Zoomlion ZT20J User Manual

I
Foreword
This Service and Maintenance Manual applies to the ZT20J (ZT68J) aerial work platform (hereinafter
referred to as the AWP).
This manual describes proper inspection, servicing and maintenance. Users must fully understand and
apply the contents described in this manual to maximize the performance and ensure the long-term safe
and efficient use. This manual does not cover the use and maintenance of the engine. For details on
engine, please refer to the engine instruction manual.
The manual includes the structure and schematic diagram of the main components. If it is necessary to
repair and replace the components, the material code of the required replacement parts can be found in
Parts Manual.
This manual should be considered a permanent part of your machine and should remain the machine at
all times.
Do not repair the parts marked with professional maintenance. Zoomlion AWP Machinery
Company does not take the consequence for wrong maintenance.
The highest criterion users must keep in mind that Safety first! Pay special attention to the safety
control device for regular inspection. Do not operate the machine when the safety device fails or
working abnormally. Do not modify the structure or add additional parts for more functions.
Otherwise, you will be responsible for any personal injury or damage caused by the unauthorized
modification.
The warranty period for the aerial work platform is as specified in this Service and Maintenance
Manual. When maintenance is required, our company provides on-site service or please go to our
designated maintenance point for maintenance.
Our company reserves the right to continually revise the contents of this manual with technical
improvements. Any changes are subject to change without notice. Some of the pictures in this
manual may not match the actual product due to design improvement, etc., but it does not affect
your use. The product status is subject to the actual product.
Symbols and their description:
Danger indicates an imminently dangerous situation. If not avoided, will result in death or

Zoomlion ZT20J Specifications

General

Brand	Zoomlion
Model	ZT20J
Category	Lifting Systems
Language	English

Summary

Foreword

Safety Symbols and Warnings

Explains the meaning of CAUTION, WARNING, NOTICE, and REMIND symbols.

Maintenance Safety Instruction

Personnel Duties, Requirements, and Safety Equipment

Outlines responsibilities, qualifications, and necessary safety gear for maintenance personnel.

Maintenance Precautions and Site Safety

Details essential precautions for performing maintenance tasks safely and effectively.

Technical Parameters

Performance and Specification Data

Details machine performance metrics like capacity, speed, height, and outreach.

Component Specifications (Engine, Battery, Tire)

Provides specifications for key components like engines, batteries, and tires.

Functional Speed, Torque, Lubrication, and Pressure

Lists functional speeds, torque, lubrication specs, and system pressure settings.

General Introduction to Machine Operations

Machine Preparation and Inspection Schedules

Covers general preparation, inspection types, and a comprehensive maintenance schedule.

General Maintenance Practices and Guidelines

Covers general maintenance practices, cleaning, disassembly, and lubrication procedures.

Lubrication, Cylinder Drift, and Component Checks

Details hydraulic oil management, cylinder drift tests, and pin/bearing inspection.

Welding Procedures and Electrical Greasing

Guides on welding safety and using insulating grease in electrical connections.

Engine Electrical System Maintenance

Instructions for maintaining the engine's electrical system, ensuring proper connections and function.

Chassis and Turntable Systems

Tire and Wheel Systems

Covers tire inflation, damage assessment, replacement, and wheel installation procedures.

Axle, Swing, and Drive Systems

Details swing axle tests, chassis sensors, drive systems, and oscillating axles.

Reducer, Motor, and Bearing Maintenance

Guides for travel reducer, traveling motor, rotary motor/reducer, and slewing bearing maintenance.

Slewing Mechanism Gear Clearance Adjustment

Procedure for adjusting the gear clearance in the slewing mechanism for smooth operation.

Boom and Platform Systems

Platform, Jib, and Boom Assembly Components

Disassembly/inspection of load cells, actuators, jib cylinders, and boom assembly.

Cylinders, Cables, and Wire Rope Systems

Procedures for leveling/lifting cylinders, boom cables, and wire rope maintenance.

Sensor Checks and Speed Limit Functions

Guides for load cell, tilt sensor, length sensor checks, and speed limit functions.

Hydraulic and Electrical System Maintenance

Hydraulic Filter Maintenance Procedures

Details the maintenance intervals for high pressure, oil filling, and return oil filters.

Pressure Setting and Starting Procedures

Instructions for setting hydraulic system pressure and initial startup procedures.

Fault Code Diagnostics and Troubleshooting

Lists and explains various fault codes for the system, aiding in problem diagnosis.

Common Faults and Solutions

Provides common issues and their corresponding solutions for troubleshooting the equipment.

Electrical Information and Schematics

Multimeter Usage and Measurement Techniques

Guides on using a multimeter for voltage, resistance, and current measurements.

Connector Handling and System Schematics

Instructions for connector assembly/removal and diagrams of electrical/hydraulic circuits.