start switch key to the START position, as shown in Fig. 4-19, and the engine will be started.



MAX



HEAT



OFF ON



Safe Operation of Excavator Procedures and Operational Techniques



MIN



Fig. 4-18



START



HEAT



OFF ON START



Fig. 4-20



Fig. 4-19



c) When the engine is started, release the start switch key and the key will automatically be returned to the ON position as shown in Fig. 4-19; d) Do not operate the operating device lever and traveling pedal when the oil pressure alarm light is still on after the engine is started, as shown in Fig. 4-20.



4-10



ZE215E Operation Manual



Attention 1. If the indicator light of the oil pressure gauge does not go out after 4-5 seconds as shown in Fig. 4-20, shut down the engine immediately to check the oil level for oil leakage, and take necessary measures if any.



4.2.3.2 Engine start in cold weather



Warning 1. Do not use starting auxiliary fluid as it can cause explosions. If the temperature drops, the engine will not start easily. The following shall be noted when starting the engine on a cold day: a) Replace the fuel oil and lubricating oil with low-viscosity oil. Refer to Table 3-1 in Maintenance Manual for details. b) Replace the coolant of the cooling system, and the mixing ratio details of anti-freezing solution are shown in Table 3-1 in Maintenance Manual; c) As storage capacity drops dramatically at a low temperature, cover or remove the battery from the machine to place it in a warm place, and reinstall it the next day.



4.2.4 Operation after engine start



Attention 1. If you want to cancel the warm-up operation in the process, press the "cancel the warm-up operation" button on the instrument to cancel it (the user had better not interrupt the warm-up operation at will to avoid damage to the machine); 2. In the process of warm-up, the control handle is useless. Only after the warm-up is finished or it is canceled can the control function of the lever be restored. 3. Do not operate the lever while the hydraulic oil is still at low temperature. The warm-up operation shall be continued until the temperature of the hydraulic oil reaches about 30°C. It will extend the service life of the machine; 4. Do not accelerate the engine suddenly until the warm-up operation is completed. Do not run the engine continuously at low or high speeds for more than 20 minutes. Otherwise, the oil supply pipe for the turbocharger may leak. If the engine has to be run at idle, it shall be loaded intermittently or run at intermediate speed.



4.2.4.1 Automatic warm-up operation (in cold areas) a) When starting the engine in a cold area, the automatic warm-up operation shall be carried out. b) If the water temperature of the engine is low (less than 10℃), the engine will be automatically warmed up when the it is started (this function needs to be set in the user setting item of the instrument). c) If the water temperature of the engine reaches the specified temperature (30℃) or the set time (15 minutes), the automatic warm-up will be cancelled. 4-11



Safe Operation of Excavator Procedures and Operational Techniques



Do not start the operation immediately when the engine is started, warm up shall be conducted for the machine. There are two ways of warm-up: automatic and manual warm-up operation. Select the warm-up operation based on the ambient temperature. If the operating device is operated without adequate warm-up, it will respond slowly to the movement of the lever and will not operate as required by the operator. Adequate warm-up shall be conducted especially in cold areas.



ZE215E Operation Manual



4.2.4.2 Manual warm-up operation If the user wants to conduct the manual warm-up, the following steps shall be followed firstly: a) Turn the fuel control knob to the center position between low speed and high speed, as shown in Fig. 4-21, and operate the engine at a intermediate speed for about 5 minutes at no load. b) Adjust the safety lock joystick to the open position as shown in Fig. 4-15, and lift the bucket from the ground; c) Operate the bucket lever and arm lever slowly as shown in Fig. 4-22 to move the bucket cylinder and arm cylinder to the stroke end; d) Carry out full stroke operation of bucket and arm for 5 minutes, and switch between bucket operation and arm operation in a cycle of 30 seconds.



Attention 1. Do not interfere with the machine body or the ground when retracting the operating device.



Arm operation



MAX



Unload Excavate



Bucket operation Unload



Excavate



MIN



Safe Operation of Excavator Procedures and Operational Techniques



Fig. 4-21



Fig. 4-22



After the warm-up operation, check whether all instruments and indicators on the machine instrument controller are in the following state.



•



Low coolant level alarm: No alarm



•



Battery voltage alarm: No alarm



•



Low fuel level alarm: No alarm



•



Coolant temperature alarm: No alarm



•



Oil pressure alarm: No alarm



•



Air filter cleaner blockage alarm: No alarm



•



Hydraulic oil temperature alarm: No alarm



•



Coolant thermometer: Pointer in green area



•



Hydraulic oil thermometer: Pointer in green area



•



Fuel level gauge: Pointer in green area



Checking steps: a) Check exhaust color, noise or vibration for abnormalities, repair shall be conducted in case of any abnormalities; b) If the air filter cleaner is clogged and the instrument is shiny, clean or replace the filter element immediately. Refer to "Maintenance Manual" for cleaning the filter element; c) Turn the fuel control knob to the high speed (MAX) position, as shown in Fig. 4-23, and check whether the instruments and apparatus is in normal operation for 3 to 5 minutes.



4-12



ZE215E Operation Manual



d) Repeat the following operation slowly 3 to 5 times.



Boom operation Lift - drop Arm operation Retract- Stretch out Bucket operation Dig - unload Turning operation Left - right turn Travel (low speed) operation Forward - backward



MAX



• • • • •



MIN



e) Use the power mode button on the machine instrument to select the operating mode to be adopted; Operating mode instrument display:



• • • •



Fig. 4-23



Mode P: used for heavy load operation, the complete machine shows the maximum operating potential; Mode E: used for general operations Mode L: Used for a light load operation, suitable for flat ground, slope repair, and other operations, the arm moves more gentle; Mode B: Used for hydraulic crushing hammer and other attachments.



4.2.5 New machine running-in



Warning 1. Zoomlion machines have been thoroughly adjusted and tested before being delivered. However, the operation of the machine in bad conditions will have an adverse effect on the performance of the machine at the beginning and shorten the service life of the machine;



in this Manual during the run-in. Precautions are as follows: a) Run the engine at a low idle speed for 15 seconds when it is started. Do not operate the lever or fuel control knob at the moment; b) Run the engine at a low speed for about 5 minutes when it is started. c) Avoid heavy load operation or high-speed operation, and it shall be run in about 80% of the maximum load; d) Avoid sudden starts, sudden acceleration, sudden turns, and sudden stops except in emergency situations; Faults like sintering and clamping stagnation may occur without running-in, which will shorten the service life of the machine.



