ZE220Elc Maintaining Manual

ZE220ELC HYDRAULIC
EXCAVATOR
MAINTENANCE MANUAL
First Edition of Dec. 2012

Hydraulic Excavator Maintenance Manual
To users
My respectable users thank you for choosing Hydraulic Excavators of Zoomlion brand. Before its
maintenance, please read up on the content of the manual and have a full understanding of it, then comply
with the relevant rules in the manual strictly.
Doing a regular inspection, maintenance and repair on the machines are the essential means to make
sure that they fully exert the good qualities, work safely and reliably and prolong their life. In order to make
you convenient for inspection, maintenance and repair the machines, we provide this Maintenance Manuel
for you.
The maintenance manual gives you a detailed introduction of the rules and explanations about the
inspection, maintenance and repair of hydraulic excavators and it also introduces the methods of judging and
solving the common faults.
In order to make the machines work normally and for you and other people’s personal safety, make sure
that you have read up on this manual and on other attached documents before maintenance and repair the
machines. If you have any doubts or questions, please contact the local service engineers and we will provide
the technical support for you timely and effectively. Our company will not bear any undesirable
consequences resulted in disobeying the rules of this maintenance manual.
In the process of maintaining the machines, the stuff mustn’t dismantle or adjust the hydraulic
components without authorization. When the hydraulic components are broken down or the parts are
damaged, please call our local service engineer. Because of the constant improvement, promotion and the
difference of the product standard and model, the details of some pictures and the text content in this manual
may be a little different from the products that you possess. Our company keeps the right of revising the
content about Maintenance Manuel due to technical improvement. We are subject to change without prior
notice and we hope that all users can understand us.
This manual applies for the Zoomlion brand ZE220ELC hydraulic excavator.
Thank you very much for your trust and support for Zoomlion products. We send our heartfelt wishes to
you: wish you all the best!
I
Safety Information Instructions

The safety and warning icons referred to in the specification are as follows:
Danger
High risk alert: it will cause deaths or severe injuries if not avoided.
Warning
Moderate risk alert: it will probably cause severe injuries if not avoided.
Attention
Slight risk of danger, Mild risk should be paid attention to, as it will probably cause
slight or moderate injuries if not avoided.
Caution
Safety tips sign: it will probably cause property damage if ignored.
Tips
It gives tips and instructions for individual information.
Importance
It emphasizes the importance of individual information.
It indicates that this operation doesn’t meet the safety standard which is prone to casualty
accidents. So it is forbidden to implement.
II
Catalogue
To users .............................................................................................................................................................. I
Safety Information Instructions .................................................................................................................... II
Chapter One: Maintenance Safety Criterion for the Excavators ............................................................. 1-1
1.1 Basic safety requirements for maintenance ...................................................................................... 1-1
1.2 Maintenance considerations ............................................................................................................. 1-1
Chapter Two: General Drawing and Main Parameters of the Excavators ........................................... 2-1
2.1 Outline Drawing of the Excavators.............................................................................................. 2-1
2.2 Main Technical Parameters of the excavators............................................................................... 2-1
Chapter Three: Maintenance of the Excavators .................................................................................... 3-1
3.1 Maintenance Information of the Excavators................................................................................. 3-1
3.2. Maintenance of the Electrical System ......................................................................................... 3-3
3.3. Maintenance of the Hydraulic System ........................................................................................ 3-4
3.4 Lubricating Oil, Fuel and Cooling Liquid .................................................................................... 3-4
3.5 Wearable Parts ............................................................................................................................ 3-9
3.6 The Technical Specification of Tightening Torques ...................................................................... 3-9
3.7 The Periodic Replacement of the Safety Key Parts .................................................................... 3-11
Chapter Four: Maintenance Schedule of the Excavators ...................................................................... 4-1
4.1 Everyday Maintenance................................................................................................................ 4-1
4.2 Maintenance in the Initial 250 Hours and 500 Hours.................................................................... 4-3
4.3 Maintenance of every 250 hours.................................................................................................. 4-4
4.4 Maintenance of Every 500 Hours ................................................................................................ 4-8
4.5 Maintenance of Every 1000 Hours ............................................................................................ 4-11
4.8 When in Need ........................................................................................................................... 4-16
4.9 Maintenance of Hydraulic Breaker ............................................................................................ 4-32
III
Chapter Five: Common Faults and the Eliminating Methods............................................................... 5-1
5.1 Phenomena of Unreal Faults ............................................................................................................ 5-1
5.2 Electrical System.............................................................................................................................. 5-2
5.3 Hydraulic system.............................................................................................................................. 5-3
5.4 The Engine sections ......................................................................................................................... 5-4
Appendix 1 ZE220ELC Schematic Diagram of the hydraulic system
Appendix 2 ZE220ELC Schematic Diagram of the electrical system
IV
ZE220ELC Hydraulic Excavator
Maintenance Manual
Chapter One: Maintenance Safety Criterion for the Excavator

Maintenance Safety Criterion for the Excavators

Chapter One: Maintenance Safety Criterion for the Excavators
1.1 Basic safety requirements for maintenance
It has a significant role of doing well on the maintenance and repair of the excavators for extending
service life, ensuring man-machine safety, improving work efficiency and increasing economic efficiency.
Except read the relevant requirements referred to "Safety Tips", maintenance staff should comply with the
following items:
1. The worker in charge of maintenance can not perform the maintenance work unless they have
mastered the knowledge of structure, performance, assembly and disassembly procedures, technical
requirements, precautions of the excavator.
2. For the projects with great difficulty to maintain, consult to manufacturers if not be sure.
3. Routine maintenance is usually carried out before starting the vehicle and after completing the work
everyday. Park the vehicle on the level ground before maintenance, and lock the locking mechanism, then
carry on maintenance.
4. Before maintenance, the surrounding area of the parts will be maintained should be cleaned and
scrubbed thoroughly, particularly for the surrounding area of oil inlet, filter, oil nozzle, and the tank cover
should be cleaned to prevent dust to enter into the oil.
5. Remember that there is high pressure in the hydraulic circuit, when refueling, draining or inspection
and maintenance, the pressure should be released first.
6. Start the vehicle and rise the oil temperature to 30℃～40℃ to drain before changing the engine oil.
7. Use clean oil and grease. When inspecting or replacing the oil, it should not perform at the dusty
place otherwise the dust will mix into the oil.
8. The electrical system can not be handled in the rain.
9. When check or add cooling water, beware of the hot water spraying to hurt people.
10. After the replacement of oil filter element or coarse strainer, discharge air in the oil-way.
11. It is prohibited to refuel without filter net over the oil inlet.
12. Before overhauling the gearbox, hollow out the pocket. Beware of wrenches, nuts and other things to
fall into the cabinets, resulting in unnecessary troubles.
13. Oil should be far away from the fire sources, and do not use a torch instead of lighting.
14. When changing the O-rings, gaskets or other seals, the part surface should be cleaned strictly and
installed carefully.
1.2 Maintenance considerations
1-1
Maintenance Safety Criterion for the Excavators
Carry out the technical maintenance correctly and timely, that is performing the technical maintenance
for the machinery frequently and regularly, such as inspection, cleaning, lubrication, adjustment, fastening
and so on. This will not only increase the production efficiency, reduce wear and avoid unexpected failures,
but also improve the excavator economy, extend the service life of the machine, and reduce the maintenance
costs.
The machine specifyes the maintenance-hour which is recorded by the hour meter.
When the operating environment condition is poor s of, the required maintenance time should be
operated earlier
Attention
1. When maintenance, comply to the relevant regulations of the "safety operation specification".
2. When the maintenance is performed under the vehicles, hang the sign on the driver's seat, or
make a sign around the excavator , if necessary.
3. When cleaning, refueling, checking the tension of the fan belt of the vehicles and inspection on
the moving parts and their nearby parts, the engine must be stopped running.
4. When carrying on maintenance, inspection and charging the batteries, stop the engine and
remove the battery cap at the same time. When dismantle the batteries and charger connector, close
the charger switching.
5. When carrying on maintenance, it is prohibited to close to the open fire, including the fire
source of smoking, spark and etc..
6. When refueling oil, draining oil, inspecting and maintaining for the hydraulic system, release
the pressure first.
7. Special adjustment tool should be used when adjust the oil pressure, or failures will occur when
perform difficulty maintenance.
8. In the process of inspection and maintenance, except for the necessary personnel, other
personnel should not approach.
9. The refueling parts, oil standard surface and all oil containers should be kept clean; the
specified brand oil by Zoomlion should be used; when check and replace the various types of oil, in
order to maintain the high cleanliness , it should be performed in the dust-less environment,.
1-2
Maintenance Manual
Chapter Two: General Drawing and Main Parameters
of the Excavator
Chapter Two: General Drawing and Main Parameters of the Excavators

2.1 Outline Drawing of the Excavators
The appearance of ZE220ELc excavator in this manual is shown in Fig 2-1
General Drawing and Main Parameters of the Excavators

1 bucket 2 bucket cylinder 3 Arm 4 Arm cylinder 5 Boom 6Boom cylinder 7 hood 8 Counter weight 9 Upper
Frame 10 Travel motor 11 Track shoe 12 Track frame 13 Front idler 14 cab
Fig 2-1 The outline drawing of the ZE220ELC excavators

2.2 Main Technical Parameters of the excavators
The main technical parameters of ZE220ELC hydraulic excavators can be seen in Table 2-1.The overall
size can be seen in Figure 2-2, and the working range can be seen in Figure 2-3
2-1
Table 2-1 Main technical parameters of 220ELc hydraulic excavators
Parts Items ZE220ELC

Bucket volume m3 1.05(1.2)
Model Cummins 6BTAA5.9-C150
6cylinders,4 stroke water injection,
Type
turbo-charged inter-cooled type
Rated power kW/rpm 112/2000
Engine Maximum torque (N-m/rpm) 614/1500
Displacement (ml) 5883

Starter motor (v) 24
Electric generator (Amp) 70
Main pump Model The swash plate double variable piston pump
Maximum flow rate (L/min) 2×210
Pilot pump Gear pump
Hydraulic system
The double-speed swash plate piston motor
Travel motor
with automatic brake valves and parking brake
The swash plate piston motor with automatic
Rotary motor
brake valves
Working device hydraulic circuit
32.1 (35 when pressurized)
(Mpa)
System pressure Travel hydraulic circuit (Mpa) 34.3
Rotary hydraulic circuit (Mpa) 25.5
Pilot hydraulic circuit (Mpa) 3.9
Boom(mm) 2－120×1315×85
Hydraulic cylinder Arm(mm) 1－135×1540×95
(cylinder number Bucket(mm) 1－120×1120×85
－cylinder bore × Rotary motor The swash plate piston motor
stroke ×piston Speed-reduction mechanism Secondary planet reducer
diameter
Rotary speed 11.5
Rotary braking Wet multi-disc brake
Travel motor The swash plate piston motor
Speed-reduction mechanism Secondary planet reducer
Steering control Two operation levers with pedals
Driving and braking
Parking brake Wet multi-disc brake
system
Maximum tractive force (kN) 192
Climbing ability 35°（70﹪）
Travel speed (high/low) (km/h) 5.0/3.2
Track frame Box structure
Track shoe (piece/side) 49
Chassis Track roller (piece/side) 9
Sprocket(piece/side) 2
Track guarding frame (piece/side) 1
Fuel tank (L) 350
Volume of coolant Coolant (L) 30
and lubricating oil Engine oil (L) 22
Rotary device (L) 3.4
2-2
Parts Items ZE220ELC

