Operation and Maintenance3.1 Be Familiar With Instruments And Buttons 3.1 Be Familiar With Instruments And Buttons ‘The cab of ZLSOG wheel loader is well-designed for you, which will supply a happy and comfortable ‘operating environment for you. First of al, let us get familiar with the following items: © Keys: three sets of keys (two keys for each set) for ZLS0G wheel loader ¥ Door key 3 Key for engine startup 4 Key for side door of engine hood ‘© Doors: lock is on the handle of the door. Turn the key counter-clockwise to a certain position to lock the door; if the door is locked when it is open, pull the inside handle behind the door to unlock it. © Control mechanism and instruments (see Fig. 3-1,3-1b,3-Ic) © Shift control (Gee Fig. 3-2) © Working apparatus control (Gee Fig. 3-3) ‘© Control handle for braking system valve (see Fig. 3-4) © Key switch for engine startup (ee Fig. 3-5) © Control handle for hydraulic system valve ( nqutral-limit valve) (see Fig. 3-6) © Seat 3-1) ‘© Lift switch of the rear hood ( placed at the inside of the left battery box) (sce Fig. 3-8)3.1 Be Familiar With Instruments And Buttons ‘Switch group won = 3 32 ‘Switch group I 4 0 oe ae Py 23 O88 88 @®8 7 7 f r s a a" Figure 3-1a Controls and instruments 1. Engine oil pressure gauge 2. Voltage gauge 3. Engine water temperature gauge 4, Indicator lamp group 5. Tachometer 6. Torque converter oil temperature gauge 7. Fuel gauge 8. Braking air pressure gauge 9, Statuplextinguish switch 10. Switch of front rain wiper and spraying 11. Switch of rea cain wiper and spraying 302 12, Switch of rotary alarm 13, Accelerator pedal 14, Water ketle 15. Switch of steering lamp 16, Bugle button 17, Control handle to working do’ 18, Hydraulic breaking valve 19, Armrest 20. Brake control valve 21, Hand brake button 22, Smoke lighter 23. Extinguisher 24, Air-conditioner 25. Spare switch 26. Hom switch 27. Switch of working lamp 28, Switch of indoor lamp 29, Switch of instrument gauge 30, Switch of rear lamp 31. Switch of front lamp 32. Shift control handle 33. Brake pedal3.4 Be Familiar With Instruments And Buttons WDCGMG ‘Switch group I go on =) 13 14 eg 2 | iE 5 9 au fdaya * Indicator tamp group 9531 98 9940 41 42 43 46 s (SDBEER, ™ [fil] 2. 23. 8O 68 Fig. 3-1b Controls and Instruments 20 4 1. Engine ol pressure gauge 16, Bugle button 31. Front working lamp switch 2. Low pressure indicator lamp 17, Control handle wo working device 32, Shift control handle 3. Engine waler temperature gauge 18. hydraulic breaking valve 33. Braking pedal 4. Tachometer 19, Armest 34, Radio (Optional) 5. Torque converter oil temperature gauge 20, Brake contol valve 35. Trouble amp 6. Fuel gauge 21. Hand brake button 36, Left steering indicator lamp 7. Braking air pressure gauge 22. Smoke lighter ee 8. Startuplextingush switch 23, Extinguisher Salsas 9, Switeh of front rain wiper and spraying 24. Ait-condtioner itceae aie ee 10, Switch of rear rain wiper and spraying 25. Hom switch 4 Low pisere indicator lamp 11. Switch of rotary alarm 26, Emergency steering switch (Optional) 49 Preheat ta lamp 12. Spare switch 21, Trouble diagnosing switch of engine 43, Parking brake lamp 13, Accelerator pedal 28, Switch of trouble diagnosing lamp 44, Spare position 14, Water kettle 29. Indoor lamp switch 45, Right soering indicator lamp 15. Switch of steering lamp 30. Rear working lamp switch 46, Spare position3.1 Be Familiar With Instruments And Buttons 29 28 27 2% 2 26 23 32 — WXCMG ‘Switch group i 8 so 4 _ 2 : . : : : : : : . 3a 38 96 97.9899 40 4142 (| 43 fa 2 foo} @®@ 8 ty 1. Engine oil pressure gauge 2. Voltage gauge 3. Tachometer 4, Engine water temperature gauge 5. Fuel gauge Fig, 3-1¢ Controls and Instruments 15. Bugle button 29. Front working lamp switch 16. Control handle to working device 30. Shift control handle n. hydraulic breaking valve 18, Armrest 19, 6. Torque converter oil temperature gauge 20. 7. Startuplextinguish switch a. 8, Switch of front rain wiper and spraying 22. 9. Switch of rear rain wiper and spraying 23. 10, Switch of rotary alarm. 11, Spare switch 12, Accelerator pedal 13. Water kettle 14, Water kettle 24. Hand brake button ‘Smoke lighter Extinguisher Air-conditionet Spare switch 3 Emergency steering switch (Optional) 39 31. Braking pedal 32. Trouble indicator lamp 33, Left steering indicator lamp 34. Diagnosing lamp 35. Spare position 36. Spare position 37. Charging indicator lamp 38. Low pressure indicator lamp . Preheat start lamp 25. Trovble diagnosing switch of engine 49, parking brake lamp 6. 