4.2.6 Engine shutdown



Attention 1. If the engine is suddenly shut down before being cooled, the engine life will be greatly shortened. Therefore, do not suddenly shut down the engine except in emergency situations; 2. Do not suddenly shut it down when the engine overheats, and it shall be run at a low idle speed to make it gradually cool, and then shut it down. Engine shutdown steps: a) Run the engine at a low idle speed for about 5 minutes to allow it to cool gradually; b) Turn the start switch key to the OFF position as shown in Fig. 4-24 to shut down the engine; c) Take down the startup switch key. 4-13



Safe Operation of Excavator Procedures and Operational Techniques



2. Be sure to run the machine in for the first 100 hours (as shown in the hour-meter). Follow the precautions



ZE215E Operation Manual



4.2.6.1 Inspection after engine shutdown The inspection steps are as follows:



HEAT



OFF



a) Inspect the machine, check the operating device, the upper



ON



and lower body of the machine, and check for oil or water leaks. It shall be repaired in case of any abnormality;



START



b) Check the engine room for paper, debris, and other inflammables, and it shall be cleaned in time in case of any to avoid fire; c) Remove dirt adhering to the lower body.



4.3 Safety operation rules for excavators



Fig. 4-24



4.3.1 Traveling of excavator Turn the fuel control knob to a higher speed to increase the engine speed, as shown in Fig. 4-23.



Warning 1. Check the direction of track frame before operating steering lever; 2. If the drive wheel is in front, the traveling lever shall provide reverse operation; 3. Make sure it is safe around the machine and sound the horn before moving the vehicle. 4. Don't let anyone near the machine; Safe Operation of Excavator Procedures and Operational Techniques



5. Remove all obstacles along the machine's route; 6. The rear of the machine is a blind area, so special attention shall be paid during reversing. 7. When the automatic idle function works, the engine speed will suddenly be increased by operating the lever. Therefore, it must be operated with care. 8. For machines equipped with a walking alarm (optional), check whether the warning device works normally.



4.3.1.1 Forward of machine The forward steps of machine are as follows: a) Turn the safety lock joystick to the open position, retract the operating device and lift it off the ground 400 to 500mm (16 to 20in) as shown in Fig. 4-25. b) When the drive wheel is at the back of the machine, slowly push forward the lever or slowly press down the front of the pedal (as shown in Fig. 4-26) to make the machine travel; c) When the drive wheel is at the front of the machine, slowly pull back the lever or slowly press down the back of the pedal to make the machine travel. Note: At low temperature, if the traveling speed of the machine is abnormal, a



400-500mm Fig. 4-25



thoroughly warm-up shall be conducted. In addition, if the lower body is blocked by dirt, the traveling speed of the machine is abnormal, dirt and soil on the lower body shall be cleaned.



4-14



ZE215E Operation Manual



Sprocket



Sprocket



Sprocket



Sprocket



Fig. 4-27



Fig. 4-26



4.3.1.2 Backward of machine a) Turn the safety lock joystick to the open position, retract the operating device and lift it off the ground 400 to 500mm (16 to 20in). b) Operate the LH-RH traveling lever or LH-RH traveling pedal as follows:



When the drive wheel is at the back of the machine, slowly pull back the lever or press down the back of the pedal (as shown in Fig. 4-27) to make the machine travel.



•



When the drive wheel is at the front of the machine, slowly push forward the lever or slowly press down the front of the pedal to make the machine travel.



4.3.1.3 Excavator braking N



Warning 1. Avoid sudden stop and leave plenty of space during



N



parking. 2. Place the LH-RH lever in the neutral position as shown in Fig. 4-28 and stop the machine.



4.3.2 Steering of excavator



Fig. 4-28



Warning 1. Check the position of the drive wheel before operating the traveling lever. If the drive wheel is in front, the traveling lever shall provide reverse operation;



4-15



Safe Operation of Excavator Procedures and Operational Techniques



•



ZE215E Operation Manual



Change direction with the traveling lever(1) as shown in Fig. 4-29. Try to avoid sudden changes in direction. Stop the machine before turning (spot turning), especially when turning in reverse.



1



Fig. 4-29



4.3.2.1 The machine turning when shutdown



B A



Push forward the RH traveling lever to make the machine turns left front; Pull back the RH traveling lever to make the



B



machine turn left rear, as shown in Fig. 4-30.



(A): Turn the left front Safe Operation of Excavator Procedures and Operational Techniques



Sprocket



(B): Turn the left rear When turning to the right, operate the LH traveling lever in the same manner.



A Fig. 4-30



4.3.2.2 Turning in traveling Pull the traveling lever towards the neutral position direction



A



B



when driving forward, and the machine will turn to the left front. Push the left traveling lever towards the neutral position direction when driving backward, and the machine will turn left



Sprocket



rear, as shown in Fig. 4-31.



(A): Turn the left front (B): Turn the left rear Operate the RH traveling lever in the same manner when making a right turn in traveling. Fig. 4-31 4-16



ZE215E Operation Manual



4.3.2.3 Spot traveling Pull back the LH traveling lever and push forward the RH traveling lever when turning left, as shown in Fig. 4-32. Pull back the RH traveling lever and push forward the LH traveling lever when turning right on the spot.



Sprocket



4.3.3 Control and operation of the operating device Fig. 4-32



Warning



1. If the lever is operated when the automatic idle function is in effect, the engine speed will suddenly rise. Therefore, attention shall be paid when operating it; 2. If the operating device lever is operated quickly, it will move quickly. The operating device is operated by the lever on the left and right sides. The LH lever controls the arm and slewing, and the RH lever controls the boom and bucket. The movement direction of the lever and the operating device is shown in Fig. 4-33. When it is released, the lever automatically returns to the neutral position and the operating device remains on the spot. When the machine is at rest and the operating device lever is in the neutral position, the engine speed is kept at low speed even when the fuel control knob is set to the MAX position due to the automatic idle function.



1. An accumulator is installed in the operating circuit of the machine to lower the operating device to the ground by turning the starting switch key to the ON position and operating the lever within 15 seconds, even after the engine is shut down. This operation can also be used to remove residual pressure in the hydraulic oil cylinder loop or to lower the boom after the machine is mounted on the trailer.



4.3.3.1 Arm control Move the left operating device lever forward or backward and operate the arm as shown in Fig. 4-33.



Fig. 4-33 4-17



Safe Operation of Excavator Procedures and Operational Techniques



Attention



ZE215E Operation Manual



4.3.3.2 Slewing control



Warning 1. The rear of the machine extends outside the track width. Check the surrounding area for the safety before slewing the superstructure; 2. If the swing lever is operated rapidly, the upper body will rotate rapidly. To turn the upper body, please swing the lever to the left or right, as shown in Fig. 4-34.