Travel device (L) 2×5.5
Hydraulic system (L) 300
Hydraulic oil tank (ml) 180
Operating weight (kg) 22400
A (Overall length mm) 9570
B (Overall width mm) 3090
C (Overall height(to the top of
3125
boom mm)
D (turning radius of the tail mm) 2837
E (Tail Length mm) 2800

F (Counter weight from the
1065
The Overall size ground level mm)
（Refer to G(Minimum ground clearance
440
mm)
Figure2-2） H (Track grounding length mm) 3650
J (Length of the track mm) 4440
K (Track gauge mm) 2390
L (Width of the track mm) 700
M(Height of the shoe tooth mm) 26
N (Overall height ,the top of cab
2960
mm)
P(Width of the rotary frame mm) 2720
A (maximum digging distance
9835
mm)
B (maximum reach on the ground
9660
mm)
C (maximum digging depth mm) 6580
Working range
D(E) (maximum vertical digging
(Refer to Fig2-3) 5735
depth mm)
E (maximum digging height mm) 9665
F (maximum discharge height
6810
mm)
G (minimum turning radius mm) 3295
Maximum digging force of the
147
bucket (kN)
Digging force
Maximum digging force of the
103
arm (kN)
2-3
Fig 2-2 Drawing of the appearance size of ZE220ELC
2-4
Fig 2-3 Sketch of ZE220ELC working range
2-5
Maintenance Manual
Chapter Three: Maintenance of the Excavator

Chapter Three: Maintenance of the Excavators

3.1 Maintenance Information of the Excavators
When operating the machines, users must carry out regular maintenance so as to guarantee safety
consistently. In addition, to improve safety further, users should also replace the key parts regularly. Because
the materials of these parts will change as time passes by, and parts are prone to wear down or deteriorate. It
is hard to judge the conditions of parts through regular maintenance. Therefore, replace parts as soon as the
prescribed time arrives no matter what conditions, which is necessary to these their functions completely all
the time. These parts have special and close relationships for the safety and fire prevention.
If these parts are abnormal before the replacement cycle arrives, they must be repaired or replaced
instantly. Please contact with Zoomlion or Zoomlion distributors to change the safety key parts. Before
maintaining and repair the excavators, please read “Operation Manual” and the following maintenance
guidelines at first.
Tips
1. Don’t carry out any undescribed inspection and maintenance in this instruction book.
Maintenance of the Excavators

2. The maintaining and repairing work should be carry out on the flat and firm ground .
3.1.1. Hour Meter’s Readings
Check the hour meter every day and see whether the reading has arrived the required time to carry out
maintenance.
3.1.2. Pure wearable Parts of Zoomlion
Use the specified pure parts of Zoomlion in “SPARE PARTS CATALOG” as the replacements.
3.1.3. Lubricating Oil
Use the designated engine oil and lubricating oil by Zoomlion. Choose the engine oil and lubricating oil
with suitable viscosity according to the environment temperature.
3.1.4. Windshield Washer Fluid
Use the car-using windshield washer fluid and make sure not to let dirty things go inside.
3.1.5. Clean Engine Oil and Lubricating Oil
Use the clean engine oil and lubricating oil, and keep the oil or the grease container clean. Don’t let the
impurities mix into the oil and the grease.
3.1.6. Check the Discharged Oil and the Used Filter Element
After changing the oil or the filter element, check if there is metal debris and impurities in the used oil
3-1
and the filter element. If a lot of metal debris and impurities are found, report to the executive and take proper
measures.
3.1.7. Fuel Coarse Strainer
If the machine is assembled with fuel Strainer , don’t unload the strainer element when adding fuel.
3.1.8. Welding Specification
a) Turn off the engine starting switch and disconnect the battery cathode.
b) Don’t use the voltage over 220V continuously.
c) Connect the grounding cables within 1m from the welding position . If the grounding cables are close
to the apparatus, connectors and so on, the apparatus failures will appear.
d) Avoid sealing elements or bearings between the welding position and the grounding point.
e) Don’t use the axis pin of working device or the surrounding regions of the hydraulic cylinder as the
grounding point.
3.1.9. Prevent Dropping Things into the Interior of the Machine
a) When opening the inspection window or the oil inlet of the oil tank, notice not to drop nuts, bolts or
tools into the interior of the machine. If these things fall into the machine, it will cause machine damage and
fault and cause accidents. If something falls into the machine, take it out at once.
b) Don’t put unessential things in your pockets, only the necessary things for inspection can be taken .
3.1.10. Working Field with Much Dirt
When working in field with much dirt, please do as the following procedures:
1) The dirt indicator should be used frequently to check whether the air filter is blocked and clean the
filter element more frequently.
2) Clean the radiator filter regularly in case of being clogged.
3) Clean and change the fuel filter element often.
4) Clean the electric parts, especially the starter motor and the alternator to avoid accumulating dirt.
5) When checking or replacing oil, in order to prevent the dirt from entering into the oil, move the
machine to a place without dirt.
3.1.11. Avoid Mixing Lubricating Oil
Don’t mix the oil with different brands together. If a different brand is required , please discharge all the
used oil and change it with the new brand oil.
3.1.12. Lock the Engine Cover and the Left and Right Doors
When carrying on the maintenance with the engine cover and the left and right doors open, use the
3-2
locking lever to lock the engine cover and the left and right doors firmly. If inspect or maintain under the
conditions of opening and not locked, there is risk of wind blowing to close the cover and door suddenly, and
it will cause injure to personal.
3.1.13. Hydraulic System—Exhausting
When repairing or changing the hydraulic equipment, or dismantling and installing the hydraulic
pipeline, please discharge the air in the oil pipeline. The relevant details can be seen in the chapter
“Discharge the Air in the Hydraulic System”.
3.1.14. Installation of Hydraulic Hose
1) When dismantling the parts sealed by O-rings or sealing gaskets, please clean the mounting surface
and change them with new parts. Don’t forget to install the O-rings and sealing gaskets.
2) When installing the hoses, don’t twist the hoses or bend them into circles with minor diameters
because it will damage the hoses and shorten the hoses’ service life obviously.
3.1.15. Maintenance and check after the Inspection
After the inspection and maintenance without further check, accident will happen and cause severe

injuries or damage. Please do as the following procedures:
a) Inspection after shutting down the machines (when shutting down the engines)
1) If the maintained parts are inspected;
2) If all the inspection and maintenance have been carried out correctly (Refer to the chapter
“Maintenance for the Excavators” of the manual);
3) If there are tools or parts falling into the interior of the machines;
4) If there is water leak or oil leak;
5) If all the bolts are fastened.
b) Inspect when operating the engines
The inspection details about operating the engines can be seen in the relevant chapter of “Operation
Manual”, and pay attention to safety.
1) Whether the inspection and maintenance items are operated normally;
2) Whether there is oil leak when the engine speed rises and the load.is imposed.
3.1.16. Choose Fuel and Lubricating Oil Matched with the Environment
It is obliged to use fuel and lubricating oil matched with the environment temperature.
The relevant details can be seen in the chapter “Choose the suitable lubricating oil, fuel and coolant ”.
3.2. Maintenance of Electrical System
3-3
a) It is very dangerous when the electrical devices are damp or the wire insulation layers are damaged.
This will lead electricity leak and cause machine fault, and don’t use water to wash the interior of the cab.
When washing the machines, notice not to let water enter into the electrical parts.
b) The maintenance about the electrical system is to check the fan belt tension force, to check if fan belt
is damaged or worn down and check the liquid level of the storage battery.
c) Don’t install any electrical element which is not specified to install by Zoomlion.
d) The disturbance of the external signals will cause fault of the controller in the control system. When
installing radio receiver or other wireless devices, please contact with Zoomlion or Zoomlion distributors .
e) When working on the beach, clean the electrical system carefully in case of corrosion.
f) When installing the air cooler or other electrical devices in the cab, link it to the specialized power
connector, and the selected power can’t be linked absolutely to fuse, starting switches or electrical relay of
the storage battery.
3.3. Maintenance of Hydraulic System
The hydraulic system is under high temperature during work and after work. When being in operation, it
is still in the condition of high pressure. Therefore, when doing inspection and maintenance to the hydraulic
system, comply with the following procedures:
a) Stop the machine on flat ground, descend the bucket to ground, and release pressure in the hydraulic
cylinder pipeline.
b) Shut down the engine.
c) Before starting maintenance, please wait for the temperature dropping.
d) Even if the temperature decreases, there still is pressure in the interior. When loosening plugs, screws
or the connectors, don’t stand in front of the parts. Before dismantling the parts, loosen them gradually to
release the internal pressure.
e) When doing inspection and maintenance to the hydraulic oil pipeline, the internal pressure must be
discharged.
f) The inspection or maintenance includes: check oil level of the hydraulic oil, change filter element and
add hydraulic oil.
g) When dismantling the high pressure hose, check whether the O-ring is damaged. If it is damaged,
change it.
3.4 Lubricating Oil, Fuel and Coolant

3.4.1. Deal with Lubricating Oil, Fuel and Coolant and Analyze the Oil Quality
3.4.1.1 Lubricating Oil
The lubricating oil is used for engine and working device under poor conditions (high temperature and
3-4
high pressure), and it will deteriorated during work. So the oil brand specified in Table 3-1 should be used.
a) Change the oil at the regulated time, even if the oil is not dirty.
b) The lubricating oil is like the blood in people’s body. Please notice to prevent impurities (water,
metal particles and dust and so on) from entering into them when dealing with it. Most of the machine’s
problems are caused by the impurities’ entering. Please look out specially to prevent any impurities from
entering when stored or refueled.
c) Refuel according to the specified oil volume. Too much or too little oil will cause faults.
d) If the oil in the working device is not clean, there is water or air in the oil pipeline, please contact
with Zoomlion or Zoomlion distributors .
e) When changing oil, change the relevant filter element. Especially when changing the engine oil filter
element , add fresh, clean and specified engine oil into the new filter element before the installation.
f) Make regular analysis of the oil quality in order to check the machines’ conditions. Please contact
with Zoomlion or Zoomlion distributors for those users who hope to obtain this service.
g) When the machine is delivered, the hydraulic system uses HM 46.

