Zoomlion ZA14J Installation and user guide

ZA14J (ZA45J)
Service and Maintenance Manual
Zoomlion Heavy Industry Science & Technology Co.Ltd.
Add：No.996 Tengfei Rd Wangcheng District Changsha Hunan P. R. China
E-mail:[email protected] Eel:400-800-0157
Zip Code:410200
Open up the WeChat, Scan the QR code above; All rights reserved 2015©Zoomlion,reserves all rights,Without the written permission of Zoomlion, the contents of any part of this sample may not be copied for any purpose.

ZA14J (ZA45J)
Service and Maintenance Manual
2020.1 A
Service and Maintenance Manual
Comply with ANSI SAIA_A92.20-2018 and CSA-B354.6-2017
Standard

Foreword
This Service and Maintenance Manual applies to the ZA14J 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.
Users must comply with the highest standards of 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 service center
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.
I

Foreword
Symbols and their description:
Danger indicates an imminently dangerous situation. If not avoided, will result in death or serious
injury.
Warning indicates a potential hazardous situation. If not avoided, will result in death or serious injury.
Caution indicates a potential hazardous situation. If not avoided, will result in minor or moderate injury.
Notice indicates information of property and device damage, or wrong operation. If not avoided, could
result in property loss, damage to machine parts or reduced mechanical properties.
Used to indicate or add additional information to individual information.
Indicates that this operation does not comply with safety regulations and is prohibited or prone to
casualties.
II

Contents
Foreword................................................................................................................................................... I
Content................................................................................................................................................... III
SECTION 1 MAINTENANCE SAFETY INSTRUCTION ............................................................1-1
1.1 Maintenance Personnel Duties, Requirements and Safety Equipment .............................................1-1
1.1.1 Duties..............................................................................................................................1-1
1.1.2 Basic requirements..........................................................................................................1-1
1.1.3 Personnel safety equipment ............................................................................................1-1
1.2 Maintenance Precautions..................................................................................................................1-2
1.2.1 Precautions......................................................................................................................1-2
1.2.2 Precautions in maintenance ............................................................................................1-3
SECTION 2 TECHNICAL PARAMETERS......................................................................................2-1
2.1 Performance......................................................................................................................................2-1
2.2 Specification and Performance .........................................................................................................2-1
2.3 Capacity............................................................................................................................................2-2
2.4 Components Specification................................................................................................................2-2
2.4.1 Engine.............................................................................................................................2-2
2.4.2 Battery ............................................................................................................................2-3
2.5 Tire....................................................................................................................................................2-3
2.6 Functional Speed...............................................................................................................................2-4
2.6.1 Operating procedure when testing speed........................................................................2-4
2.6.2 Test cautions ...................................................................................................................2-4
2.7 Torque Requirements........................................................................................................................2-5
2.8 Lubrication........................................................................................................................................2-5
2.8.1 Hydraulic oil...................................................................................................................2-5
2.9 Pressure Setting.................................................................................................................................2-6
SECTION 3 GENERAL INTRODUCTION......................................................................................3-1
3.1 Machine Preparation, Inspection and Maintenance..........................................................................3-1
3.1.1 General introduction.......................................................................................................3-1
3.1.2 Preparation, Inspection and Maintenance.......................................................................3-1
3.1.3 Pre-delivery and daily inspection ...................................................................................3-1
3.1.4 Machine annual inspection .............................................................................................3-1
3.1.5 Preventive maintenance..................................................................................................3-2
III