Fig. 4-34 Safe Operation of Excavator Procedures and Operational Techniques



4.3.3.3 Boom control To operate the boom, please push forward or pull backward the RH lever, as shown in Fig. 4-35.



Fig. 4-35



4-18



ZE215E Operation Manual



4.3.3.4 Bucket control To operate the bucket, please swing the RH lever to the left or right, as shown in Fig. 4-36.



Fig. 4-36



4.3.3.5 Bucket replacement



Warning 1. When hitting the bearing pin with a hammer, the metal particles may fly into your eyes, resulting in a serious injury. So please wear always the goggles, safety helmet, gloves and other protective articles 2. The bucket shall be placed stably after removal; 3. If the bearing pin is hit too hard, it may fly out and hurt people around. Therefore, it is required to ensure no people around before hitting the bearing pin. 4. When removing the bearing pin, special attention should be paid not to stand or place your foot or any part of your body under the bucket; 5. When removing or installing the bearing pin, please pay attention not to scrape your hands; 6. When aligning with the hole, please don't put your fingers in the pinhole. Please park the machine on the solid and flat ground. For safety, please make clear signals and operate with caution in making connections. a) Place the bucket on the flat ground.



Attention 1. When removing the bearing pin, the bucket shall be placed in a position just in contact with the ground; 2. If the bucket is heavily dropped on the ground, it will increase the resistance will be increased, causing the difficulty to remove the bearing pin.



4-19



Safe Operation of Excavator Procedures and Operational Techniques



during such operation;



ZE215E Operation Manual



b) Dismantle the double nuts from the locking bolt of each bearing pin for the arm and the connecting rod, and then the locking bolt; next, remove the bearing pin (A) of the arm and the bearing pin (B) of the connecting rod successively, and then the bucket, as shown in Fig. 4-37.



Attention 1. After removal of the bearing pins, please make sure that they are not soiled by the sediment, and the seals at two ends of the shaft sleeve are not damaged. c) Align the arm and the connecting rod with the hole ① and ② respectively, and then apply them with the lubricating grease and install the bearing pins (A) and (B). Note: a) Install them in the reverse sequence of dismounting; b) In installing the bucket, please mount an O-ring on the bucket with the position as shown in the right Fig. for the bearing pin of the arm. After inserting the bearing pin, load the R-ring into the appropriate slot. For the bearing pin (B) of the connecting rod, install the bucket after the O-ring is loaded into the appropriate slot. c) Tighten the locking bolts and nuts for each bearing pin, and then apply them with the lubricating grease.



1



A 2



C Safe Operation of Excavator Procedures and Operational Techniques



B



3



4



5



B



A Fig. 4-37



1. Hole



2 .Hole



A .Bearing pin of the arm



3. Bucket



B .Bearing pin of the bucket



C .Position of the connecting rod's bearing pin



4-20



4. O-ring



5.Arm



ZE215E Operation Manual



4.3.4 Operation under different working modes 4.3.4.1 Working modes: For effective operation, please select a working mode matched to the working conditions with the power mode selector switch, as shown in Table 4-1. When the starting switch is turned to ON, the working mode will be set to Mode E. Then, you may use the work mode switch to switch the working mode to the mode most applicable to the engine. Table 4-1 Operations under Different Working Modes Working Mode Mode P Mode E Mode L



Applicable Operation Heavy-load mode, under which the machine could give full play to its greatest working potential Normal mode, under which the machine inputs about 85% of the total engine power for operation Light-load mode, under which the machine inputs about 65% of the total engine power for operation



Mode B



Auxiliary operating devices such as hydraulic breaker



4.3.4.2 Mighty digging switch: To increase the digging force during the operation process, please press the button on the right side, as shown in Fig. 4-38. This function shall be enabled as required in conjunction with the working conditions.



Fig. 4-38



Warning 1. When the machine is traveling, special caution shall be given in operating the operating device lever if necessary: 2. If any lever is operated under the automatic idling mode, the engine speed will suddenly increase. So please operate with caution.



4.3.5.1 Prohibition from operating with the swing force Do not use the swing force to compact the ground or crush objects. This is not only dangerous, but will shorten significantly the service life of the machine or damage it, as shown in Fig. 4-39.



Fig. 4-39 4-21



Safe Operation of Excavator Procedures and Operational Techniques



4.3.5 Prohibitions



ZE215E Operation Manual



4.3.5.2 Prohibition from operating with the traveling force Do not dig the bucket into the ground to excavate with the traveling force, otherwise, the machine or operating device will be damaged, as shown in Fig. 4-40.



Fig. 4-40



4.3.5.3 Prohibition from operating with the end of the hydraulic oil cylinder stroke



Full-Retracting



When the piston rod of the hydraulic cylinder has moved to the stroke end, the hydraulic cylinder will be damaged in case of applied with additional external force. Please avoid such operation, as shown in Fig. 4-41. Safe Operation of Excavator Procedures and Operational Techniques



Fig. 4-41



4.3.5.4 Prohibition from operating with the bucket's falling force Don't use the bucket's falling force to excavate or as a pickaxe, hydraulic breaker or pile driver. This will shorten significantly the service life of the machine, as shown in Fig. 4-42.



Fig. 4-42



4-22



ZE215E Operation Manual



4.3.5.5 Prohibition from operating with the machine's falling force Don't excavate with the falling force of the machine, as shown in Fig. 4-43.



Fig. 4-43



4.3.5.6 Prohibition from excavating the hard rocky ground Don't use the excavator to excavate the hard rocky ground. It'd better excavate it after it is crushed with other measures. This could not only avoid damages to the machine, but also be quite economic.



4.3.5.7 Prohibition from changing the lever gear suddenly when the machine is traveling rapidly



Warning



Forward



1



1. Don't change the lever gear suddenly, otherwise, a sudden startup will occur, as shown in Fig. 4-44;



3



Reverse



Neutral



Safe Operation of Excavator Procedures and Operational Techniques



2. Please avoid switching the lever from the driving gear to



2



the reverse gear (or from the reverse gear to the driving gear) suddenly; 3. Please avoid the sudden gear switching for the lever, such as switching from high-speed operation to stop (by releasing the lever).



Fig. 4-44



4.3.5.8 Prohibition from using it for hoisting The machine is prohibited from being used as a crane.



4.4 Safety operation technologies 4.4.1 Safety traveling When traveling on obstacles such as gravels or stumps, the machine (especially the lower body) will be subject to a large impact, as shown in Fig. 4-45. Therefore, please reduce the traveling speed and make the obstacles to be crossed from the center of the track. Such obstacles shall be removed or avoided for being crossed as far as possible. The machine shall travel at a low speed on uneven roadbeds, such as stone roadbeds or uneven roads with large stones. When the machine is traveling at a high speed, its front idler shall be in the driving gear. To switch among traveling speeds, please press the traveling speed selector switch.