21. 28, Indoor lamp switch Rear working lamp switch Switch oftrouble diagnosing lamp 41. Spare position 42 43. 444, Radio (Optional) icator lamp ~3.1 Be Familiar With Instruments And Buttons WMG Redracting control Lock switch ‘Adrection Gear til Gear iv oa Gear AY, aD SD Fig. 3-2 Shift Controt (Note: press the button at the head of the handle in the direction of A when using KD forced shifting function) oa bre tn boom Te bickt <2 nau => Tete Baca wo Grae ne boom Fig. 3-8 Working Apparatus Control Flemeout Py ** cose "7 an Cet peer C sunpepona breaking unetion AL \ tren tinction i Fig. 3-4 Control of Braking Valve 7 (tis tor oil over air braking system) Fig. 3-5 Start Key of Engine 3.053.1 Be Fami Double-direction anti-vibration type seat: and comfortability is increased. f OT With instruments And Buttons @XCMG ‘Start the hydraulic neutal breaking function lose the hydraulic neural breaking function has good buffer function at up, down, back and forward directions Fig. 3-7 Seat Raise the hood Drop the hood Fig. 3-8a Lift switch of the rear hood (Itis placed at the inside of the left battery box, itis used for electrically drive device.) Fig. 3-8b Handle of hand oil pump {Itis place on the front of left battery box, it is used for the lift device controlled by hand oil pump.) +8.2 Vehicle Running-In WEMG 3.2 Vehicle Running-In ‘The machine has already been checked and adjusted completely before sale. However, it works under the atrocious environment at the beginning, the using life of the machine may be shortened obviously. S is necessary to carry out run-in to the machine at the first 50 operating hours and pay attention to maintenance service. Please follow the regulations stated below during the run-in period: © After starting, idle the machine for 5 minutes. # Its forbidden to accelerate the engine suddenly during pre-warming. ‘© Apart from emergency case, sudden startup, acceleration, tumaround and sudden brake should be avoided. © During run-in period, forward gears are T, Il, IM and WV; rear gears are 1, I and Ill. Every gear should be scheduled in run-in equally. © During nu period, it is better to load the machine with loose materials and prevent sudden and hurry operation. The loading capacity should not exceed 70 percent of the ration and the driving speed should not exceed 70 percent of the rating maximum speed. ‘© Pay attehtion to the lubrication state of the machine, replace or add lubricant according to the prescribed time. © Ofien pay attention to the temperature of gearbox, torque converter, front and rear axle, wheel hub and brake drum. If overheating problem occurs, be sure to find the reason and resolve the problem. © Check the tightness of every bolt and nut. © After 10 hours run-in of a new machine, the following should be carried out: 4 Check the tightness of every bolt and nut overall. Especially for cylinder head bolt of diese! engine, fixbolt of engine, gearbox and front & rear axle, hub nut, connecting bolt of the transmission shaft ete. All the above bolts should be checked once. ‘% Clean the rough and fine engine oil filter and fuel filter. ‘te Check the tightness of fan belt, generator belt and air-conditioner compress belt. tr Check the gravity and reserves of the storage battery electrolyte, tighten the joints of storage battery. + Check the oil level of the speeder. +t Cheek the airproof state of the hydraulic system and brake system. + Check the connection and ening state of every control stick and accelerator pusher. 3% Check the temperature and connection state of every component in the electric system, power supply state of dynamotor, state of lighting and turning signal light. 3.3 Loader Utility 3.3.1 Starting Up (Overall inspection before starting up © Disengage the steering locking mechanism, to have it be in unlocking position, so as to facilitate steering. © Check loader’s bottom side and external sides, and inspect if there is any serew loosing, dirt, oil leakage, coolant leakage and damaged parts. And state of auxiliary and hydraulic units should also be checked. 