Tips
1. If the hydraulic oil which is not recommended by our company is used, it will cause blockings of
the filter element, please do not use it.
2. When changing the hydraulic oil, please clear away the remaining oil in the pipeline and the
cylinder to the greatest extent.
3.4.1.2 Fuel
a) The injection pump is a precision component, which can not work normally if the fuel used contains
water or dirt.
b) When storing or adding fuel, pay special attention not to let impurities mix into it.
c) Be sure to use the fuel specified in Table 3-1.
When using fuel, select it according to the environment temperature. Otherwise the fuel is easy to freeze
during low temperature, (especially when it is lower than -15℃(5℉) ). Therefore, replacement the fuel
matched with temperatures.
d) To avoid moisture in the air from condensation and forming water inside the fuel tank, refuel the oil
tank fully after the work everyday.
e) Before starting the engine, or in ten minutes after refueling, discharge the sediments and water in the
oil tank.
3-5
f) If the fuel in the engine is used up, or if the filter element is changed, discharge the air in the oil
pipeline.
3.4.1.3 Coolant
a) There is much Calcium and other sundries in river. If using river water, the scale will affix on the
engine and radiator, which will cause the fault of heat exchange and overheating. Don’t use any water
unfitted to drink.
b) When using antifreeze, comply with the notes in the “Maintenance Manual”.
c) There is the specified antifreeze in the cooling liquid by Zoomlion. This kind of antifreeze can
prevent the cooling system from corrosion effectively, and it can be used successively for 2 years or 4000
hours. Therefore, this antifreeze can be used even in blazing areas.
d) The antifreeze is flammable, so it should be noticed especially not to be near the open flame.
e) According to the environment temperature, the mixture ratios of water and antifreeze are different .
The details about the mixture ratio can be seen in the chapter “The recommended oil for common parts”.
f) If the engine is overheating, please wait for the engine to cool down before adding coolant .
g) Apart from leading the engine to overheat, the shortage of coolant will also cause corrosion of the
cooling system due to air –entering.
3.4.1.4 Grease
Grease is used for preventing the joint from being twisted and noise. After being used for a long time’,
whatever parts should be added grease if they are not flexible or make noise.
Attention
1. Pay special attention to erase the used grease extruded when adding grease. The sand or dirt
which affixes on the grease will cause abrasion of the rotating parts.
3.4.1.5 Storage of Lubricating Oil and Fuel
a) Put them indoor to prevent water, dirt or other sundries from entering into them.
b) If storing the oil tank for a long time, lay it on the side with the oil inlet on the side face, in order to
prevent sucking the moisture. If the oil tank has to be put outside, use a waterproof cloth to cover it or take
other protecting measures.
c) In order to prevent the oil from going bad in the long process of storage, the sequence of entering first
and exiting first must be adopted (the lubricating oil or the fuel with longest storage time should be used first)
3.4.1.6 Filter Element
a) Filter elements are very important safety components which can prevent impurities in the oil pipeline
3-6
and the gas pipeline from entering into the important devices to cause faults. Replace all the filter elements
regularly.
b) Don’t use the filter element which has been cleaned again (the filter element type). Use a new one
to replace it.
c) When replacing the filter element, check if there are metal particles adsorbed on the used filter
element. If metal particles are found, please contact with Zoomlion or Zoomlion distributors .
d) Before use, don’t open the package of spare filter element.
e) Use the filter elements specified by Zoomlion.

3.4.2 Choose Suitable Lubricating Oil, Fuel and Coolant
Importance
1. Please choose the pure exclusive oil of Zoomlion excavators at the designated places.
2. When starting the engine with a temperature being lower than 0°C, make sure to use the
multi-level oil recommended by Zoomlion as the engine oil even if the temperature may rise above
10°C in the daytime. Use low-viscosity lubricating oil limitedly which can improve the low temperature

starting property, but which use for a long time will shorten the engine’s life.
3. The coolant is essential in whatever climate. The antifreeze can reduce coolant’s freezing point
and improve coolant’s boiling point. Even if in unfrozen regions, make sure to choose the antifreeze
liquid specified by Zoomlion because it not only has the antifreeze function, but also prevents the
cooling system from corrosion and prolongs the parts’ life.
4. If you have any questions on the choice of the oil, please consult Zoomlion or Zoomlion
distributors .
3.4.2.1 The Recommended Oil for the Main Parts of the Excavators
Table 3-1 The recommended oil
Liquid Environment temperature (°C)

Parts
type -40 -30 -20 -10 0 10 20 30 40
API CH-4 15W-40
The engine oil

Engine oil API CH-4 10W-30
pan
API CH-4 5W-40
No.0
The engine fuel

Diesel oil No.-10
tank
No.-2
3-7
ISO HV 32
Hydraulic oil Hydraulic ISO HM 46

tank oil
Extraordinary DTE10 46
ISO HM 48
SAE 85W-140
The rotary
reducer, travel
reducer, Gear oil SAE 80W-90
sprocket and
thrust wheel SAE 80W-140
The water and ethylene glycol mixture (50:50)
Cooling system Antifreeze

The water and ethylene glycol mixture (40:60)
The turning
points of
working
device, tension Grease The common lithium grease No. 2 (GB7324-2010)
cylinder,
slewing
bearing
SAE: Society of Automotive Engineers
API: American Petroleum Institute
ISO: International Standardization Organization

3.4.2.2 Fill the Oil When New Machines Are Delivered
Refuel the oil products listed in Table 3-2 when new machines are delivered.
Table 3-2 The list of filling oil when new machines are delivered
The technical standards of the oil Volume (L)

Parts
products ZE220ELC
The engine oil pan API CH-4 15W-40 22
No.0 diesel oil (in summer)/ No.-10 diesel
The fuel tank -
oil (in winter)
The rotary reducer 3.4
SAE 85W-140
The travel reducer 2×5.5
The hydraulic system ISO HM46 300
The mixture of water and ethylene glycol
Cooling system 30
(50:50)
3-8
3.5 Wearable Parts

Table 3-3 Wearable parts’ list
Item Part No. Part name Quantity Replacement cycle
Engine oil filter 1000400170 Filter element 1 Every 500 hours
1000400151 Filter element 1 Every 500 hours
Fuel filter 1000400152 Filter element 1 Every 500 hours
Air breather of hydraulic
tank
Hydraulic oil filter 1010600437 Filter element 1 Every 1000 hours
Pilot filter 1019802318 Filter element 1 Every 500 hours
1010500127 Outer filter element 1
Air filter --
1010500128 Inner filter element 1
1999900644 Pin 5
--
1999900643 Bucket tooth 5
1999901391 Lateral edge (left) 1
Bucket
1999901390 Lateral edge (right) 1
--
003001016B0001010 (Bolt) (10)
1040200673 (Nut M24×2-10 level) (10)
The wearable parts (seen in Table 3-3), such as filter elements and bucket teeth, should be changed
when carrying on regular maintenance or before wear limits. In order to use the machines economically,
change the wearable parts correctly and select Zoomlion parts with high quality as the replaced parts. When

ordering the parts, please check the part numbers of the corresponding machines in the “Components and
Parts Atlas”. Comment：the parts in the bracket should be changed as well.
3.6 The Technical Specification of Tightening Torques
Warning
1. If the nuts, bolts or other parts are not tightened to the specified torques, the tightened parts
will be loose or damaged, which will lead the machine faults or cause problems during operation.
2. Pay special attention when tightening torques.
Tightening torques is decided according to the across flats width of nuts and bolts. Unless otherwise
specified to tighten the metric nut and the bolt to the torque seen in Table 3-4. If the nuts or bolts need to be
changed, use Zoomlion parts with the same size to change them. The tightening torques of the
commonly-used hydraulic hoses’ metric nipples can be seen in Table 3-5.
Table 3-4 The list of the tightening torques
The tightening torques (N·m)

Diameters of thread (mm) Widths of across flats (mm)
Grade 10.9 Grade 8.8
M6 10 13～16 9～12
3-9
M8 13 30～36 22～30
M10 16 65～78 45～59
M12 18 110～130 78～104
M14 21 180～210 124～165
M16 24 280～330 193～257
M18 27 380～450 264～354
M20 30 540～650 376～502
M22 34 740～880 512～683
M24 36 940～1120 651～868
M27 41 1400～1650 952～1269
M30 46 1700～2000 1293～1723

M33 50 2473～3298 1759～2345
M36 55 2800～3350 2259～3012
Table 3-5 The list of the tightening torques of the commonly-used hydraulic hoses’ joints
The types of thread The tightening torques (N·m)
M14×1.5 20~35
M16×1.5 25~40
M18×1.5 30~45
M20×1.5 35~50
M22×1.5 40~70
M24×1.5 40~70
M26×1.5 60~100
M30×2.0 80~120
M36×2.0 100~150
M42×2.0 150~220
M45×2.0 180~250
3-10
3.7 The Regular Change of the Safety Key Parts
In order to improve safety further, users should change the parts listed in Table 3-6 regularly. These parts
have special close relationships to safety and fire prevention.
As these parts’ materials change with time going by, they are easy to wear down or deteriorate. But
through regular maintenance, it is hard to judge totally the conditions of them. Therefore, they should be
changed no matter what conditions as soon as the specified time arrives. It is necessary for these parts to keep
their functions consistently and completely. But if these parts become abnormal before the changing cycle,
they must be repaired or changed immediately. Please contact with Zoomlion or Zoomlion distributors to
change the safety key parts.
Tips
1. If hose clamp appears metamorphism, deformation or claws, change it when changing the hose.
2. When changing hose, change the O-ring, sealing gasket and other similar parts at the same
time.
Table 3-6 The changing cycle of the key parts

No. Regular change of safe key parts Quantity Replacement cycle
1 Fuel hose (Fuel tank—Oil-water separator) 1
2 Fuel hose (Oil-water separator—Additional fuel filter) 1
4 Fuel return pipeline (Injection pump—Fuel tank) 1
5 Overflow hose (Engine output connector—Fuel tank) 1
6 Pump outlet hose (Pump—Controlling valve) 2
7 Work device hose (Inlet and outlet on boom cylinder) 4

Work device hose (Bucket cylinder pipeline—Controlling
8 2
valve)
Every two years or
9 Work device hose (Inlet and outlet on bucket cylinder) 2 every 4000 hours,
Work device hose (Arm cylinder pipeline—Controlling the first comes first
10 2
valve)
11 Work device hose (Inlet and outlet on arm cylinder) 2
Rotary pipeline hose (Inlet on rotary motor—Controlling
12 2
valve)
13 Main suction hose 1
14 Travel pipeline hose (Controlling valve—Rotary joint) 4
15 Travel pipeline hose (Rotary joint—Travel motor) 4
16 Warm hose(Engine—Air conditioner evaporator) 2
17 Seat belt (selective) 1 Every three years
3-11
Maintenance Manual
Chapter Four: Maintenance Schedule of the Excavator

Chapter Four: Maintenance Schedule of the Excavators

4.1 Everyday Maintenance
4.1.1 Everyday Inspection Items
The details about the following items can be seen in Chapter four “Inspection before Engine Starts” in
operation manual.
·Check the liquid level of coolant
·Check the oil level of the engine oil pan
·Check fuel level
·Discharge the water and sediments in the fuel tank
·Check the water and sediments in the oil-water separator
·Check the oil level of the hydraulic oil tank
·Check the wires
·Check the speaker ’s function
·Lubricate the work device( every 8~10 hours during working)
·Check if the radiator and insect-proof screen are clean, clean them when necessary.
4.1.2 Lubricate the Slewing Bearings (3 places)
1. Descend the work device onto ground.
Maintenance Schedule of the Excavators

2. Use oil gun to instill the grease through the
nozzle shown by the arrow in Figure 4-1.
3. Erase all the squeezed used grease after

adding the grease.
4.1.3 Lubricate the Work Device
Attention
Fig 4-1 Lubricate slewing bearing
1. If there is abnormal noise on lubricating positions, lubricate them besides the maintenance
cycle.
2．After digging in the water, lubricate the pin rolls immersing in the water.
The lubricating procedures of are as follows:
a) Adjust the work equipment to the lubricating posture shown below (seen in Figure 4-2)，then fall the
4-1
work equipment onto ground and shut down the engine.
b) Use the grease gun shown by the arrow to press the grease in.
c) Erase the squeezed used grease after adding the grease.
Fig 4-2 The correct parking position when lubricating work equipment
(1) The hinge pin of boom cylinder (two places) , seen in Figure 4-3.
Fig 4-3 Lubricate work equipment (Ⅰ)
(2) The hinge pin of boom (two places);
(3) The end of boom cylinder piston rod (two places);
(4) The root pin of arm cylinder (1 place), seen in