Fig. 4-45



4-23



ZE215E Operation Manual



4.4.2 Allowable water depth



Warning 1. If the machine angle exceeds 15° when it is traveling from water, as shown in Fig. 4-46, the back part of its upper body will be immersed in water, causing damage to the radiator due to water splashes resulted by the cooling fan; 2. Do not drive the machine in water that is deeper than the centerline of the carrier roller (1); 3. Parts immersed in water for a long time shall be applied with the lubricating oil, till the used lubricating oil (especially around the bucket and bearing pins) is extruded completely.



1 Fig. 4-46



4.4.3 Traveling on slopes



Warning 1. Please lift the bucket about 20-30cm (8-12in) above the ground when traveling, rather than traveling down the slope in a backward manner; Safe Operation of Excavator Procedures and Operational Techniques



2. When traveling on bumps or other obstacles, the operating device shall be close to the ground and travel slowly; 3. Don't turn on or cross a slope, as shown in Fig. 4-47 (A). Be sure to carry out such operations on flat ground that may be a little farther but safe; 4. When working on a slope, the machine will lose balance and then tip over in case of turning or operating the operating device. So such operations shall be avoided;



（A）



5. When the bucket is provided with some load, it will be quite dangerous to turn the machine toward a slope. If such operation is necessary, a platform shall be built on the slope with soil so that the machine can be balanced during the operation, as shown in Fig. 4-47(A); 6. For the danger of tipping over, don't drive the machine to travel up or down a steep slope; 7. If the track shoes are slipping or the force of the track is insufficient to drive the machine to travel up a slope, don't help the machine to climb with the drawing force of the arm for the danger of tipping the machine over.



4-24



Platform （B） Fig. 4-47



ZE215E Operation Manual



20-30cm



(a)



20-30cm 20-30cm



(b)



Fig. 4-48



Fig. 4-49



a) When traveling up a slope: When the machine is traveling up a slope of above 15°, the operating device shall be retracted into the position as shown in Fig. 4-48(a); To ensure the balance when traveling up a steep slope, the operating device shall be extended and lifted 20-30cm (8-12in) above the ground for traveling at a low speed, as shown in Fig. 4-48 (b).



•



If the engine misses when the machine is traveling up a slope, please turn all the levers to the neutral position, place the bucket on the ground, and then start the engine.



b) When traveling down a slope: Keep the machine travel at a low speed with the traveling lever and the fuel control knob. When the machine is traveling down a slope of more than 15°, the operating device shall be adjusted to the state as shown in Fig. 4-49, and



•



•



One side of the drive wheel shall be suspended when the machine is traveling down a slope; If the above mentioned side of the drive wheel is not suspended when the machine is traveling down a slope, the track tends to slack with the danger of gear jumping; To brake the machine when it is traveling down a slope, please turn the traveling lever to the neutral position for automatic application of the braking force.



Warning 1. If the engine misses during traveling on a slope, never turn the machine with the LH lever. Otherwise, the upper body will be turned under its dead weight; 2. Never open or close the door when the machine is traveling on a slope. Instead, keep the door locked securely before it is opened or closed.



4.4.4 Escape from the mud The machine shall be always operated with caution to avoid it to be stuck in the mud. In case of being stuck in the mud, the machine shall be released from the mud with the following steps: a) For the case with one side of the track stuck in the mud:



Attention 1. When lifting the machine with the boom or arm, the bottom of bucket must be in contact with the ground (never push the machine with the bucket teeth). The angle between the boom and the arm shall be kept in the range of 90° to 110°. 4-25



Safe Operation of Excavator Procedures and Operational Techniques



meanwhile the engine speed shall be reduced.



ZE215E Operation Manual



When only one side of the track is stuck in the mud, please lift the track with the bucket and then place some boards or logs under it to drive the machine out the mud. If necessary, place some boards under the bucket, as shown in Fig. 4-50 (a). b) For the case with both sides of the track stuck in the mud: If two sides of the track are stuck in the mud, causing the



(a)



machine to slip without the ability of moving, please place some logs or boards as mentioned above under them. Then, make the bucket dig into the ground on the front of it, operate the arm with the same method as excavating, and then turn the traveling lever to the driving gear to drive the machine out the mud, as shown in Fig. 4-50 (b).



(b) Fig. 4-50



4.4.5 Machine parking Safe Operation of Excavator Procedures and Operational Techniques



Warning 1. Sudden parking shall be avoided. The machine shall be parked within a space as much as possible; 2. The machine shall be parked on the solid and flat



120°



ground; 3. Avoid parking the machine on a slope; 4. If it is necessary to park the machine on a slope, please place some cushions under the track and then make the bucket dig into the ground to prevent the machine



Fig. 4-51



moving, as shown in Fig. 4-51; 5. The accidental touching on the operating device lever will result in the sudden movement of the operating device or machine, leading to a serious personal injury or accident. Therefore, be sure to place firmly the safety lock joystick in the locked position before standing up from the seat. Operation steps to park the machine: a) Turn the LH-RH traveling levers to the neutral position and then park the machine; b) Operate the fuel control knob to reduce the engine speed to the low speed, as shown in Fig. 4-52 (see the next page); c) Drop the bucket horizontally, till its bottom is in contact with the ground, as shown in Fig. 4-53; 4-26



Fig. 4-53



ZE215E Operation Manual



d) Place the safety lock joystick to the locked position.



N



N



MIN



Fig. 4-52



4.4.6 Operation under special weather conditions 4.4.6.1 Operation in cold days Please operate the machine with the following steps since the engine will not be started easily and the coolant will be frozen under a low temperature: a) Fuel and lubricating oil The fuel and the lubricating oil both with a low-viscosity shall be applicable to all the components. For details for the viscosity specified, please see the Maintenance Manual. b) anti-freezing solution



1. The anti-freezing solution is toxic. Be careful not to splash it into your eyes or on your skin. If this happens, please rinse your eyes or skin with plenty of clean water and then seek medical attention immediately. 2. And meanwhile, do not approach the anti-freezing solution to any source of ignition since it is flammable. Do not smoke when handling it; 3. When replacing the anti-freezing solution or handling the coolant in repairing the radiator, please contact the Zoomlion distributor or consult your local distributor for the anti-freezing solution. Pay attention not to flow such solution into the sewer or spill it on the floor.