3073.3 Loader Utility ‘© Carry out checking before starting up: ‘tr Check the water level in water tank; 4% Check the fue! level in fuel tank; + Check the level of diesel engine oil; 4 Check the airproof state of oil pipelines, water pipel Check the wire connection on the battery; + Check the oil level in hydraulic oil tank; ‘ Check the airproof state of hydraulic system pipelines and accessories; +t Check whether the driving brake, emergency and parking brake is reliable or not; ‘3 Check whether every control stick is flexible and in neutral position or not; +t Check whether the tire pressure is normal; 3 Check whether the seat belt and every safety device are in good order. Only after the all elements are in proper order can the engine be started, s and air pipelines and accessories; © Starting the engine Starting up or extinguishing the engine is realized electrically, so attention should be paid when operating the engine, Items To Be Attended: © Before starting up, place all control sticks in neutral position, speed-gear in idle gear and switches in reset position © At the time of starting up, it is not allowed to accelerate throttle to its max. position to avoid damage against ‘engine within sudden time. ‘Adhere to correct process of starting up engine. ‘© Adjust the operator's seat as desired, © For other instruction concerning engine operation, please refer to specific documentation of diese! engine. Process For Starting Up Engine: © Place the gear-shifting control stick at the left side under the steering-wheel to idle-gear position (protection function of idle-gear starting up). © Tum the start-up key clockwise to "ON" position, and switch on the power relay. Slightly step on the accelerator, and then continue tum the electric lock clockwise, then the engine can start. In the normal case, ‘one startup time can not last 5 seconds. © If you fail to start the engine, wait at least 1 minute before attempting to start it again. If your machine can not start for three successive times, check the machine according to the explanation in the operation ‘manual, Start the engine again after resolving the trouble problem. © Afier startup, warm the machine for about 5-10 minutes at the idle speed. And at the same time pay close attention to the indication of meters. If there is no abnormal situation, and alarm buzzer stops giving an alarm, then you can release the parking brake and drive the machine,ce sousmiuy MG @® After the engine being started up ‘© Have the engine run at idle speed. If It is found that pressure gauge of engine oil could not indicate the normal readings within 10 seconds, then you need to check out the causes, afterwards re-start it again. Otherwise it will cause problems to the ens ‘© If the engine runs at high rotation speed when the engine oil pressure does not reach the required reading, it will damage the turbo super-charger of the engine. © In order to have hydraulic oil warm up quickly, repeatedly operate every control stick to make hydraulic oil after warming-up could flow smoothly in all hydraulic cylinders and oil circuit. © After starting up the engine, let the engine run at idle speed for about 5-10 minutes. Only after the water temperature reaches 55°C and braking alarming buzzer stops giving an alarming, then could the machine be driven forward. © It is not allowed to keep the engine continuously running at idle-gear with high speed or low speed for more than 20 minutes. © If itis necessary to keep the engine running at idle-gear, then it is needed to have the engine be loaded every ‘now and then or let the engine run at medium-range speed. ‘Afterwards, The Following Checking Should Also Be Implemented Before Driving The Machine Forward: © Check if every switches, lights, hom, scraper and control stick could function properly. © Check if there is any leakage on all working systems. ¢ Listen if there is any abnormal sound from transmission mechanism of engine. ‘© Check ifthe braking device is reliable or not © Check if all working mechanism could work properly. ‘© Check the oil level in gear-box, and replenish when necessary. Before extinguishing the engine, it is not allowed to tur the starting-key to "start" position, 3.3.2 Traveling D Move In order to avoid accident, before moving the machine it should be ensured that there is no other people on or around the machine, and also make sure the machine being under control. $40cm vee the i ' Step down braking pedal, and place the gear- es shifting handle on I or I gear. Push ot pull the handle to Forward or Reverse position. 