Figure 4-4.
(5) The connecting pin between boom and arm (two

places);
(6) The end of arm cylinder piston rod (one place);
Fig 4-4 Lubricate work equipment (Ⅱ)
4-2
(7) The root pin of the bucket cylinder (one place),

as seen in Figure 4-5.
Fig 4-5 Lubricate work equipment (Ⅲ)
(8) The connecting pin of arm-connecting rod (1

place);
(9) The connecting pin of arm- and -bucket (one

place), as seen in Figure 4-6.
Fig 4-6 Lubricate work equipment (Ⅳ)
(10) The Rocker bar connecting pin (2 places);
(11) The end of bucket cylinder piston rod (1 place);

(12) The connecting pin of bucket-connecting rod (1
place), as seen in Figure 4-7.
Fig 4-7 Lubricate the work device (Ⅳ)
4.2 Maintenance in Initial 250 Hours and 500 Hours
The following maintenance is implemented only when new machines are used after500 hours at the first
time.
● Change the oil-return filter element of the hydraulic oil
● Change the reducer oil of the rotary motor
4-3
● Change the reducer oil of the travel motor
It needs the specialized tools for inspection and maintenance. Please contact with Zoomlion or
Zoomlion distributors. The details about the methods of change or maintenance can be seen in the part
“Maintenance of every 250 hours, every 500 hours, every 1000 hours, every 2000 hours and every 4000
hours”.
4.3 Maintenance of every 250 hours

4.3.1 Check the Oil Level in the Oil Pan and Refuel
Warnings
1. After shutting down the engine, the parts and the oil are still under high temperatures which
will cause serious scalding. Before starting operation, wait until the temperature drops.
a) Pull out the dipstick, and erase the oil on the dipstick with cloths
b) Insert the dipstick into the conduit completely.
c) When pulling out the dipstick, the oil level is appropriate if it is between the Mark H and L.
d) If the oil level doesn’t reach the Mark L on the dipstick, open the oil filling port and add engine oil.
e) If the oil level is higher than the Mark H, loose the oil discharging bolt and discharge the superfluous
oil.
f) After checking the oil level or refueling, insert the dipstick into the hole and install the oil inlet cover.
4.3.2 Check the Oil Level in the Travel Motor Reducer and Refuel
Warnings
1. After shutting down the engine, the parts and the oil
are still under high temperatures which will cause serious
scalding. Before starting operation, wait until the temperature
drops.
2. If there is remaining pressure in the case, the oil or the

screw-plug will fly out. So loose the screw-plug slowly to
release pressure. Fig 4-8 Check the oil level in the
terminal transmission case
Prepare a hex wrench.
a) Lay the oil level line of travel motor reducer to be horizontal, make the mark and the screw-plug (P)
vertical with ground, seen in Figure 4-8.
b) Use the hex wrench to dismount the screw-plug (F) and check whether the oil level is in the range
from the bottom of the screw-plug hole to that of 10mm (0.4 in) lower than the bottom of the screw-plug
hole.
4-4
c) If the oil level is too low, install the screw-plug (F), operate the travel joystick and steer the machine
forward and backward to rotate the sprocket wheel by a full turn. Then repeat the second step to check.
d) If the oil level is still low, instill the engine oil from the hole of the screw-plug (F) until the engine oil
overflows.
f) After inspection, install the screw-plug (F).
Note: There are two screw-plugs (F). When refueling, it is easier through the screw-plug hole by which
the interior gears can not be seen.
4.3.3 Check Status of the Storage Battery with Indicator
The status of the storage battery can be judged by the electric eye indicator on the surface of the storage
battery. Under normal good status, the electric eye indicator indicates green. But if the electric eye indicator
indicates white or black, as seen in picture4-9, it shows that the storage battery is short of electricity or lacks
liquid. In this case, to charge or replace .
Fig 4-9 Check status of the storage battery with indicator

4.3.4 Check and Adjust the Tension of the Belts of the Air Conditioner Compressor
a) Check
Use the finger force with about 58.8N (6kgf) to press the belt in the middle part between the drive pulley
and the compressor pulley, and check the deflection which should be 5-8mm(0.20in-0.31in), as seen in
Figure 4-10.
b) Adjust
1) Loose (as seen in Figure 4-11). The bracket fixes the compressor. When loosing the bolt (2) and (3),
the bracket moves with the fixed position of the screw-plug (3) as a pivot.
2) Loose the nut installed on the fixed bracket and tighten the bolt (1). Tighten it to make the deflection
of the belt be 5-8mm (about 58.8N ).
4-5
Fig 4-10 Check tension force of air

conditioner compressor
Fig 4-11 Adjust tension force of air
conditioner compressor
3) Check whether each belt is damaged, whether the V-shape groove and the V-shape belt are worn
down. Pay special attention that the V-shape belt cannot touch the bottom of the V-shape groove.
4) If the belt has been lengthened without margin to adjust, or if there is an incision or a crack on the
belt, please change it.
5) When adjusting the new belt, readjust it after operating for one hour.
4.3.5 Clean the Air Conditioner Filter
1) Dismantle the panel on the back of the cab, loose the installing bolt, and take down the air filter and
the filter on the side, as seen in Figure 4-12.
2) Use the compressed air to clean the filter. If there is

oil on the filter or the filter is too dirty, wash it with neutral
mediums. After washing it in the water, dry the filter
thoroughly before reusing it. If it is unable to remove the

blockings of the filter through blowing with air or washing
in the water, replace by a new filter.
3) After cleaning the filter, reinstall it and install the

rear panel in the cab. Fig 4-12 Clean air conditioner filter
The normal interval of cleaning the filters is 250 hours, but if the machine is in a workplace with much
dirt, shorten the maintenance cycle and clean the filters more frequently.
Remark: If the filter is blocked, the air quantity will decrease and abnormal sound can be heard from the
air conditioner.
4.3.6 Add Oil to the Oil Pan and Change Filter Element of the Engine Oil
Warnings
will cause serious scalding. Before starting operation, wait until the temperature drops.
4-6
Make the following procedures:
·The fuel-injection quantity of the oil pan: 11L
·Filter wrench
a) Dismantle the bottom cover on the bottom of the

machine, and then lay a container under the drain valve (P) to
contain the oil, as seen in Figure 4-13.
b) To prevent the oil from splashing, unscrew the drain

plug slowly to drain oil, then screw the plug.
c) Open the lid on the rear right side, and then use the
filter wrench to turn the filter (1) towards left in order to
dismantle it.
d) Clean the filter seat, and add clean engine oil to the
new filter. Coat engine oil on the filter’s sealing surface and
on the threads (or coat a thin layer of grease), and then install
the filter on the filter seat.
Tips
1. Check that the old sealing doesn’t adhere to the

filter seat. If the old sealing still retains, it will cause
Fig 4-13 Replace the engine oil filter
leaks.

e) Make the sealing surface touch with the sealing
surface of the filter seat during installation, and then tighten it
for 3/4-1 round further.
f) After changing the filter, open the engine cover and add
engine oil through the oil inlet (F) to the position between the
Mark H and Mark L on the dipstick (G), as seen in Figure
4-14.
Warnings
Fig 4-14 Dipstick mark
1. Please purchase the pure engine oil designated by Zoomlion to guarantee oil quality and make
sure the 500-hour changing cycle.
g) Operate the engine at an idling speed in a short time, and then shut down the engine and check the oil
level again to make it between the Mark L and Mark H on the dipstick (G). The details can be seen in 4.3.1
4-7
“Check the Oil Level in the Oil Pan and Refuel”.
h) Install the bottom cover.

4.3.7 Change the Fuel Filter Element
Warnings
1. After operating the engine, the parts are in high temperatures. Before changing the filter
cartridge, wait until all the parts cool down.
2. Don’t let the open fire approach the fuel.
Prepare a filter wrench and an oil container to contain

the fuel.
a) Lay a container under the filter to contain the fuel.
b) Revolve the filter (1) and (2) anticlockwise with the

filter wrench to dismantle them, as seen in Figure 4-15.
c) Clean the filter seat and add clean fuel to the new
filter. Coat engine oil on the sealing surface and then install
the filter on the filter seat. Fig 4-15 Change the fuel filter cartridge
d) After the sealing surface touching with the sealing surface of the filter seat, tighten it for 1/2 round
further.
If the filter is screwed too tight, the sealign will be damaged, which will lead fuel leak. If the filter is
screwed too loose, fuel will leak from the sealing. Therefore, the filter must be tightened to an appropriate
position.
After changing the fuel filter, discharge the air in the system as the following ways:
a) Add oil to the fuel tank (add until the floater is on the highest position)
b) After changing the filter (1) and (2), loose the exhausting screw-plug on the filter.
c) Loose the button on the oil transport pump and press it up and down repeatedly with hands to make
the fuel flow out until there isn’t any more bubble in the fuel flowing from the exhausting screw-plug. Then
tighten the button on the oil transport pump.
d) Tighten the exhausting screw-plug and use the pure Zoomlion filter.
After changing the filter, start the engine and check if the sealing surface of the filter leaks oil.
Remark: when the engine fuel is used up, discharge the air in the fuel system with the oil transport
pump.
4.4 Maintenance of Every 500 Hours
4-8
Conduct the maintenance of every 250 hours in the meantime.

4.4.1 Check the Grease Height in the Rotary Pinion and Add Grease
Prepare a dipstick.
a) Dismantle the bolt (1) (2 pieces) on the upper part

of the rotating rack and dismantle the lid (2), as seen in
Figure 4-16.
b) Insert the dipstick into the grease and check the

grease height where the pinion passes by,which should be
at least 14mm (0.6 in). If necessary, add more grease.
c) Check if the grease is milky. If the grease turns to

be milky, it must be replaced. Please contact with
Zoomlion or Zoomlion distributors . The total volume of
the grease: 9L Fig 4-16 Check the Height of the Grease in the
Rotary Pinion
d) Use bolt(1) to install the lid (2).
4.4.2 Check Oil Inlet Filter of Hydraulic Oil Tank
The oil inlet filter of hydraulic oil tank should be checked every 500 hours.
4.4.3 Clean and Check the Radiator Fins, the Oil Cooler Fins and the Condenser Fins
Warnings
1. If the compressed air, the high-pressure water or the vapor attacks your body directly, or using

them to blow away the dust or dirty things, there is risk of severe damage. Goggles, dust cover or other
protection equipments must be used..
When compressed air is used, it will damage the radiator fins if the nozzle is too close to the radiator
fins. When cleaning them, keep a appropriate distance so as to prevent them from damaging the radiator fins.
Don’t spray the radiator core directly. If the radiator is damaged, it will cause water leak and overheat. In the
working places with much dirt, do such inspection every day without being limited by the maintenance cycle.
The procedures of cleaning and checking the radiator fins, the oil cooler fins and the condenser fins can be
seen in Figure 4-17:
a) Open the engine cover.
b) Loose the bolts and unload the cooler.
c) Clean the protection net and reinstall it.
d) Before installing the protection net, check and clear the dust, the dirt and dry leaves in every cooler
fin. If there are some, blow away them with compressed air. Apart from compressed air, vapor or water can
also be used.
4-9
e) Check the rubber hose. If flaws are found on the hose