Warning 1. Don't use the methanol, ethanol or propanol-based anti-freezing solution; 2. Don't mix the anti-freezing solutions with different brands for use; 3. For regions without permanent anti-freezing solution to be purchased, the ethylene glycol-based antifreezing solution that doesn't contain any preservative can be only used in cold months. In this case, the cooling system shall be cleaned twice a year (respectively in spring and autumn). The anti-freezing solution shall be injected into the cooling system in autumn rather than spring. For details about the mixing ratio of the anti-freezing solution in replacing the coolant, please see the Maintenance Manual. c) Battery 4-27



Safe Operation of Excavator Procedures and Operational Techniques



Warning



ZE215E Operation Manual



Warning 1. Be sure to keep the battery far away from any fire or sparks since some flammable gas will be generated by the battery; 2. The battery electrolyte is quite dangerous. If the electrolyte gets into your eyes or on your skin, please rinse with plenty of clean water and then seek medical attention immediately; 3. Please rinse with plenty of water if some battery electrolyte gets on the machine since it could dissolve the paint. 4. If the battery electrolyte is frozen, don't charge the battery with different power sources or start the engine, otherwise, there will be a risk of battery explosion; 5. When the ambient temperature drops, the battery capacity also drops. The battery electrolyte will be frozen under a low battery charging ratio. The battery shall be charged fully as much as possible and isolated from low temperatures, so that the machine could be started easily the next morning. Note: a) Measure the specific gravity for the electrolyte and then convert the charging ratio according to the method shown in Table 4-2; Table 4-2 Relationship between the Charging Ratio and the Liquid Temperature Charging Ratio



Liquid Temperature



Safe Operation of Excavator Procedures and Operational Techniques



20°C



0°C



-10°C



-20°C



100



1.28



1.29



1.30



1.31



90



1.26



1.27



1.28



1.29



80



1.24



1.25



1.26



1.27



75



1.23



1.24



1.25



1.26



b) For the reason of significant reduction of the battery capacity under low temperatures, the battery shall be covered at night or removed from the machine and then placed in a warm environment, and installed back on the machine the next morning.



4.4.6.2 Operation in snowy days Roads covered by snow or ice are quite slippery. So special attention shall be paid during traveling of the machine or in operating it. Never operate the joystick suddenly. Otherwise, the machine will be slipped even through it travels on a quite small slope. Therefore, special attention shall be paid during operation on a slope. a) The frozen ground will become soft under high temperatures, which may cause the machine to be tipped over; b) If the machine is stuck in deep snow, there will be a risk of tipping over or being immersed in snow. Pay attention not to make the machine travel out the road shoulder or immersed in the snow; c) Be sure to remove the snow with caution since there will be a risk for the machine to be tipped over or impacted by the objects buried in snow that cannot be seen. Please operate with the following steps after the season changes and the weather is warming: Replace the fuel and engine oil with the specified viscosity for all the components. For details, please see the Article specifying that "please use the ethylene glycol-based anti-freezing solution (special for use in winter, one-season type) if no permanent anti-freezing solution could be used for some reasons; alternatively, the cooling system shall be emptied and cleaned completely and then provided with fresh soft water if no anti-freezing solution could be used" in the Maintenance Manual. 4-28



ZE215E Operation Manual



4.4.7 Tasks after completion of above operations 4.4.7.1 Inspect and clean the machine Check the engine water temperature, hydraulic oil temperature and fuel level displayed on the machine's dashboard. To remove the mud and water on the lower body, please do the followings: a) Run the engine at a low speed, and then turn it by 90° to turn the operating device to the side of the track; b) Lift the machine to lift the track slightly above the ground. Idle the track. Repeat such operations for the left and right tracks; c) The mud on the girder of the track frame that cannot fall off by itself shall be removed with hands.



Warning 1. The idling track is dangerous, which shall be kept far away from people; 2. After completion of the above operations, the fuel tank shall be filled up to prevent the moisture in the empty tank from condensing to form water when the temperature drops. To prevent the mud and water on the lower body from freezing, causing the machine cannot move the next morning, the following precautions shall be observed: a) The mud and water on the machine shall be thoroughly removed to prevent damage to the seals due to the mud, dirt and water droplets entering the seal; b) The machine shall be parked on the solid and dry ground. If possible, please park the machine on solid boards. Because the boards could prevent the track from being frozen in soil, so as to ensure that the machine could be started the next morning; c) Open the drain valve to discharge the water collected in the fuel system to prevent it from freezing. Safe Operation of Excavator Procedures and Operational Techniques



4.4.7.2 Locking The following parts shall be locked, as shown in Fig. 4-54: (1) Engine hood (2) Left side door of the machine (3) Cab door (4) Toolbox cover (5) Oil inlet of the fuel tank (6) Right side door of the machine (7) Oil inlet of the hydraulic tank



1 7



5



2



4



3 Fig. 4-54



6



4-29



ZE215E Operation Manual for Hydraulic Excavator Chapter V Accessories and Options



ZE215E Operation Manual



Chapter V Accessories and Options 5.1 General precautions 5.1.1 Safety precautions a) There are safety or legal constraints when installing options or accessories. Therefore, please contact Zoomlion or Zoomlion distributors in advance. If this fails, we will not be liable for any accident or damage arising from this; b) The use of accessories or options not approved by Zoomlion will not only affect the service life of the machine, but also cause some safety problems. So any injury, accident or machine failure arising from this will have no relationship with Zoomlion; c) When installing and using the optional accessories, please read carefully the operation manuals for such accessories and the general instructions in these operation manuals.



Warning 1. To prevent serious injuries or damages, the accessories shall be used properly; 2. Please read through the operation manuals of the accessories, and never use them before thoroughly understanding the contents in the operation manuals. If any operation manual is lost, please ask the manufacturer or distributor for a new one; 3. The necessary front cover shall be installed on the machine according to the conditions of accessories; 4. Since the vibrational noise of accessories can make it difficult for a colleague to deliver the intent of the operation, it is necessary to assign a person to deliver and determine signals to be used before starting the operation; 5. In case of heavy loads on the accessories, do not perform the turning operation on the side of the steering on a slope since it is very dangerous; 6. Compared to machines equipped with a bucket, those equipped with a hydraulic breaker have a heavier load on the front of the operating device and are unstable. Therefore, don't perform any operation when the accessory is turned to any side to avoid the risk of tipping over; 7. After equipped with the accessories, the turning range and center of gravity of the machine will also properly the condition of the machine; 8. Before starting the operation, a warning line shall be placed around the machine to prevent people from access. Do not operate the machine when there is someone near it; 9. To prevent serious accidents caused by mishandling, do not put one of your feet on the pedal except the case of operating the machine with the pedal.



5.1.2 Precautions in disassembly & installation operations When disassembling or installing accessories, be sure to follow the following steps to ensure the safety of operation:



Warning 1. Disassembly & installation operations performed on the solid and flat ground; 2. When operating by more than two people, the signals shall be determined and followed during operation; 3. When lifting or handling heavy objects (more than 25kg or 55lb), be sure to use a crane; 5-1



Accessories and options



change, which could cause the accidental movement of the machine. So it is necessary to understand



ZE215E Operation Manual



4. When removing heavy components, they shall be supported before disassembly. When lifting with a crane, special attention shall be paid to the position of the center of gravity; 5. It is quite dangerous to operate the machine while the crane is still holding the load. A  bracket shall be prepared and be sure that it is safe; 6. When placing or mounting the removed accessory, make sure that it is stable and can not tip over; 7. Do not walk under the load lifted by the crane. Please stand in a safe place where there is no danger even if the load falls.