3093.3 Loader Utility Step down the braking pedal, operate hand- Release the braking pedal, and slowly stop ig switch to release parking brake. down the throttle Pedal to accelerate. ‘© The loader can travel only after braking pressure reaching normal safe value (0.4SMPa) and releasing stop parking brake when the loader has air-push-oil brake system. © Itis prohibited to lift bucket to the highest position to carry material. When carrying material, the clearance between low articulation point of lifting arm and the ground should be maintained at 400-500mm, so as to keep stable traveling. ‘© When driving the machine on the slope ground or on the ground with tough condition, it is prohibited to drive machine with high speed. © Select proper traveling gear before driving down from slope. Never make gear shifting during driving down from slope. © It is also prohibited to drive machine with override speed when coming down from slope. You can reduce speed by means of braking pedal. If the mac! is influenced tractively by the load on it, then shift the speed gear to I gear firstly. ‘® Imerchange between gear shifling and forward / reverse. ‘© When shifting speed gear, it is now allowed to accelerate to avoid the sudden shock to transmission system. © In order to improve operation comfortability for operator and also prolong the service life to maximum of every working components, it is a Must to reduce traveling speed or apply braking when it needs to make ‘gear shifting. ‘© It is very dangerous to make interchange between Forward and Reverse with high-speed, so it is now allowed to do so, When making shifting for Forward or Reverse, firstly step on braking pedal to reduce traveling speed, then apply shifting for Forward or Reverse. (The maximum speed allowed during direction shifting is [2knv/h.) © Itis not necessary to stop the machine for applying gear-shifting during machine traveling. And itis also not necessary to step on braking pedal. When making gear-shifting from low speed to high speed, firstly release the acceleration throttle for a while, and at same time operate the control stick of gear-shifting, then step on the accelerate pedal again. If it is from high speed to low speed, firstly release the throttle to slowly reduce traveling speed, then apply gear-shifting. @ Steering During driving, turn the steering-wheel to the direction as desired, then the machine will make steering. ‘© This type of machine takes its articulation pin as its center, so during steering, the front frame and rear frame are not in alignment, © Incase of towing the machine with its engine being shut off, you can use the emergent steering switch, which is located on the instrument control panel, as shown in Fig. 3-1b, with No. 21 or Fig. 3-Ic, with No.19. © It will be very dangerous if making steering at very high traveling speed, so it is not allowed to do so. ‘© Making stecring when traveling on slope will cause tilting over to the machine, so it is now allowed to do so. 340 5@® Braking ‘© Don't put your feet on the braking pedal, if itis not very necessary, ‘© Don't step on the braking pedal repeatedly, if it is not necessary. © If it is necessary to put the gear-shifling handle at its neutral position when engaging the brake system, please move the “On/Off” handle, which is located on the control panel, to right, and step down the foot- braking pedal, then the power transmission from the gearbox will be disconnected. After you release the foot-braking pedal, the machine itself can automatically restore its previous gear. ‘© When driving the machine down a slope, itis not allowed to have the machine braked by means of cutting off power transmission converted from the gear-box, i.e: don't move the “On/Off” handle to right. © When driving the machine down slope, take the engine as braking device. Never make gear-shifting or apply idle gear of gearbox. No matter when applying braking during Forward driving or Reverse driving, there are two types: one Is cutting off power output, the other is non-cutting off power output. When driving the machine with | gear and II gear, you can apply braking by means of cutting off power output or non-culting off power output. ‘auTion | (The braking pedal on the left is for non-cutting off power output, and on the left is for cutting off power output.) When driving machine with Ill and IV gears it is, not allowed to apply braking by means of cutting off power output. During traveling, except the emergency case, itis not allowed to reduce traveling speed or to stop the machine by using emergency braking button, 3.3.3 Parking © Steps for parking Release the throttle pedal, and step on braking ‘The machine stops completely. Operate the pedal tll the machine stops thoroughly. hand braking. Switch and have it engaged. Lower the bucket horizontally on the ground and