Contents
3.2 Maintenance and Service Instruction................................................................................................3-2
3.2.1 General instruction..........................................................................................................3-2
3.2.2 Safety and operating standards.......................................................................................3-3
3.2.3 Cleaning..........................................................................................................................3-3
3.2.4 Component disassembly and installation........................................................................3-3
3.2.5 Component disassembly and reinstallation.....................................................................3-3
3.2.6 Pressure-fit parts.............................................................................................................3-3
3.2.7 Bearing............................................................................................................................3-3
3.2.8 Washer ............................................................................................................................3-4
3.2.9 Bolt and torque applications...........................................................................................3-4
3.2.10 Hydraulic line and electric wiring.................................................................................3-4
3.2.11 Hydraulic system ..........................................................................................................3-4
3.2.12 Lubrication....................................................................................................................3-4
3.2.13 Battery ..........................................................................................................................3-4
3.2.14 Lubrication and maintenance........................................................................................3-5
3.3 Lubrication and Information.............................................................................................................3-5
3.3.1 Hydraulic system ............................................................................................................3-5
3.3.2 Hydraulic oil...................................................................................................................3-5
3.3.3 Hydraulic oil replacement...............................................................................................3-7
3.3.4 Lubrication specification ................................................................................................3-7
3.4 Cylinder Drift Test............................................................................................................................3-7
3.4.1 Platform drift ..................................................................................................................3-7
3.4.2 Cylinder drift ..................................................................................................................3-8
3.5 Pin and Bearing Inspection Instruction.............................................................................................3-9
3.5.1 Fiber bearing...................................................................................................................3-9
3.6 Welding on the Device......................................................................................................................3-9
3.6.1 Perform the following operations when welding on the device......................................3-9
3.6.2 Not perform the following operations when welding on the device...............................3-9
3.7 Use Insulating Grease in Electrical Connection Location ..............................................................3-10
3.8 Engine Electrical System Maintenance...........................................................................................3-10
SECTION 4 CHASSIS AND TURNTABLE.......................................................................................4-1
4.1 Tire and Wheel..................................................................................................................................4-1
4.1.1 Tire inflation ...................................................................................................................4-1
4.1.2 Tire damage ....................................................................................................................4-1
IV

Contents
4.1.3 Tire replacement .............................................................................................................4-2
4.1.4 Wheel replacement .........................................................................................................4-2
4.1.5 Wheel installation...........................................................................................................4-2
4.2 SwingAxle Exhaust and Locking Test .............................................................................................4-3
4.2.1 Floating cylinder exhaust................................................................................................4-3
4.2.2 Swing axle lock test........................................................................................................4-4
4.3 Chassis Angle Sensor System...........................................................................................................4-5
4.4 Auxiliary Power System ...................................................................................................................4-5
4.5 Oscillating axle system.....................................................................................................................4-5
4.6 Traveling Drive system.....................................................................................................................4-6
4.7 Travel Reducer..................................................................................................................................4-7
4.7.1 Disassembly....................................................................................................................4-7
4.7.2 Installation ......................................................................................................................4-8
4.8 Traveling Motor................................................................................................................................4-9
4.8.1 Disassembly....................................................................................................................4-9
4.8.2 Installation ......................................................................................................................4-9
4.9 Generator ........................................................................................................................................4-10
SECTION 5 BOOM AND PLATFORM.............................................................................................5-1
5.1 Platform and Jib................................................................................................................................5-1
5.1.1 Load cell disassembly.....................................................................................................5-1
5.1.2 Rotary actuator disassembly...........................................................................................5-2
5.1.3 Jib lifting cylinder...........................................................................................................5-2
5.2 Boom Assembly................................................................................................................................5-3
5.2.1 Cable disassembly ..........................................................................................................5-4
5.2.2 Upper cylincer disassembly............................................................................................5-5
5.2.3 Lower leveling cylinder and lifting cylinder ..................................................................5-6
5.2.4 Upper boom disassembly................................................................................................5-7
5.2.5 Telescopic cylinder disassembly.....................................................................................5-9
5.2.6 Tower boom and its cylinder disassembly....................................................................5-10
SECTION 6 ELECTRICAL SYSTEM MAINTENANCE ...............................................................6-1
6.1 Fault Code.........................................................................................................................................6-1
6.2 Common Faults and Solutions..........................................................................................................6-5
V

Contents
SECTION 7 ELECTRICAL INFORMATION AND SCHEMATIC ...............................................7-1
7.1 General Introduction.........................................................................................................................7-1
7.2 Multimeter Basic Operation..............................................................................................................7-1
7.2.1 Grounding.......................................................................................................................7-1
7.2.2 Backside detection..........................................................................................................7-1
7.2.3 Minimum value/maximum value....................................................................................7-1
7.2.4 Polarity............................................................................................................................7-1
7.2.5 Range..............................................................................................................................7-2
7.2.6 Voltage measurement......................................................................................................7-2
7.2.7 Resistence measurement.................................................................................................7-2
7.2.8 Conduction measurement ...............................................................................................7-3
7.2.9 Current measurement......................................................................................................7-3
7.3 DEUTSCH Connector ......................................................................................................................7-4
7.3.1 DT/DTP series connector assembly................................................................................7-4
7.3.2 DT/DTP series connector disassembly ...........................................................................7-5
7.3.3 HD30/HDP20 series connector assembly.......................................................................7-5
7.3.4 HD30/HDP20 series connector disassembly ..................................................................7-6
7.4 Electrical Schematics........................................................................................................................7-8
7.5 Hydraulic Schematics .....................................................................................................................7-14
VI