Attention 1. The crane shall be operated by an operator with a qualification certificate, which shall never be operated by those without such certificate; 2. For details in disassembly & installation operations, please contact Zoomlion or Zoomlion distributors.



5.1.3 Precautions in the installation of accessories



Attention 1. If a heavier operating device is installed, causing an increase in the turning stroke (i.e., the movement distance of the operating device from the driver's operation of the lever to stop turning to the complete stopping of the upper body), there will be risks of misjudging the distance and hitting certain objects, so please provide a margin when operating the lever to stop turning. In addition, the hydraulic drift will also increase (when the operating device is parked in the air, it will gradually decrease under its own weight); 2. When installing the boom and the arm, be sure to follow the correct procedure. The failure in following the correct procedure will cause serious damages or injuries, so please contact Zoomlion or Zoomlion distributors before installation. 3. If a long operating device is installed, the operating range will be extended suddenly, bringing the risks of misjudging the distance and hitting certain objects. Therefore, it is necessary to leave some space for objects in the operating area when operating the operating device.



Accessories and options



4. If a longer or heavier operating device is installed, it is prohibited from turning the machine on a slope. Instead, it shall be turned in the way as shown in Fig. 5-1; It is prohibited from turning the machine on a slope. If necessary, please operate on the platform as shown in Fig. 5-2 (b).



Fig. 5-1 5-2



ZE215E Operation Manual



Platform



(a)



(b)



Fig. 5-2



5.2 Operation instructions for accessories and options



Warning 1. Please read the instructions in the sections for accessories and options in the operation manuals of accessories and this Manual; 2. Safety will be involved when installing the accessories or options. Therefore, please contact Zoomlion or Zoomlion distributors before installation. Otherwise, it will not only cause safety problems, but also affect adversely the operation to the machine and the service life of the equipment; 3. Zoomlion will not be liable for any injury, accident or damage caused due to use of unapproved accessories or options.



5.2.1 Combination of the operating device



Attention 1. If you use an operating device other than the type or combination we provide for you, please consult Zoomlion or its agents in advance; otherwise, Zoomlion will not be liable for any injury, accident or 2. When using an unfamiliar operating device for the first time, please check for any danger involved before the operation, and then operate it with caution. The accessory combinations applicable to the arm and the bucket of this machine are listed in Table 5-1. Table 5-1 Accessory Combinations of ZE215E Operating Device



Bucket name



Bucket capacity (m3)



Standard bucket



1.0



Oversize bucket



1.1



Rock bucket



0.9



Standard boom (5,700mm) Application Ordinary excavation Loadingexcavation Heavy-duty operations



Standard arm



Short arm



(2925mm)



(2400mm)



◎



◎



△



○



●



●



5-3



Accessories and options



damage caused due to this;



ZE215E Operation Manual



Note: 1) The meanings of symbols in the table:



●: Suitable for handling materials with a density less than or equal to 2,000kg/m3 ◎: Suitable for handling materials with a density less than or equal to 1,800kg/m3 ○: Suitable for handling materials with a density less than or equal to 1,500kg/m3 △: Suitable for handling materials with a density less than or equal to 1,200kg/m3 , only for loading 2) Category of purposes Ordinary excavation: excavation or loading of sand, gravel, clay, etc. Light-duty excavation: excavation or loading of dry, loose soil and sand, sludge, etc. Loading: loading of dry, loose soil and sand.



Warning 1. The boom shall be operated with caution during the oblique excavation, since it will interfere with the lower body when it is dropped completely; 2. For excavation or loading of hard soil or rocks, it is recommended to use a rock bucket with high strength and high wear resistance.



5.2.2 Selection of track shoes Please select track shoes suitable for the operating conditions. See Table 5-3 for the types of track shoes. Table 5-3 Selection of Track Shoes Types of track shoes A (standard)



Accessories and options



B (optional)



Technical specification 600mm, three-tooth track shoe



700mm, three-tooth track shoe



Application Rocky ground, riverbed, common soil



Common soil, soft ground



Precautions in use The machine shall travel through gravel and rocky roads at a low speed. This type of track shoes cannot be used on grounds with lots of gravels and rocks. They can only be used on flat grounds. If it is necessary to cross any obstacles with them, the machine shall travel at a low speed. This type of track shoes shall only be used where the machine is sunk or the type A or B track shoes cannot be used.



C (optional)



5-4



800mm, three-tooth track shoe



Extremely soft ground (swamp ground)



This type of track shoes cannot be used on grounds with lots of gravels and rocks. They can only be used on flat grounds. If it is necessary to cross any obstacles with them, the machine shall travel at half speed of the low speed.



ZE215E Operation Manual



Attention 1. Track shoes in Type B and C are wide ones, which are therefore restricted in use. When using these track shoes, the conditions of use shall be thoroughly investigated and studied against the precautions to determine their suitability; 2. When selecting the width of a track shoe, try to choose the narrowest one according to the ground pressure required. If the track shoes being used are wider than the wanted, the load on them will increase, causing them to be bent, links and bearing pins to be broken, the track shoe bolts to be loose, etc.



5.3 Operation for the recommended options This section describes the precautions to be observed when operating a machine with options (mainly hydraulic breaker).



Attention 1. Choose the accessories that best fit the machine; 2. The models of machines that can be equipped with accessories are different. For the selection of accessories and machine models, please contact Zoomlion or Zoomlion distributors.



5.3.1 Hydraulic breaker 5.3.1.1 Purpose of the hydraulic breaker A hydraulic breaker can be used for demolition of buildings, rupture of pavements, tunneling operations, crushing of steel slags and stones, and crushing operations in quarries.



5.3.1.2 Precautions in use of the hydraulic breaker



Warning 1. Before installing the hydraulic hammer, be sure to contact Zoomlion or the distributor designated by Zoomlion in advance.



Accessories and options



When using a hydraulic breaker, please pay attention to the following points: a) Except for replacing the breaker or hose, the pipe cut-off valve of the breaker shall be kept in ON (always on), as shown in Fig. 5-3; b) When performing the crushing operation, the drill rod shall be perpendicular to the impact surface, as shown in Fig. 5-4;



5-5



ZE215E Operation Manual



!