force it touch ground securely. ont‘Position the machine on the flat ground where there is no falling stone, slope or not in risk of suffering floods. It is necessary, the machine can be parked temporarily on the slope ground, for which place a wedge tunder the wheels to prevent the machine moving. © In Winter season, after the machine being parked, water inside the engine, radiatorand cooling system should be completely drained off to avoid damages to the machine to be caused by freezing. The machine has been added with anti-freezing addition when ex-factory. Please refer to the instruction for anti-freezing addition, ‘@ Steps for stopping the engine 3 Keep the engine running for about 5 minutes Tum the starting-key to "Off Position. After to let it cool down. the engine extinguishes, release the starting-key to restore it back to “neutral” position, Remove the key and keep it well. @® Leaving from the machine ‘© Before leaving the machine unattended, itis a must to lock the articulation joint with a locking bar and have the parking brake system be engaged, so as to avoid un-intended operation to the control levels, which, otherwise, could result severe hazards possibly caused by any un-intended movement of the machine, © It is also required to lower the working equipment (the bucket) totally down to ground if leaving the ‘machine unattended, and lock the control handles. Afterwards, shut off the engine. ‘© When coming down form the machine, use ladder or handrail, face towards the machine, and keep at lease three point of your body contacting the machine, It is not allowed to jump from the machine directly. © Check if there is any building-up of dusts or small pellets. If it is the case, clean it timely to prevent the risk of fire. © Clean away all combustible materials around the machine to avoid the risk fie. © Lock the door and windows, and pull out the key. @ Instructions to be followed after finishing work everyday © Check the fuel level, ane© Check the engine oil level and its clearness. If it is found that the engine oil level is too high or gets thin, find out the cause and remedy it ‘© Check if there is any leakage on oil pipelines, water pipelines, air pipelines and every component. © Check the state of fastening and sealing for gearbox, torque converter, hydraulic pump, steering device and driving axle, and also check if these parts get overheated. © Check if the mounting screws on hub, transmission shaft and bearing get loose. ‘© Check if all working mechanism could work property. ‘© Check the appearance of tyres and its pressure. © Apply grease to lubricating nipples as instructed. ‘© Clean away the dust and other contamination built-up on the machine and inside the bucket. 3.3.4 Working ‘The machine is equipped with KD mandatory gear-shifting function. The machine can travel to material piles at speed gear II. When the machine reaches material piles, press "KD" button ( refer to Fig. 3-2), the machine will change into gear I automatically. After the bucket is full with material, move the gear-shifting control handle backwards to Reverse position, then the machine will change into Reverse gear II from Forward gear I. In addition, ZF gearbox makes it possible to change from Forward gear I directly into Reverse gear I, and from forward gear Il to Reverse gear Il. When making gear-shifting, it doesn't need to stop the machine. So during working with carrying materials, it is not necessary to turn the gear-shifting control handle for selecting speed gear. You can follow the following steps: Press KD button Move backward Forward gear I Forward gear I Reverse gear I Move forward Forward gear I ® Digging operation Digging operation is to stop or drive the machine and dig the bucket into earth or stones for loading. sides of bucket, no just on one side. And make sure the machine facing towards ‘) ‘When performing digging operation, the load must be evenly carried on both ION | front, and both front frame and rear frame being in alignment. a33.3 Loader Utility © Shoveling operation Keep the bucket in parallel with the ground, and push the bucket fully into heap, and then shift the lifting ‘arm into raising position, and then moving the machine while raising the bucket. Afterwards, slowly operate the bucket for 2-3 times to tilt it back to keep the material inside bucket. In addition, when it is hard to dig into the heap, slightly tilt the bucket in the ratio of 1 forward and 2 backward, and you must ensure the wheels not