or the hose has become hard because of being aged,
change a new hose. Besides, check whether the hose is
damaged
f) Dismantle the bottom cover and clear away the dust,
the dirty things and dry leaves on it.
Fig 4-17 The radiator fins, the oil cooler

fins and condenser fins
4.4.4 Clean the Interior of the Air Conditioner System
Warnings
1. If the compressed air, the high-pressure water or the vapor hits your body directly, or using
them to blow away the dust or dirty things, there is risk of severe damage. Goggles, dust cover or other
protection equipments must be used.
2. Check the air conditioner filter, and if necessary, change the inner and outer filter elements
together.
4.4.5 Change the Filter of the Ventilation Device on the Hydraulic Oil Tank
Warnings
will cause serious scalding. Before cleaning the filter cartridge of the ventilation device in the hydraulic
oil tank, wait until the temperature drops.
2. When dismantle the oil inlet lid, the oil will spray. So turn the lid slowly to release the interior
pressure and then dismantle it with caution.
a) Dismantle the lid from the oil inlet (F) on the top of the hydraulic oil tank, as seen in Figure 4-18.
b) Change the inner filter.
4-10
Fig 4-18 Change the filter of the ventilation device on the hydraulic oil tank
4.4.6 Check and Adjust the Valve Clearance of the Engine
As the exclusively-used tools is required when dismantling and adjusting the parts, please ask Zoomlion
or Zoomlion distributors for maintenance work.
The maintenance work of every 250 hours and every 500 hours should be done at the same time. The oil
in the rotate motor reducer and the travel motor reducer needs to be changed in the initial 500 hours.
4.5.1 Change the Oil-return Filter on the Hydraulic Oil Tank
Warnings
will cause serious scalding. Before cleaning the strainer of the hydraulic oil tank, wait until the
temperature drops.

2. When dismantling the oil inlet lid, the oil will spray. So turn the lid slowly to release the interior
pressure and then dismantle it with caution.
If the machine is installed with hydraulic breaker, the hydraulic oil will go bad more quickly, compared
with the ordinary bucket operation. When conducting the maintenance work, the details can be seen in
“Maintenance for Using Hydraulic Breaker ”.
Fig 4-19 Maintenance posture of work equipment
4-11
The procedures of changing the filter cartridge of the

hydraulic oil are as follows:
1) Lay the work device on firm and flat ground in

accordance with the maintenance posture seen in Figure 4-19,
and then descend the work device to ground and shut down
the engine.
2) Dismantle the lid of the oil filling port (F) and release
the interior pressure, as seen in Figure 4-20.
3) Loose four bolts and dismantle the lid (1). When

Fig 4-20 Dismantle the lid from the oil
dismantling the lid, the lid will fly out under the impact of the filling port to release the interior pressure
spring (2)’s force. Therefore, when dismantling the bolts, hold
the lid downward.
4) Take out the spring (2) and oil return filter (3), as seen in Figure 4-21.
5) Dismantle the fitting screw and the oil-return seat of by-pass valve in the oil-return filter. And take
out the oil-return filter to replace it with a new one. Then install the oil-return seat of by-pass valve and the
connecting screw.
6) Install the oil-return filter to the previous position.
7) Install the spring (2) on the top of the oil-return filter.
8) Lay the lid (1) on the installing position. Then press down the lid with hands and install the lid with
the bolts.
9) Install the lid of the oil filling port.

10) In order to discharge the air, start the engine in accordance with the requirements of “Start the
Engines”, and operate the engine at a low speed for ten
minutes.
11) Shut down the engine.

4.5.2 Change the Oil in the Rotate Motor Reducer
Warnings
1. After shutting down the engine, the parts and the

oil are still under high temperatures which will cause
serious scalding. Before starting operation, wait until the
temperature decreases.
Fig 4-22 The oil filling port of the rotary
·The oil volume: 3L motor and the dipstick position
1) Lay a container under the drain plug on the bottom
4-12
of the machine to contain the oil.
2) Loose the drain plug under the machine to release the oil and then tighten it.
3) Dismantle the lid of the oil filling port (F) and then add the engine oil with specified amount through
the oil filling port (F), as seen in Figure 4-22.
4) Pull out the dipstick (G), and erase the oil on the dipstick with a cloth.
5) Insert the dipstick (G) thoroughly into the dipstick tube and then pull it out.
6) When the oil level is between the Mark H and Mark L on the dipstick, it is appropriate. If the oil level
doesn’t reach the Mark L, add the oil through the oil filling port (F).
7) If the oil level is higher than Mark H, discharge the superfluous engine oil from the drain valve and
recheck the oil level. When discharging the superfluous engine oil, pull out the hose from the access port and
then open the drain valve.
4.5.3 Change the Oil in the Travel Motor Reducer
Tips
1. After shutting down the engine, the parts and the oil are still under high temperatures. Before
starting operation, wait until the temperature decreases.
2. If there is remaining pressure in the case, the oil or the screw-plug will fly out. So loose the
screw-plug slowly to release the pressure.
·Oil volume (each): 2.5L
·A hex wrench

1) Adjust oil lever of reducer to be horizontal.
2) Lay an oil container under the screw-plug (P).
3) Dismantle the screw-plug (P) and (F) with hex wrench and
discharge the oil. Check if the O-ring on the screw-plug is damaged.
If necessary, replace it with a new one.
4) Tighten the screw-plug (P), seen as Fig 4-23.
5) Add engine oil through the hole of the screw-plug (F).
6) When the oil overflows from the screw-plug (F), install the
screw-plug (F). Fig 4-23 Change the oil in the terminal
transmission case
Tighten the screw-plug (P) and the screw-plug (F) to the torque
of 68.6±9.8N·m (7±1 kgf·m).
Note: There are two screw-plugs (F). It is relatively easy to refuel through the hole of the screw-plug
4-13
with which the interior gears can’t be seen.
The maintenance work of every 250 hours, every 500 hours and every 1000 hours should be conducted
at the same time.
4.6.1 Clean the Strainer of the Hydraulic Oil Tank
Warnings
1 After shutting down the engine, the parts and the oil are still under high temperatures which will
cause serious scalding.
2 Before cleaning the strainer of the hydraulic oil

tank, wait until the temperature drops.
When dismantling the lid of the oil filling port, the oil
will spray. Therefore turn the lid slowly to release the
interior pressure, and then dismantle it with caution.
1) Loose four bolts, and then dismantle the lid (1), as

seen in Figure 4-24. At this time, the lid may fly out under
the impact of the spring (2). Therefore, press down the lid
when dismantling the bolts
2) Pull out the upper part of the rod (3) and dismantle
the spring (2) and the strainer (4).
3) Clear away the dirty things adhered to the strainer (4)

Fig 4-24 Clean the strainer of the hydraulic

and then wash it in the clean diesel or the flushing oil. If the oil tank
strainer (4) is damaged, replace it with a new one.
4) Reinstall the strainer (4) and insert it into the bulge (5) of the oil tank.
5) When assembling them, make the bulge under the lid (1) fasten the spring (2) firmly and then tighten
it with the bolt.
4.6.2 Clean and Check the Turbocharger
Please contact with Zoomlion or Zoomlion distributors for the cleaning and inspection work.
4.6.3 Check the Alternating Engine and the Starter Motor
If the electric brush may wear down or the bearing’s grease is used up, please contact with Zoomlion or
Zoomlion distributors for the inspection or repairing. If the engine starts frequently, check it every 1000
hours.
4.6.4 Change Oil in the Hydraulic Oil Tank
4-14
Warnings
will cause serious scalding. Before cleaning the elements of the ventilation device in the hydraulic oil
tank, wait until the temperature drops.
2 When dismantling the lid of the oil filling port, the oil will probably spray. Therefore turn the lid
slowly to release the interior pressure.
Make the following preparations:
·The oil refilling volume: 150L
·Prepare a handle used on the socket spanner.
a) Rotate the upper mechanism, making the

emission plug under the straw locate in the middle part
of the left track or the right track, as seen in Figure 4-25.
b) Withdraw the bucket arm and the bucket to the

end of the route, and then drop the swing arm, making
the bucket teeth touch with the ground.
c) Lock the safety-locked control rod and shut down

Fig 4-25 Rotate the upper mechanism
the engine.
d) Dismantle the lid of the oil filling port (F) on the upper part of the hydraulic oil tank, as seen in
Figure 4-26.
e) Lay a container under the emission plug on the bottom of the machine to contain the oil. Use the

handle to dismantle the emission plug and discharge the oil. Check the O-ring installed on the plug. If it is
damaged, change it. After discharging the oil, tighten the emission plug (1).
The tightened torque: 69 ± 10 N·m. Please pay attention not to let the oil splash on your body when
dismantling the emission plug.
f) Add the specified engine oil through the oil filling port (F). Check the oil level which should be
between H and L on the sight gauge. The details about the methods of exhausting can be seen in the chapter
“Exhaust the Air in the Hydraulic System”.
The maintenance work of every 250 hours, every 500 hours, every 1000 hours and every 2000 hours
should be conducted at the same time.
Check water pump
4-15
As the belt wheel may have clearance, from where oil or water may leak, which can make the vent (A)
block, please contact with Zoomlion or Zoomlion distributors for inspection, overhauling or replacement.
Fig 4-26 Change oil in the hydraulic tank
4.8 Maintenance When in Need Fig 4-27 Check the water pump
4.8.1 Check, Clean and Change Air Filter
4.8.1.1 Check and Change the Filter
Attention
1 If conducting inspection, cleaning or replacement during the engine operation, dust will enter
into the engine and cause the engine damage. Before carrying on these operations, shut down the
engine.
2 When compressed air is used, dirty things fly out, and cause the risk of personnel injuries. In
this case, wear protection glasses, dust mask or other protective devices.
3 When dismantling the outer filter element of the air filter, it is dangerous to pull out the outer
filter element hard. When standing at a high position with an unstable foothold to work, pay attention
not to fall down due to the reacting force produced from pulling out the outer filter element .
4.8.1.1.1 Check
If the air filter is blocked, the air filter block on the monitor gives an alarm that it is time to clean the
filter element in the air filter, as seen in Figure 4-28.
4.8.1.1.2 Replacement
4-16
(a) Replace the filter element and the O-ring
If it has been over one year from installing the

filter element and that the air filter is blocked, after
cleaning the filter element , the air filter block on the
monitor gives an alarm that it is time to change the
outer filter element, the inner filter element and the
O-ring.
Fig 4-28 Check filter element of the air filter
(b) Change the vacuum relay valve
If the vacuum relay valve is damaged or the rubber deforms obviously, replace it.
Explanation: Before the air filter block on the monitor gives an alarm, don’t clean the filter element of
the air filter. If cleaning the filter element frequently before the air filter block-alarm, the air filter will not
display its functions and the cleaning effect will also decrease. In addition, in the process of cleaning
operation, much dust adhered to the filter will fall into the inner filter. element
4.8.1.2 Clean the Outer Filter Element
Attention
1. Notice not to let the filter element be exposed to sunshine before and after cleaning the filter
element .
a) Open the rear part door of the machine’s left side and dismantle four clips (1), then dismantle the lid

(2), as seen in Figure 4-29.
b) Hold the outer filter element and shake it up and down from side to side softly. In the meantime, turn
the filter element from side to side and pull out it vertically. Notice not to dismantle the interior filter
element , otherwise dust will come in to cause the engine faults. Don’t use screw driver or other tools.
c) After dismantling the outer filter element , cover the air inlet in the body case of the air filter with a
clean cloth so as to prevent the dust or dirty things to enter into it.
d) Wipe off or brush off the dirty things adhered to the interior of the body case of the lid (2) and the air
filter. And erase the accumulated dust or dirty things on the vacuum relay valve (3) installed on the lid (2), as
seen in Figure 4-30.
4-17
Fig 4-29 Clean the outer filter element
e) Use compressed air (lower than 0.69MPa (7kgf/cm, 99.4 PSI)) to blow out along the crease of the
filter element from the inner side of the filter cartridge. Then blow out along the crease of the filter element
from the outer side of the filter element and blow out from the inner side again.
·Each time after cleaning the filter element , dismantle one seal from the filter element .
·Replace the outer filter element which has been cleaned repeatedly for five times or has been used
for a whole year. Change the inner filter element in the meantime.
·If the indicator light on the monitor flickers before long the clean outer filter element is installed,
change the outer filter element and the inner filter element at the same time even though the filter has not
been cleaned for five times.
When changing the filter element, affix the seal

Seal
encapsulated in the case the same as the filter element .