SECTION ONE MAINTENANCE SAFETY INSTRUCTION
1.1 Maintenance Personnel Duties, Requirements and Safety Equipment
1.1.1Duties
The maintenance personnel must maintain the aerial work platform and to be responsible for the safe
use and normal operation. The Maintenance and Service Manual provided by the company shall be
observed and all necessary maintenance shall be carried out under the safe working system.
1.1.2 Basic requirements
Maintenance personnel should meet the following conditions:
a) Inspectors and maintenance personnel should have appropriate qualifications or authorization;
b) Experienced technicians or professional engineers;
c) Familiar with the aerial work platforms maintenance and the potential danger;
d) Received appropriate education and training, including courses related to the use of special
equipment;
e) Familiar with the relevant maintenance procedures and safety precautions of aerial work platforms.
1. Only the trained and qualified personnel who have obtained the qualification certificate can
repair the aerial work platform;
2. Do not perform any maintenance when you cannot work properly after being unwell, drinking
or taking medicine.
1.1.3 Personnel safety equipment
a) The operator must use safety equipment when operating the machine;
b) Select suitable safety equipment such as helmets, gloves, protective goggles, safety belts, boots and
hearing protection devices according to the work site conditions;
Figure 1-1 Personnel safety equipment
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c) Check safety equipment before and after work, perform maintenance according to specified
procedures or replacement if necessary;
d) Keep inspection and maintenance records if needed;
e) Certain safety equipment (such as helmets and seat belts) might be damaged after prolonged use
and should be inspected and replaced periodically.
1. Inspect safety equipment regularly, replace damaged parts if necessary;
2. All personal protective equipment does not provide 100% protection;
3. Please wear protective gear properly and be familiar with the various hazards that may be
encountered during the operation for safety consideration;
4. Periodic maintenance and repair must be carried out by professional maintenance personnel.
Inspection or maintenance in a space-constrained, poorly ventilated location may result in
poisoning.
1.2 Maintenance Precautions
1.2.1 Precautions
a) Ventilation;
Ventilation is required when starting the engine in a space-constrained site. Connect a hose to the
exhaust pipe to discharge the smoke to the outside. Open the doors and windows to keep air flowing.
b) Clean up the work site;
Implementing the inspecting or maintaining works in a messy place may result in personal injury or a
fall accident.All obstacles should be removed before work.
c) Stop the engine before performing inspections or maintenance work.
Do not perform inspections or maintenance while the engine is running to prevent accidents;
Remove the key before inspection and maintenance, and place a No Operation warning sign on the door
or on the joystick of the control panel.
During inspection or maintenance, any unrelated personnel inadvertently start the engine, which
may cause mechanical damage or personal injury.
a) Inspection or maintenance must be carried out by at least 2 people while the engine is running. One
1-2

of them must be in front of the turntable or platform control panel so that the engine can be shut
down at any time if necessary, and others can conduct inspection or maintenance. Personnel should
keep close contact to work safely;
b) Clean the aerial work platform before inspection or maintenance. The dust or debris on the aerial
work platform not only makes the faulty components or parts difficult to find, but also can be
mixed into the components or parts during operation. In addition, dust or mud can cause injury to
the eyes or make the floor slippery that results in injury;
c) When cleaning the machine with a high-pressure water gun, it is forbidden to directly align the
electrical control box and the connector, otherwise it will cause an electrical short circuit.
It is strictly forbidden to align water or water jets with electrical components! Otherwise there is
danger of electric shock!
Figure 1-2 Mind electric shock
1.2.2 Precautions in maintenance
a) Prevent fire.
1) Use non-flammable cleaning fluids for parts and components cleaning;
2) Store fuel and grease items away from flames or sparks;
3) No smoking;
4) Do not allow flames or sparks to get close to flammable objects;
5) Have a fire extinguisher and understand how to use it;
6) Use explosion-proof lights when checking fuel, oil and battery fluids;
7) Keep flammable objects away from flying sparks or molten metal during grinding or welding.
b) Only trained technicians could conduct welding and repairing for every part and wear-resistant
parts.
1-3