CAUTION ON OFF



keep it always open



Fig. 5-3



90°



90°



Fig. 5-4



c) When applying the impact force, the drill rod shall be pressed onto the impact surface so that the front end of the chassis is less than 5cm (2in) above the ground; the machine shall not be lifted too much above the ground, as shown in Fig. 5-5; d) When the continuous impact is applied to the same impact surface, the impact position shall be changed to a point near the edge if the drill rod cannot penetrate or break the surface within 1 minute, as shown in Fig. 5-6;



Accessories and options



5cm



Fig. 5-5



Fig. 5-6



e) The penetration direction of the drill rod will not be aligned with the direction of the hydraulic breaker body gradually. So the bucket cylinder shall be adjusted all the time to keep the two aligned with each other, as shown in Fig. 5-7. f) The drill rod shall always be pressed onto the impact surface to prevent the generation of impact forces when there is no resistance, as shown in Fig. 5-8.



5-6



ZE215E Operation Manual



Fig. 5-7



Fig. 5-8



5.3.1.3 Prohibitions To ensure the service life of the machine and safe operation, do not operate the machine in any of the following ways. a) Do not operate all the cylinders to their stroke ends; instead, keep always a 5cm (2 in) allowance; b) The machine shall be prohibited from hitting stones, as shown in Fig. 5-9;



Fig. 5-9



c) The machine shall be prohibited from being operated with the turning force, as shown in Fig. 5-10;



Accessories and options



Fig. 5-10



d) The drill rod shall be prohibited from being moved during impacts, as shown in Fig. 5-11;



Fig. 5-11



5-7



ZE215E Operation Manual



e) It is prohibited from applying the impact force horizontally or upwards (as shown in Fig. 5-12);



Fig. 5-12



f) Never swing the drill rod when it has penetrated into the rock (as shown in Fig. 5-13);



Fig. 5-13



g) It is prohibited from gouging (as shown in Fig. 5-14);



Fig. 5-14



Accessories and options



h) The bucket cylinder shall be prohibited from being extended completely to lift the machine above the ground (as shown in Fig. 5-15).



Fig. 5-15



5-8



ZE215E Operation Manual



5.3.1.4 Injection of lubricating grease for the hydraulic breaker



Attention 1. The injection of lubricating grease with an improper posture will



Right



cause the hydraulic breaker to be filled with too much lubricating grease, possibly resulting in the entering of soil or sand into the lubrication pipe and then damages to the



Rod



movable components when the hydraulic breaker is used. Therefore, the lubricating grease must be filled under a proper posture. Please inject the lubricating grease under a proper posture (as shown in Fig. 5-16). (a) Proper inject the lubricating grease after the drill rod has been pressed into the ground



(a)



Wrong



(b) Improper don't inject the lubricating grease when the breaker body is placed at one side of the drill rod (c) Improper don't inject the lubricating grease when the drill rod is off the ground



(b)



Wrong



Accessories and options



Fig. 5-16 (c)



5-9



ZE215E Operation Manual for Hydraulic Excavator Chapter VI Transport and Storage of Excavator



ZE215E Operation Manual



Chapter VI Transport and Storage of Excavator 6.1 Transport For transport safety, the machine can be transported in several parts. Therefore, please contact Zoomlion or Zoomlion distributors before transporting the machine. The machine shall be generally transported with a trailer that meets the requirements in weight and size provided in Technical Specifications. Please note that the weight and shipping dimension provided in the Technical Specifications will vary depending on the type of track shoe, arm or other accessories. The following provisions shall be followed during the transport: a) Study all the provisions and local regulations on restriction of the weight, width and length of loads and, if necessary, decompose the operating device. As a result of the difference in operating devices, the loads are also different in weight, width and length. Therefore, this point shall be taken into account when determining the transport route; b) When passing a bridge or road, please check first whether the structural strength of the bridge or road is sufficient to bear the weight of the machine. When transporting on the road, please ask the relevant authorities to check and follow their instructions. The specific steps for shipping are described below.



6.1.1 Loading and unloading



Warning 1. Before loading/unloading, turn the auto idle button to OFF (cancel). If it is in ON, the machine will travel suddenly; 2. When loading or unloading the machine to or from the trailer, the machine shall be moved at a low speed, without any operation to the traveling speed selector switch; 3. Keep the engine running at a low speed and operate the machine slowly when loading/unloading; 4. Do not load/unload the machine during the automatic warm-up; 5. The machine shall be loaded/unloaded on the solid, flat ground and a certain safe distance from the road edge shall be kept; 6. A slope with sufficient width, length, thickness and strength as well as a loading/unloading angle of at most 15° shall be used (as shown in Fig. 6-1). When building a soil slope, the soil shall be fully compacted, with some measures taken to prevent the slope from collapsing;



Transport and storage of excavator



7. To prevent the machine from slipping on the slope, please remove all the mud and dirt from the track before loading or unloading. The slope surface shall be kept clean and free of water, snow, ice, lubricating grease or oil;



MAX15°



Fig. 6-1 8. Do not turn on the slope, otherwise, there will be a risk of tipping over for the machine. If necessary, the machine shall be driven out the slope for direction adjustment and then traveling on the slope again; 9. Don't perform loading and unloading with the operating device, otherwise, it will be dangerous; 6-1



ZE215E Operation Manual



10. When the machine is parked on a slope, don't operate any lever except the traveling lever; 11. The gravity center of the machine will be changed suddenly at the joint of the slope and the trailer, resulting in the risk of losing balance for the machine. Therefore, the machine shall travel slowly to cross this area; 12. The trailer will be unstable if the upper body of the machine is turned on the trailer, so the operating device shall be retracted to turn the upper body slowly.



6.1.1.1 Loading The excavator must be loaded on a slope with a platform following the steps below: a) The loading could only be performed on the solid and flat ground, with a certain safe distance from the road edge; b) Appropriate braking shall be applied to the trailer and some cushions shall be placed under tires to ensure that the trailer



Ramp



does not move. Then, build a slope between the trailer and



Block



the machine. Make sure that the slopes on two sides are on the same level. The slope shall not exceed 15° at most, and the distance between the slopes shall be adjusted to match the center of the track (as shown in Fig. 6-2); c) Make sure that the machine is in the low-speed gear;



MAX 15° Block Fig. 6-2



d) Disable the auto-idle function, operate the fuel control knob, and adjust the engine speed to a low level; e) If the machine is equipped with an operating device, the operating device shall be placed in front; and then, keep the machine travel forward for loading; If no operating device is equipped, keep the machine travel backwards for loading; f) Keep the machine travel slowly with the traveling direction aligned with the slope. Try to lower the operating device under the premise of causing no influence. When the machine is traveling on the slope, don't operate any other levers or pedals except the traveling lever (as shown in Fig. 6-3); g) The machine will be unstable when it travels to the part above the rear wheels of the trailer, so please drive it slowly and carefully (do not operate it for turning); h) The machine will tilt forward at the moment of passing through the rear wheels of the trailer, so do not contact the operating device with the trailer body. Drive the machine forward to the specified position and then stop it; i) Slowly rotate the upper body by 180° to place the operating device at the back (as shown in Fig. 6-4); j) Park the machine in the specified position on the trailer.