Affix the seal on the position shown in the Figure
4-31.
The vacuum valve
Fig 4-30 The vacuum valve Fig 4-31 The seal and inspection after replacement
4-18
f) Take down the cloth or seal installed in the procedure 3.
g) After cleaning and when checking with lamp, change the filter element if there are small holes or thin
parts on the filter element . Notice not to strike or beat the filter element and not to use the pleats, the sealing
gaskets or the filter element with seal failure when cleaning the filter element .
4.8.1.3 The Installation of Air Filter Element
Tips
1. Don’t use damaged sealing gasket or seal, or the sealed filter element with damaged pleat.
2. When the filter element or the O-ring has been used for over one year, it will go wrong if
cleaned or used again. So replace it with a new one.
3. The sealing parts of the counterfeit component lack precision, which will make dust
come in, and cause engine damage. Therefore, do not use such counterfeit components.
4. If the inner filter element is dismantled, do not operate the engine, otherwise it will cause
the engine damage.
a) Check whether dust or oil stain adheres to the sealing part of the new filter element or cleaned filter
element.
b) When the outer filter element has been dismantled, make sure that the inner filter element doesn’t
shift or deflect. If the inner filter element is oblique, insert hands into the filter element and push it upright.
c) When installing the outer filter element on the body case of the air filter, push it upright by hand . It is
easier to insert the filter element by using hands to hold it and shaking it slightly up and down from side to
side at the same time when pushing the filter element.

Notice that when inserting the filter element , the risk of damaging the cover or the body case of the
filter may happen if the rubber in the terminal part dilates or the outer filter element isn’t pushed upright and
you still install the lid (2) on the fastener (1) hard. Therefore, pay much attention during installation.
d) Install the lid (2) according to the following steps, as seen in Figure 4-32.
1) Align the lid (2) and the filter element.
2) Use the terminal part of the fastener (1) to hook the bulge of the body case of the air filter and
lock it.
3) When locking the fastener (1), fasten the fastener following the opposite side’s sequence (top,
bottom, left and right) in accordance with the same way of tightening the bolt.
4) When installing the lid (2), make the vacuum relay valve tend towards the ground.
5) When installing the lid (2), check that the gap between the body case of the air filter and the
lid (2) should not be too large. If the gap is too large, reinstall it.
4.8.1.4 Change the Inner Filter Element of the Air Filter
4-19
a) Dismantle the outer filter element at first, and then dismantle the inner filter element.
Fig 4-32 Install the filter element of the air filter
b) Use a piece of clean cloth to cover the air joint (the side of air outlet).
c) Clean the interior of the body case of the air filter, and then dismantle the lid from the air outlet in the
second step.
d) Install a new inner filter element to the connector, and then tighten the nut. Notice not to
clean and reuse the inner filter element. When changing the outer filter element, change the
inner filter element in the meantime.
e) Install the outer filter element to the right position, and then lock the lid (3) with the clip
(2).
4.8.2 Clean the Interior of the Cooling System
Warnings
1. After shutting down the engine, the cooling liquid is still under high temperature and the
radiator has a relatively higher interior pressure. If dismantling the lid to discharge the coolant in this
case, there is risk of scalding. Before dismantlement, wait until temperature drops and turn the lid
slowly so as to release the pressure.
2. Do cleaning when the engine works. When standing up or leaving from the operator’s seat,
adjust the safety-locking control rod to the LOCK position.
3. The details about starting the engine can be seen in chapter four “Start the Engines” of the
Operation Manual.
4. If the shield in the bottom is dismantled, there is risk of touching the air fan. When the engine
works, don’t enter the rear part of the machine.
Clean the interior of the cooling system and replacement the coolant and preservative according to the
Table 4-1.
4-20
Table 4-1 Replacement of coolant and preservative
Clean the interior of the cooling system and Replacement of

Types of coolant
change coolant preservative(selective)
The permanent antifreeze Change every year (in autumn) or every

(applicable in all seasons) 2000 hours, whichever arrives first
Impermanent antifreeze which Every Change every six months (in spring and Every 1000 hours or when
contains glycol(applicable in autumn). (Discharge the antifreeze in spring cleaning the interior of the
only in winter) and add the antifreeze in autumn) cooling system and
changing the cooling
liquid
When the antifreeze is not Change every six months or every 1000
used hours, whichever arrives first
As the mixed proportion of the additive in each antifreeze is different, please do not mix for use. Please
clean and change after halting the machine in the horizontal place. The mixture proportion varies with the
environment temperature’s change. The minimum proportion should be 30% in accordance to the volume.
When confirming the proportion of the antifreeze and the water, check the previous lowest temperature
and confirm it according to the following mixed proportion chart given. When confirming the mixed
proportion, you’d better underestimate the temperature by 10°C.
Tips
1. The antifreeze is inflammable, put it far away from flame.
2. The antifreeze is poisonous, so when dismantling the emission plug, pay attention not to let
coolant with antifreeze splash into eyes. Otherwise use a great amount of water to wash and clean the
eyes and send for a doctor for treatment immediately.

The running water should be used as cooling water. If the river water, well water or other such water
sources must be used, please contact with Zoomlion or Zoomlion distributors . In order to control the mixed
proportion, the densitometer is recommended for use. Prepare a container to contain the discharged coolant
and prepare a hose to add water. The operation methods as follows:
a) Turn the radiator lid (1) slowly and dismantle it, as seen in Figure 4-33.
b) Dismantle the bottom cap, and then lay a container under the drain valve to contain the coolant.
Open the drain valve on the bottom of the radiator to discharge the cooling liquid.
c) After discharging the cooling liquid, close the drain valve and add the tap water. When adding the
radiator with full water, start the engine and operate it at a low speed so as that the temperature rises to at
least 90℃, then continue operating it for about ten minutes.
d) Shut down the engine, and open the drain valve to drain the water.
e) After draining the water, clean the radiator with the detergent. As to the relevant cleaning method,
please comply with the instructions of the detergent.
4-21
f) Close the drain valve.
g) Install the bottom cap.
h) Add the water to the water inlet through the ware injector.
i) Operate the engine for about five minutes at a low speed and then operate it for five minutes at a high
speed so as to discharge the air mixing in the cooling water (at this time, the radiator lid (1) has been
dismantled).
j) After discharging the cooling water in the auxiliary water container (3) (as seen in Figure 4-34), clean
the interior of the auxiliary water container and then add water to the liquid level between Full level and Low
level.
k) Shut down the engine. About three minutes later, add water to the water inlet and then tighten the
radiator lid.
Fig 4-33 The radiator lid Fig 4-34 The auxiliary water container
4.8.3 Check and Tighten the Bolt on the Track Shoe
If the machine is used in the situation that the bolt (1) on the track shoe is loose (as seen in Figure 4-35),
the bolt will be broken. Therefore, tighten the loose bolt right away.
4.8.3.1 The Tightening Methods
(a) The track shoe
Tighten the tightening torque to 490±49N·m (50±5kgf·m), and then check whether the nut and the track
shoe get in touch closely with the contacting surface of the chain. After check, tighten it by 120°±10° again.
(b) The road pad
The tightening torque is 549±59N·m (56±6kgf·m), and then check whether the nuts and the track shoe
sget in touch closely with the contacting surface of the chain link.
4-22
4.8.3.2 The Tightening Order
Tighten the bolt according to the order in Figure 4-36. After tightening it, check whether the nut and the
track shoe get in touch closely with the mating surface of the chain link.
Fig 4-35 Check and tighten Fig 4-36 Tightening order of bolts
bolts on the track shoe
4.8.4 Check and Adjust the Track Tension
The attrition of the pin rolls and pin bushes on the under part of the car body section varies with the
operation conditions and the soil type. Therefore, in order to keep the standard tension, the tension of the
track should be often checked. And stop the machine on the flat and firm ground when checking and
maintaining it.
4.8.4.1Check
1. Operate the engine at a low and idling speed. Move

forward the machine for some distance that equals the length
of track on the ground and then stop the machine.

2. As seen in the figure on the right, choose a long rod and
put it on the track above the front idler (1) and the tug (2), as
seen in Figure 4-37.
Fig 4-37 Check the tension of the track
3. Measure the maximum distance between the upper surface
of the track and the bottom of the long rod. The standard distance: the sag “a” should be 10 ~30 mm (0.4 ~1.2
in). If the track tension is not to the standard value, adjust it according to the following methods.
4.8.4.2 Adjust
Attention
1. The screw-plug (1) has the risk of flying out under the high pressure of the grease. So make sure
not to loose the screw-plug (1) for more than one circle.
2. Don’t loose any parts except the screw-plug (1) and don’t face towards the installing direction
of the screw-plug (1).
4-23
3. If the methods provided here can not make the tension of the track loose, please contact with
Zoomlion or Zoomlion distributors.
4.8.4.2.1 When augmenting the tension
Prepare a grease gun, and operate as the following steps:
a) Use the grease gun to add grease through the nozzle (2) (seen in Figure 4-38) (the nozzle (2) and the
screw-plug (1) become one).
b) To check whether the track tension is appropriate, move forward the machine slowly (7-8 m (23
ft-26ft 3 in)).
c) Check thee track tension again. If the tension is not appropriate, adjust it again.
d) Continue to add grease until the size S is zero (0), as seen in Figure 4-39. If the tension is still loose,
it may probably be the excessive attrition of the axis pin and the pin bush which should be turned upside
down or changed. Please contact with Zoomlion or Zoomlion distributors for the repair.
Fig 4-38 Steps for adjusting the track tension (Ⅰ)

4.8.4.2.2 When loosening the tension
Warnings
1. Apart from the procedures provided below, it is very dangerous to release grease using any
other procedures.
2. If the track tension can not be loosened according to this procedure, please contact with
Zoomlion or Zoomlion distributors for repair.
a) Loose the screw-plug (as seen in Figure 4-39) (1) gradually to discharge the grease.
b) Turn the screw-plug (1) for at most one circle.
c) If the grease can not come out smoothly, move forward or backward the machine for a short distance.
4-24
d) Tighten the screw-plug (1).
e) To check whether the tension of the track H is

appropriate, move forward the machine slowly by
(7-8m).
f) Recheck the tension of the track H. If the tension

is not appropriate, adjust it again.
4.8.5 Change the Bucket Teeth
Before the bucket teeth seat is worn down, change the

bucket teeth. The changing methods are as follows:
Warnings
Fig 4-39 Steps for adjusting the track