slipping. Keep the bucket parallel with ground, a Y y=» Raise the lifting arm, and operate the bucket control handle to make it tilt backwards 2 -3 times to carry on materials. Bi! Apply low-speed gear to drive the machine (or when being in gear TI, press KD to change into gear 1) and get close the material pile. Step on the throttle and push bucket into material pile. | Keep the bucket tilting backwards to its maximum limit, and raise it 400-500mm above the ground. (being in transportation state), {fit happens that the machine wheel gets slipping, please reduce the force on the ‘AUTION | throttle pedal to decrease the load and avoid improper operation. ‘© Earth digging operation ‘The best forward incline angle of the bucket is between 0° to 10° Drive the machine in low speed. When the bucket cuts itself about 10 to 30 cm into the earth, raise the lifting arms while tilting back the bucket to cut more into the earth. Materials each time loaded into the bucket are light, so the operation can be smoothly done. 34Keep the bucket tilting forward, Drive the machine forward to push the material into bucket. (Cutting depth can be adjusted by using the boom and bucket.) n> t t Hoist the boom, and keep the bucket tilting Have the bucket tilt backward to its max. limit. backward. ‘And then raise the bucket upward so as to have 400-500mm between the bucket and the ground. ® Loading operation (Loading and transportation modes) Please choose a more efficient working method when loading earth, stones, ores into trucks, carriages and containers. Choice can be made in accordance with the condition of worksite. The working modes include ‘working in combination with transporting vehicles and working by your wheel loader itself. For the following situation, please adopt the working mode with your own wheel loader: srWhen working on loose ground, or working on the site which has not been flattened, where it is impossible to use heavy trucks for transporting. 4 Transporting distance within 500m. If using heavy trucks for transporting, it will be the waste of time. ‘The transporting speed should be decided according to transporting distance. In order to maintain safety and nice vision during transporting, the bucket should be kept at highest position, and keep the articulation point of lifting arm being in position suitable for traveling ( 400-500mm). Clean away the dust, sand or stone which leaks off from bucket, 80 as to avoid damage to tyre wheels. The route for transporting should also be cleaned \UTION | frequently. During transporting, keep a watch at the ground, and lower down the bucket and SAUTION | drive the machine at speed that will not make loaded material splash out. 345© Digging or loading on plain ground Keep the bucket slightly incline forward to the ground, adjust the digging depth by controlling the lift arms lever and tilt lever while moving the loader forward. (Special attention should be paid when the road surface being variable). Afterwards, operation can be performed following the "Shoveling Operation”. ‘© Working in combination with transporting vehicles ‘The mode has, as shown in figures below, four types. According to your practical application, a shorter one (each loading time) can be chosen. V-type eyeling operation type eyeling operation ad Latype cycling operation ‘T-type cycling operation The above-mentioned mode is to use the machine for continuous shoveling, transporting and dropping. This mode is suitable to the transporting distance of 30 to 100m in normal condition, ® Unloading operation ‘When unloading materials to the heavy trucks or goods yard, be sure to lift acting arm until the bucket (tilt the bucket to its maximum angle) can not touch the truck and material piles. Front bucket control handle makes the bucket tilt and untoad. Control of bucket control handle can unload materials fully or partially. Unloading action is required to be moderate to reduce the impact to the heavy truck. ‘When the materials adhere to and piles on the bucket, move the bucket control handle up and forth to vibrate the bucket so that materials can fall down. ‘Afier finishing unloading operation, retract the bucket to the flating position by using flatting facility, and push the acting arm rod forward to prepare for the next cycle operation @ Ground renovation With the help of angle between cutting edge and bottom plate of the bucket, the wheel loader can perform ground renovation such as earth scattering, leveling and foundation processing. 346