90°~110°



Transport and storage of excavator



MAX15°



Fig. 6-3



6-2



Fig. 6-4



ZE215E Operation Manual



6.1.1.2 Securing the machine



Attention 1. Put the radio antenna away and remove the rear view mirror. Secure the removed components into the trailer; 2. To prevent damage to the bucket cylinder during



Fig. 6-5



transport, please place a wooden block on one end of the bucket cylinder to prevent it from reaching the bottom plate (as shown in Fig. 6-5). After loading the machine on the trailer, please secure it with the following steps: a) Extend the bucket and the arm cylinder completely, and then lower the boom slowly; b) Shut down the engine and then remove the key from the starting switch; c) Make the safety lock joystick in the locked position. d) Lock the cab door, side door, battery compartment cover, and



Fig.6-6



engine hood. Place some wooden blocks under the ends of the track to prevent the machine from moving during transport and then secure the machine with a chain or wire rope (as shown in Fig. 6-6). Pay special attention to secure the machine firmly to make it not slide toward one side.



6.1.1.3 Unloading The machine must be unloaded on a slope with a platform following the steps below: a) The unloading could only be performed on the solid and flat ground, with a certain safe distance from the road edge; b) Appropriate braking shall be applied to the trailer and some cushions shall be placed under tires to ensure that the trailer does not move. Then, build a slope between the trailer and the machine. Make sure that the slopes on two sides are on the same level. The slope cannot exceed 15° at most. Adjust the distance between slopes to a level matching to the center of the track; c) Remove the chain or wire rope used to secure the machine;



0°



d) Start the engine and perform the thorough warm-up for it in cold



90



°-1 1



days; e) Adjust the safety lock joystick to the free position. f) Make sure that the machine is in the low speed gear;



Transport and storage of excavator



g) Disable the auto idle function, operate the fuel control knob, and adjust the engine speed to a low level; h) Lift the operating device, receive the arm into the boom, and then move the machine slowly; i) Stop the machine after it moves horizontally to the part above the rear wheels of the trailer; j) When moving the machine to the slope from the back of the trailer, the angle between the arm and the boom shall be



Fig. 6-7



6-3



ZE215E Operation Manual



adjusted to the range of 90°～110°. Lower the bucket to the ground, and then move the machine slowly (as shown in Fig. 6-7); k) When the machine travels on the slope, operate slowly the boom and the arm to move the machine carefully, till it leaves the slope completely.



6.1.2 Hoisting the machine



Warning 1. Don't hoist the machine when there are people on the machine; 2. Be sure that the wire rope used for hoisting the machine has sufficient strength to withstand the weight of the machine. 3. Do not hoist the machine in any other positions than those provided in the following procedure, otherwise, the machine may lose balance; 4. Do not hoist the machine with the upper structure turning to one side. Before hoisting, the operating device shall be turned to one end of the drive wheel and the lower track shall be parallel to the upper body of the machine; 5. The machine shall be kept horizontal during the hoisting; 6. During the machine hoisting, don't walk under the machine, otherwise, it will be quite dangerous.



Attention 1. The hoisting procedure applies to machines meeting the standard technical specifications; 2. Depending on the accessories and options equipped actually, the ways of hoisting may be different. In this case, please contact Zoomlion or Zoomlion distributors for consulting. The machine shall be hoisted on the flat ground with the following steps: a) Turn the upper body of the machine to make the operating device at one end of the drive wheel; b) Extend the bucket cylinder and the arm cylinder completely, and then drop the operating device to the ground with the boom cylinder, as shown in Fig. 6-8;



Transport and storage of excavator



30°-40°



Fig. 6-9 6-4



Sprocket Fig. 6-8



ZE215E Operation Manual



c) Shut down the engine, and then leave the machine after it is confirmed that nothing exists around the cab. Close the cab door and the front glass window; d) Pass through a wire rope respectively from the gap between the front first and second track rollers and the rear first and second ones. However, for machines equipped with track roller guards, the wire ropes shall be passed through from the bottom of the track; e) Adjust the lifting angle of the wire rope to 30° - 40°, and then hoist slowly the machine, as shown in Fig. 6-9; f) After the machine has been hoisted above the ground, check carefully for the balance of the machine, and then lift it slowly.



6.2 Storage 6.2.1 Precautions before storage



Attention 1. Before storing the machine, adjust the machine to the position as shown in Fig. 6-10 to protect the cylinder piston rod (from rusting).



Fig. 6-10



Follow the steps below if the machine will be stored for a long time: a) Clean and rinse all the components, and then place the machine indoors. If the machine has to be stored outdoors, please cover it and then store it on flat ground; b) Before storage, fill the fuel tank to prevent moisture from entering, and then lubricate it and replace the engine oil; c) Apply a thin coat of lubricating grease on the metal surface of the piston rod; d) To prevent the battery from being out of power, the negative terminal of the battery shall be disconnected before storage (if a negative switch is equipped, just disconnect the negative switch), and it is recommended to remove the battery to store separately before long-term storage of the machine; e) If the ambient temperature is expected to drop below 0°C (32°F), some anti-freezing solution shall be added to the coolant; f) Turn the safety lock lever to the locked position.



6.2.2 Precautions during storage



Attention 1. If the rust preventive measures must be taken for the machine stored indoors, be sure to open the doors and windows to achieve good ventilation and prevent gas poisoning; 2. The machine shall be started monthly to travel for a short distance during storage, so as to attach a new 3. If the machine is equipped with an air conditioner, please run the air conditioner for 3 to 5 minutes monthly to lubricate in cycles all the components of the compressor. Make sure that the engine is running at a low speed and then operate the air conditioner. The remaining amount of refrigerant shall be checked twice a year; 4. When operating the operating device, all the lubricating grease on the hydraulic oil cylinder rod shall be removed. 6-5



Transport and storage of excavator



layer of oil film on the surface of moving components and check if the instruments are normal;



ZE215E Operation Manual



6.2.3 Precautions after storage



Attention 1. If the monthly rust preventive measure isn't taken for the machine, please contact Zoomlion or Zoomlion distributors when the machine will be in use; 2. For machines not in use for a long time, please follow the steps below before use: a) Remove the lubricating grease applied on the cylinder piston rod; b) Apply the engine oil and lubricating grease to all the parts in need of lubrication; c) For machine not in use for a long time, the moisture in atmosphere may penetrate into the oil. Therefore, please check the oil in all the parts before and after starting the engine. If there is some water in the oil, replace it; d) Sufficient warm-up for the engine shall be provided in starting the engine of machine not in use for a long time.



Transport and storage of excavator 6-6