1. In the process of changing bucket teeth, it is
tension (Ⅱ)
very dangerous if the work device moves owing to the
incorrect operation. Please place the work device in a stable state and then shut down the engine and
lock all the operating rods firmly.
2. If strike the lock pin hardly, there is risk of lock pin flying out. So check that there is no person
in the surrounding areas.
3. When conducting the change operation, there will be often something flying out. Therefore,
wear safety glasses, gloves and other protection equipments.
a) Lay the bottom of the bucket on the cushion block so that the pin (1) can be dismantled, as seen in
Figure 4-40. Check that the work device is in the stable state, and then place the safety-locking control rod to

the locking position. Lay the bottom of the bucket horizontally.
b) Put a metal rod on the pin head, and strike the metal rod by hammer to tap the pin (1) out. Then
dismantle the bucket tooth (2).
Remark: Use a metal rod whose diameter is a little smaller than the pin.
Fig 4-40 Change the bucket teeth
c) Clean the installing surface and install the new bucket tooth (2) to the tooth seat. Push the pin (1)
4-25
partially by hand and then strike by a hammer and lock the pin so that the bucket tooth is installed on the
tooth seat.
4.8.6 Adjust Bucket Gap
Tips
1. In the process of adjusting the gap, it is

very dangerous if the work device moves
owing to incorrect operation.
2. Please set up the work device in

stable state and then shut down the
engine and lock the safety-locking
control rod firmly.
a) Set up the work device in the state

as seen in Figure 4-41. Shut down the
engine and lay the lock operating rod in
Lock position, as seen in Figure 4-42
Move away the O-ring (1) of the

connecting rod and measure the clearance “a”. Fig 4-41 Adjust the gap of the bucket
b) If moving the bucket to one side or measuring the total clearance at one position, it will be much
easier to measure. (The left-hand position is seen in the picture) Use the plug (clearance) gauge and it will be
easy to measure it precisely.
c) Loosen four fixed screw-plugs (2) and loosen the panel (3). Because the opening spacer is adopted, it
can be operated completely in the circumstance that the bolt is
not dismantled.
d) Dismantle the spacer (4) according to the clearance “a”

measured above.
[For example]: when the clearance is 3 mm and you

dismantle two spacers of 1.0 mm and a spacer of 0.5 mm, the
clearance turns to be 0.5 mm. For the spacer (4), the two types of
1.0 mm and 0.5 mm are adopted. When the clearance is smaller
than a spacer, do not do any maintenance.
e) Tighten four bolts (2). If the bolt (2) is not to tighten

easily, pull out the stop pin bolt (5) for convenient tightening.
Figure 4-42 Lay the control rod on the
lock position
4-26
4.8.7 Check Liquid Level of Cleaning Fluid of the Window Washer and Add Liquid
The reservoir (1) is in the rear door of the left-hand machine. If there is air in the cleaning fluid of the
window washer, check the liquid level of the reservoir
(1). If necessary, add cleaning fluid of washing
window, as seen in Figure 4-43.
When adding liquid, pay attention not to let dusts

enter.
As changing the mixed proportion according to

the environment temperature, add cleaning fluid
based on the mixed proportion which has considered
the influence of the environment temperature
according to the following table. The Table4-2 lists
the mixed proportion of pure cleaning fluid and water.
The pure cleaning fluid is divided into two types: one Fig 4-43 The reservoir
type is applicable to -10℃ (14℉) (for general use) and the
other type is applicable to -30℃ (-22℉) (used in cold regions). Use the pure cleaning fluid according to the
operating regions and seasons
Table 4-2 The mixed proportion of cleaning fluid
The anti-freeze
The operating regions Mixed proportion
temperature
General region -10℃ (14℉)

Pure cleaning fluid 1/3:Water 2/3
Cold regions in winter Pure cleaning fluid 1/2:Water 1/2 -20℃ (-4℉)

Extremely cold regions in winter Pure cleaning fluid -30℃ (-22℉)
4.8.8 Check and Adjust the Air Conditioner

4.8.8.1Check Liquid Level of the Refrigerant (gas)
Attention
1. If refrigerant enter into your eyes or moisten your hands, it will cause blindness or frostbite. So
don’t get in touch with the refrigerant. Do not loosen any parts in the pipeline of the refrigerant.
2. Don’t let any open flame get close to the parts of gas leak of the refrigerant.
With shortage of refrigerant (R134-a), the cooling performance will be very poor.
When the engine works in high speed, the operating air conditioner is in the state of strong refrigeration.
The observation window (inspection window) installed on the reservoir of the condenser should have no
bubbles, as seen in Figure 4-44.
4-27
· No bubble flows in the

refrigerant: correct
·There are bubbles flowing in

the refrigerant ( the bubbles go
through successively): the liquid
level of the refrigerant is low
·Colorless and transparent:

there is no refrigerant Fig 4-44 Check the liquid level through the
observation window on the reservoir
Note: when there are bubbles, the liquid
level of the refrigerant will be low. Please contact Zoomlion or Zoomlion distributors to add refrigerant. If
the air conditioner works when the liquid level of refrigerant is low, it will cause damage to the compressor.
4.8.8.2 Check in the Spare Seasons
When the machine is not used for a long time, please conduct the operation for three to five minutes
once a month so as to provide lubrication for all the parts of the compressor. The inspection and maintenance
items about the cooler can be seen in Table 4-3.
Table 4-3 The list of inspection and maintenance about cooler
The inspection and maintenance items Contents The maintenance cycle
Twice a year, in spring
The refrigerant Add liquid
and in autumn
The condenser The radiator fin is blocked Every 500 hours
The compressor Function Every 4000 hours
V-shape belt Damage and tension Every 250 hours
Function (check whether there is
The air fan motor and the air fan When necessary
abnormal sound)
Function (check whether the

The control mechanism When necessary
function is normal)
The installing condition, check if the
The connecting pipeline connecting part is loose or if there is When necessary
gas leak or damage
4.8.9 park Methods for Machines on the Slope
Generally speaking, the machines shall not stop on the slope, when it must be stopped at the special
situation, conduct as the following methods:
4.8.9.1 The Method of Utilizing Slope
Attention
1. Choose a stiff and flat place.
2. Lay a cushion block under the track in case that the machine moves, and insert the work device
to the ground.
4-28
a) Stop the machine and make the work device on

one side of the downhill, as seen in Figure 4-45.
b) Lay a cushion block under the track and insert

the work device to the ground.
Fig 4-45 Park posture of machine on slope

4.8.9.2 Methods of Utilizing the cushion block
Attention
1. Choose a stiff and flat place.
2. Lay a solid cushion block under the under part of car body so as to stabilize the machine. Pay
special attention when operating it.
a) Use boom and arm to raise the under part of car body, as seen in Figure 4-46. At this moment, operate
the operating rod slowly.
b) Insert cushion block firmly between ground and the tracks which are raised to make sure the machine
stable.
c) Lift the boom slowly and descend the machine. At the same time, check that the machine is stable all
the time.
Fig 4-46 Utilize cushion block to tilt the machine

4.8.10 Discharge the Air in the Hydraulic System
The relevant details can be seen in Chapter four “Start the Engines” of the Operation Manual.
4.8.10.1 Discharge the Air in the Pump
1) Loosen the exhausting screw-plug and check whether there is oil leakage.
4-29
2) If there is no oil leakage, as seen in Figure 4-47, dismantle the discharging hose from hydraulic pump
and add hydraulic oil through the vent to the hydraulic pump. Fix the dismantled hose firmly and make the
mouth of pipe higher than the oil level in the hydraulic oil tank so that the oil cannot eject form the hose.
3) After finishing exhausting, tighten the

exhausting screw-plug at first and then install the
discharging hose.
Notice:
·If install the discharging hose at first, the oil

will spray from the exhausting screw-plug.
·If operatethe pump when the pump is not full

of oil, it will produce extraordinary calories and
make the pump damage prematurely.
Fig 4-47 Discharge the air in the pump
4.8.10.2 Start the Engines
The relevant details can be seen in the Chapter four “Operation for the Engines”. After starting the
engine, operate it for ten minutes at a low speed and then start operation.
4.8.10.3 Discharge Air in the Cylinder
1) Operate the engine at a low speed. Stretch cylinder to the travel end 100mm (3.9in) for four or five
times (notice not to stretch to the end of the travel end).
2) Then operate every cylinder to the travel end for three or four times.
3) At last, operate every cylinder to the travel end for four or five times to discharge air completely.
Notice:
·If the engine works at a high speed at once or the oil tank is operated to the end of the travel distance of
the oil tank, the air in the oil tank will make the piston seal and damage.
4.8.11 Methods of Releasing the Interior Pressure in the Pipeline of the Hydraulic Oil Tank
Warnings
1. The hydraulic oil pipeline is under pressure all the time. Therefore, when checking or
changing pipes or hoses, release the pressure in the pipeline. If the pressure is not released, the high
pressure oil will spray and cause serious personal injuries.
2. After shutting down the engine, the parts and the oil are still under high temperature, which
will cause severe scalding. Before starting operation, wait until the temperature drops.
4-30
3. In the process of dismantling the oil filling port lid, the oil will spray. Therefore, before
dismantling the lid, turn it slowly so as to release the interior pressure.
a) Park the machine on the horizontal and stiff ground, as seen in Figure 4-48.
b) Within fifteen seconds after shutting down the engine, turn the starting switch to ON position and
operate the operating rod fully towards different directions (the work device, travel) so as to release the
interior pressure.
c) Loosen the refueling panel (F) on the top surface of the hydraulic oil tank (as seen in Figure 4-49) so
as to release the interior pressure.
Fig 4-48 Park machine on Fig 4-49 loosen the refueling

horizontal ground panel to release pressure
4.8.1.2 Change the Oil-water Separator
The Fleetguard visualization oil-water separator is adopted to the machines, which has the functions of
impurities filtering, moisture separating and fuel pre-refueling for the fuel, so it is called integrated fuel
processor. Please check the pollution degree of the filter element and decide whether it needs to be changed
according to the actual situation.

a. New filter
When the initial oil level of fuel PRO series locates at the quarter of the filter element , the resistance
forced on the filter element is least . The filtered dirt accumulates from bottom to up slowly as time increases.
The lifting height of the fuel on the filter element shows the remaining service life of the surface filter
element .
b. The oil level locates under the half position of the filter element
At this moment, the dirt accumulates continually in the filter, the oil level rises to the dirt accumulation
height gradually, and filters through clean medium so as to guarantee low hydraulic resistance.
c. Ready to replace
The oil level closes to the three quarters position of the filter element gradually; however, fuel can still
be filtered through clean and new medium.
d. Replaceable
4-31
If fuel reaches the top black belt of the filter element , it indicates that the surface area of all the filter
element has been used up. The flow resistance begins to increase, and please change the filter element
timely.
4.9 Maintenance of the Hydraulic Breaker

If the machine is installed with hydraulic breaker, the maintenance schedules of some parts are different.
For the machine installed with hydraulic knapper, the hydraulic oil deteriorates more quickly than
normal bucket digging operation. Adjust the maintenance cycle in accordance with the following steps.
4.9.1 Change the Hydraulic Filter Element
As for the new machines, change the filter element after the first 100 to 150 hours and conduct the
further replacement according to Figure 4-50.
4.9.2 Change the Oil in the Hydraulic Oil Tank
Change the oil in accordance with the Figure 4-50.

