This document is a Service and Maintenance Manual for the ZOOMLION ZA20J aerial work platform (AWP). It provides comprehensive information on the inspection, servicing, and maintenance of the machine, aiming to maximize performance and ensure long-term safe and efficient operation.
Function Description
The ZA20J aerial work platform is designed for elevated work, providing a stable and mobile platform for operators. Its primary functions include lifting and lowering personnel and equipment to various heights, extending horizontally for reach, and rotating the platform for precise positioning. The machine is equipped with a four-wheel drive system, allowing it to travel over rough terrain. An auxiliary power system is included for emergency situations, enabling the platform to return to safe ground even if the main power fails. The oscillating axle system ensures that all four wheels maintain contact with the ground, enhancing stability on uneven surfaces.
Important Technical Specifications
Performance:
- Platform Capacity: 250 kg (550 lb)
- Max Travel Speed (on slope): 45% (platform uphill), 30% (platform downhill)
- Max Travel Speed (side slope): 25%
- Platform Height: 19.38 m (63 ft 7 in)
- Horizontal Outreach: 12.30 m (40 ft 4 in)
- Turning Radius: 5.47 m (outside), 2.51 m (inside)
- Max Travel Speed (stowed): 6.1 km/h (3.79 mph)
- Max Hydraulic System Pressure: 21 MPa
- Max Wind Speed: 12.5 m/s (force 6 wind)
- Max Manual Force: 400 N (90 lbs force)
- Electrical System Pressure: 12V DC
- Gross Weight: 10,000 kg (22046 lb)
Specification and Performance:
- Turntable Swing: 360° continuous
- Tail Swing: 0.4 m (1 ft 3 in)
- Platform Dimension: 2.44 m × 0.91 m (8 ft × 3 ft)
- Width: 2.46 m (8 ft 1 in)
- Stowed Height: 2.53 m (8 ft 6 in)
- Stowed Length: 8.82 m (28 ft 11 in)
- Wheelbase: 2.52 m (8 ft 3 in)
- Ground Clearance: 0.42 m (1 ft 5 in)
- Travel Speed (working): 0.4 km/h (0.25 mph)
- Ground Bearing Stress: 1.25 MPa
- Max Tire Capacity: 5000 kg (11023 lb)
Capacities:
- Fuel Tank: 150 L (39.62 US gal)
- Hydraulic Oil Tank: 75 L (19.81 US gal)
- Engine Oil Capacity: 8 L (2.11 US gal)
Engine (Kubota V2403):
- Type: Mechanical control
- Fuel: No. 0 National IV
- Engine Oil Capacity: About 8 L (2.11 US gal)
- Rotate Speed: 1300 (idling), 2000 (low speed), 2500 (high speed)
- Current Output of Generator: 12V, 40A
- Horsepower: 49
- Coolant: Cold water, about 11 L (2.91 US gal)
Battery:
- Rated Voltage: 12 V
- 20 Hours Rate Capacity: 90 Ah
- Cold Start Current: 750 A @ -18°C (0°F)
- Storage Capacity: 160 Min @ 27°C (80°F)
Tire:
- Size: 33×12/D6 10
- Type: Foam-filled
- Ply Rating: 12
- Max Capacity (8km/h): 1375 kg/3031 lb
- Max Capacity (0km/h): 5800 kg/12787 lb
- Weight (tire and wheel): 130 kg/287 lb
Functional Speeds (Unit: s):
- Upper Boom Lifting/Lowering: 55 s ~ 65 s
- Turntable Swing (a round): 98 s ~ 118 s
- Upper Boom Extending/Retracting: 40 s ~ 50 s
- Platform Rotation (left and right): 17 s ~ 23 s
- Jib Lifting/Lowering: 17 s ~ 23 s
- Tower Boom Lifting/Lowering: 27 s ~ 33 s
Pressure Settings:
- Upper Boom Lifting/Extending, Jib Lifting, Platform Rotation, Tower Boom Lifting: 21 MPa
- Turntable Swing: 11 MPa
- Chassis Diversion: 18 MPa
- Platform Leveling: 17 MPa
Usage Features
The ZA20J is designed for safe and efficient operation, with controls available at both the platform and ground level. The machine incorporates safety features such as load-bearing performance and safety control devices. The oscillating axle system automatically locks when the boom is extended beyond a certain point or angle, ensuring stability during elevated work. The auxiliary power system provides a crucial backup for safely lowering the platform in case of main power failure. The three drive modes selectable from the platform console allow for adaptable travel speeds depending on the boom's position (stowed or working).
Maintenance Features
The manual emphasizes the importance of regular inspection and maintenance to ensure the machine's longevity and safe operation.
- Personnel Requirements: Only trained and qualified personnel with appropriate certifications and experience are authorized to perform maintenance.
- Safety Equipment: Operators and maintenance personnel must use suitable safety equipment (helmets, gloves, goggles, safety belts, boots, hearing protection) according to work site conditions.
- Maintenance Precautions:
- Ventilation: Required when operating the engine in confined spaces.
- Cleanliness: The work site and machine must be cleaned before inspection or maintenance to prevent contamination and accidents. High-pressure water guns should not be aimed directly at electrical control boxes or connectors.
- Engine Off: The engine must be stopped, and the key removed before performing inspections or maintenance, with a "No Operation" warning sign placed on controls.
- Electrical Safety: Battery positive and negative wires must be removed when welding to prevent damage to electrical components. The machine should not be used as a ground wire for welding. Insulating silicone grease should be used for all electrical connections to prevent oxidation and short circuits.
- High Temperature Parts: Allow hot components (engine, mufflers, radiators, hydraulic oil, etc.) to cool down before inspection or maintenance to prevent burns.
- High Pressure Oil: Release pressure before disassembling hydraulic lines. Wear goggles and protective gloves when checking for leaks, and never use hands.
- Lubrication: Use specified grades of oil and grease. Mixing different grades is prohibited.
- Platform Position: Maintenance is prohibited when the platform is in the raised position unless reliable support is provided.
- Post-Maintenance Checks: After maintenance, confirm operational functions, check for oil leakage, loose bolts, and other issues. Restore safety devices and recalibrate if necessary.
- Hazardous Waste Disposal: All hazardous wastes (oil, fuel, filters, batteries, hydraulic oil) must be recycled and disposed of according to environmental regulations.
- Hydraulic System Cleanliness: Maintaining hydraulic fluid cleanliness is critical. Regular fluid changes and filter replacements are specified. Hydraulic oil cleanliness should be NAS9 (ISO4406 18/15) at the factory and not lower than NAS10 (ISO4406 19/16) for normal operation.
- Cylinder Drift Test: Procedures are outlined to measure maximum acceptable cylinder drift, with specific values provided for different cylinder bore sizes.
- Pin and Bearing Inspection: Detailed instructions for inspecting and replacing fiber bearings and pins, including conditions for replacement.
- Welding Procedures: Specific steps to follow when welding on the device, including disconnecting the battery and torque pin connector, and grounding only the structure being welded.
- Electrical System Maintenance: Regular checks of battery terminals, cables, wiring harnesses, and engine electrical components are required.
- Fault Code System: The manual includes a comprehensive list of fault codes and their corresponding solutions to aid in troubleshooting.
- Multimeter Operation: Basic instructions for using a multimeter for voltage, resistance, and current measurements, including grounding, backside detection, and range settings.
- Connector Assembly/Disassembly: Detailed steps for assembling and disassembling DEUTSCH DT/DTP and HD30/HDP20 series connectors.
The manual also includes detailed schematics for the electrical and hydraulic systems, which are essential for in-depth troubleshooting and repair.
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