4.9.3 Change the Additional Filter Element Used for Breaker
Use the breaker’s 250 hours of usage as guide, (the operating rate of breaker: more than 50%) change
the filter element in accordance with the Figure 4-50.
Fig4-50 Replacement cycle of hydraulic breaker
4-32

Maintenance Manual
Chapter Five: Common Faults and the Eliminating Methods

Chapter Five: Common Faults and the Eliminating Methods

5.1 Phenomena of Unreal Faults
Please notice that the following phenomena are not real faults:
1. When arm is retrieved, the moving speed declines instantaneously if the arm exceeds or is below the
vertical line.
2. When the bucket teeth exceed or are below the horizontal line, the speed of arm declines
instantaneously.
3. When operating heavy load digging, bucket or arm vibrates.
4. When the rotation starts or stops, the brake valves make noise.
5. When marching down the abrupt slope with a low velocity, the travel motor makes noise.
6. When operating boom or arm, the control valve makes noise.
7. When operating arm or bucket in the process of engine idling, arm or bucket works slowly.
8. When the engine starts or the engine speed approaches idling, the vibration of the machine becomes
intense. But if the engine speed is improved slowly, the phenomenon of co-vibration disappears.
Tips
1. In the following tables 5-1, 5-2, Table 5-3, ( )shows that when dealing with these items, please
contact with Zoomlion or Zoomlion distributors .
2. If the faults or reasons which are not listed in the following tables appear, please contact with
Zoomlion or Zoomlion distributors for repair.
Common Faults and the Eliminating Methods
5-1
5.2 Electrical System
The common problems about electric system and the eliminating methods can be seen in Table 5-1.
Table 5-1 Common problems and the eliminating methods of the electrical system
No. Faults Main reasons Solutions
(Check and repair the

Even if the engine works in high Wire fault, loose terminals and
1
speed , jacklight is still not bright Storage battery deterioration turnoff position , change
batteries)
Check the tension of the

When the engine works, the
2 Fan belt loose belt of air fan and change
jacklight flashes
it
Even if the engine works, the Alternator fault (Replace )
3 charging indicator also doesn’t
quench Wire fault (Check, repair)
The alternator makes abnormal
4 A lternator’s fault (Replace )
noise
Wire fault (Check, repair)
When the machine works, starter Starter motor fault (Replace )
5
motor doesn’t work The storage battery is
Charge
undercharged
The pinion of the starter motor The storage battery is
Charge
6 sometimes works but sometimes undercharged
doesn’t work Safety relay’s fault (Replace )
The storage battery is
The starter motor rotates the engine Charge
7 undercharged
slowly
The starter motor’s fault (Replace )
Wire fault, Circular pinion
(Check, repair)
Before the engine starts, the starter fault
8
motor disconnects The storage battery is
Charge
undercharged
When the engine is shut down , the Monitor fault (Replace )
machine oil pressure monitor
9 The fault of the warning
doesn’t work (the starting switch is (Replace )
on the position of “on”) light’ s switch
5-2
5.3 Hydraulic system

The common faults and the eliminating methods of hydraulic system can be seen in Table 5-2.
Table 5-2 Common faults and the eliminating methods of hydraulic system

Refill the oil collector to the full
Low oil level
scale
Cold oil Preheat the machine
Increase the speed or contact
Low engine speed
slow hydraulic with your designated franchiser
1 Contact with your designated
pressure functions Pilot loop
franchiser
Contact with your designated
Pump wear
franchiser
Blocked suction pipeline of pump
franchiser
Gas leak of the pump’s suction pipe
franchiser
Overheated Plugged filter Install a new filter
2
hydraulic oil
Blocked radiator or oil cooler Clean it and straighten the blade
Travel motor
franchiser
Gas leak of the pipeline from the oil Contact with your designated
collector to the pump franchiser
3 The oil foamed The oil pipeline is Twisted or pitted Check the pipeline
There is water in the oil Change the oil
The oil level is high or low Adjust the oil level
Pump wear
distributor
Low pressure of the main safety Contact with your designated
The hydraulic tank valve franchiser
4 works but can’t hoist
the load The hydraulic oil level is low Fuel up
The suction filter is blocked Clean the filter and the system
The suction pipeline of the pump
Check the suction pipeline
leaks
Its control valve stem is damaged or Contact with your designated

it is polluted by dirty things franchiser
A hydraulic tank
5 The hydraulic pipeline is damaged Repair it or change it
doesn’t work
The joint is loose Fasten it
The O-ring in the joint is damaged Install a new O-ring

Pilot valve or pilot pipeline Change or repair
Both the two travel Contact with your designated
6 The central joint’s fault
motors don’t work distributors
5-3
Table 5-2 (continued)

The travel motor
franchiser
A travel motor Contact with your designated
7 The brake doesn’t release
doesn’t work franchiser
The pilot valve
franchiser
The pilot pipeline Repair or change
The track adjusts Adjust the tension
The track tension pulley or the roller Contact with your designated
is damaged franchiser
The machine goes Contact with your designated
8 The track frame is twisted
unsteadily franchiser
Stone or mud is blocked in the track
Remove them and repair it
frame
The travel brake doesn’t release
franchiser
5.4 The Engine sections

The common faults and the eliminating methods of the engine section can be seen in Table 5-3.
Table 5-3 Common faults and the eliminating methods of the engine section
The engine oil filter is blocked Change the filter

The monitoring lamp The oil pipe’s joint is loose, and the
(Check, repair)
1 of the engine oil damaged part leaks
pressure lights The engine oil pressure sensor’s
(Change the sensor)
fault
The monitor’s fault (Replace )
The liquid level of the cooling liquid

Check, add water, and repair
is low, water leak
The vapor squirted
from the top of the
2 Check the tension of the belt of the
radiator(the pressure The belt of the air fan is loose
valve) air fan, adjust and change
Change the cooling liquid, and
Dirty things or lime scale is
wash the interior of the cooling
accumulated in the cooling system
system
The heat sink is blocked or damaged Clean or repair it
The water level The thermostat’s fault (Change the thermostat)

monitoring lamp of
The water injection lid of the
the radiator lights or Fasten the radiator lid or
3 radiator is loose( high altitude
the water temperature change the seal
operation)
pointer points to the
red zone Water level and water temperature
(Change the sensor)
sensor’s fault
The monitor’s fault (Replace )
5-4
Table 5-3 (continued)

The fuel is not enough Fuel up
There is air in the fuel system Repair the places that sucks the air
The injection pump’s or the injection (Change the injection pump or the
The engine doesn’t nozzle’s fault injection nozzle)
4 start when the starter The starter motor starts the engine Contact with your designated
motor rotates slowly franchiser
Contact with the designated
Compression fault(the valve
franchiser (adjust the valve
clearance is not correct)
clearance)
The exhausting gas Adjust the oil to the specified oil
The oil inside the oil pan is too much
5 becomes white or level
blue The fuel is not suitable Change to the specified fuel
The filter element of the air cleaner
Clean or change
is blocked
The exhausting gas
The injection nozzle’s fault (Change the injection nozzle)
6 sometimes becomes
(Refer to the above compression
black Compression fault
fault)
The turbocharger’s fault Clean or change the turbocharger
When burning the
noise, it makes
7 The injection nozzle’s fault (Change the injection nozzle)
deflated sound
occasionally
The fuel grade used is low Change into the specified fuel
Refer to the above “The water level
It makes abnormal It is too hot monitoring lamp of the radiator
8 noise (fuel or lights”
machinery) The interior of the muffler is
Change the muffler
damaged
The valve clearance is too big (Adjust the valve clearance)
5-5

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ZE220ELC HYDRAULIC

First Edition of Dec. 2012

Safety Information Instructions

1.1 Basic safety requirements for maintenance ...................................................................................... 1-1

1.2 Maintenance considerations ............................................................................................................. 1-1

2.1 Outline Drawing of the Excavators.............................................................................................. 2-1

2.2 Main Technical Parameters of the excavators............................................................................... 2-1

Chapter Three: Maintenance of the Excavators .................................................................................... 3-1

3.1 Maintenance Information of the Excavators................................................................................. 3-1

3.2. Maintenance of the Electrical System ......................................................................................... 3-3

3.3. Maintenance of the Hydraulic System ........................................................................................ 3-4

3.4 Lubricating Oil, Fuel and Cooling Liquid .................................................................................... 3-4

3.5 Wearable Parts ............................................................................................................................ 3-9

3.6 The Technical Specification of Tightening Torques ...................................................................... 3-9

Chapter Four: Maintenance Schedule of the Excavators ...................................................................... 4-1

4.1 Everyday Maintenance................................................................................................................ 4-1

4.3 Maintenance of every 250 hours.................................................................................................. 4-4

4.4 Maintenance of Every 500 Hours ................................................................................................ 4-8

4.5 Maintenance of Every 1000 Hours ............................................................................................ 4-11

4.6 Maintenance of Every 2000 Hours ............................................................................................ 4-14

4.7 Maintenance of Every 4000 Hours ............................................................................................ 4-15

4.8 When in Need ........................................................................................................................... 4-16

4.9 Maintenance of Hydraulic Breaker ............................................................................................ 4-32

Chapter Five: Common Faults and the Eliminating Methods............................................................... 5-1

5.1 Phenomena of Unreal Faults ............................................................................................................ 5-1

5.2 Electrical System.............................................................................................................................. 5-2

5.3 Hydraulic system.............................................................................................................................. 5-3

5.4 The Engine sections ......................................................................................................................... 5-4

Appendix 1 ZE220ELC Schematic Diagram of the hydraulic system

Appendix 2 ZE220ELC Schematic Diagram of the electrical system

ZE220ELC Hydraulic Excavator

Chapter One: Maintenance Safety Criterion for the Excavator

Maintenance Safety Criterion for the Excavators

8. The electrical system can not be handled in the rain.

1.2 Maintenance considerations

Chapter Two: General Drawing and Main Parameters

Chapter Two: General Drawing and Main Parameters of the Excavators

General Drawing and Main Parameters of the Excavators

Fig 2-1 The outline drawing of the ZE220ELC excavators

Table 2-1 Main technical parameters of 220ELc hydraulic excavators

Parts Items ZE220ELC

Displacement (ml) 5883

Parts Items ZE220ELC

General Drawing and Main Parameters of the Excavators

Fig 2-2 Drawing of the appearance size of ZE220ELC

General Drawing and Main Parameters of the Excavators

Fig 2-3 Sketch of ZE220ELC working range

Chapter Three: Maintenance of the Excavator

Chapter Three: Maintenance of the Excavators

Maintenance of the Excavators

b) Don’t use the voltage over 220V continuously.

2) Clean the radiator filter regularly in case of being clogged.

3) Clean and change the fuel filter element often.

Maintenance of the Excavators

1) If the maintained parts are inspected;

4) If there is water leak or oil leak;

5) If all the bolts are fastened.

b) Inspect when operating the engines

1) Whether the inspection and maintenance items are operated normally;