Figure 1-3 Mind explosion
The positive and negative wires of the battery must be removed when welding to prevent the
positive and negative poles of the welder from forming a loop with the unit body, thereby burning
electrical components such as controllers and sensors. The company does not take the
consequences for wrong operation.
It is forbidden to use the machine as a ground wire during welding.
a) Check or maintain the machine after the temperature has been lowered;
Contact with the components might cause burn hazard, as the temperature of components goes high
when the machine is running. These components include engines, mufflers, engine cooling water,
radiators, hydraulic oil, reducers, hydraulic kits and hydraulic accessories. These components or parts
should be allowed to cool down before starting inspection or maintenance.
Figure 1-4 Mind burn hazard
b) Pay attention to the installed position of parts when unloading. Technicians performing the
installation must be familiar with each part to ensure proper installation.
1-4

It is strictly forbidden to disassemble electronic components.
a) Do not allow tools or parts to fall into the inspection hole; do not allow objects to fall into the holes
during work. Falling objects can damage the machine or cause the machine to malfunction. Any
tools or objects that fall into the inspection hole must be removed;
b) If electrical, circuit or hydraulic components (valves, pumps, etc.) need to be replaced, the replaced
parts should be checked and adjusted according to the data on the machine schematic.
Manufacturer-approved parts must be used, especially those that affect load bearing performance
and safety performance.
a) The components that affect the stability, strength and performance of the platform could be
modified only after obtaining the approval of the manufacturer, such as structural parts, carriers,
electrical components, and hydraulic components. Otherwise, any modifications to the aerial work
platform are prohibited;
b) Pay attention to high pressure oil; High pressure fuel or hydraulic oil can cause serious damage to
the skin or eyes. To avoid this danger, the following instructions should be followed:
1) The pressure inside the pipe must be released before disassembling the pipe;
2) Wear goggles and protective gloves when checking for leaks. Leakage of high pressure oil
may not be visible, use cardboard or wood chips to confirm oil leakage. DO NOT use your
hand to check for leaks.
Figure 1-5 Prevent burns from high pressure oil
c) Mind the high temperature part of the cooling system;
If the cover of the radiator is removed while the engine coolant temperature is high, steam or hot water
will be ejected, causing burns. Waiting for the temperature drop of coolant, stand in front of the radiator
cover and slowly loosen the cover to release the steam pressure before removing the cover.
d) Remove the cable from the battery before inspecting or maintaining the electrical system;
1-5

Inspection or maintenance of the electrical system without removing the cable of the battery may cause
a short circuit and damage the wiring, electrical components and electronic components of the electrical
system;
The cable on the negative terminal side (ground side) must be removed before the inspection or
maintenance work on the electrical system.
e) Mind battery liquid;
Battery fluid contains dilute sulfuric acid. Battery fluid can cause blindness when it enters the eyes, and
burns when it comes into contact with skin. Wear goggles, protective gloves long-sleeved overalls when
handling the battery;
If the eyes or skin are in contact with the battery fluid, rinse immediately with plenty of water and get
medical attention promptly.
Figure 1-6 Mind battery fluid
f) Use the specified greased items;
Use the recommended grade or the same grade of oil and grease when replenishing or replacing. The
combination of different grades of grease will result in a chemical reaction that changes the properties
of the grease and adversely affects the mechanical properties. When using a grease that is different from
the grade used in the machine, remove the original grease thoroughly before adding new grease.
Figure 1-7 Prohibition of mixing oil
g) Maintenance is prohibited when the platform is in the raised position; If there is a special demand
for maintenance, the boom and platform should have reliable support to ensure the safety and
reliability;
h) Precautions after maintenance:
1) After maintenance, the operation function must be confirmed to detect the oil leakage or
malfunction in the early stage;
2) It is necessary to confirm the machine movement, oil leakage, loose bolts and other problems
1-6

on the mechanically maintained parts;
3) Restore or reset the safety device and recalibrate the safety device if necessary;
4) Remove the tools and equipment for maintenance, replace parts and scattered objects, and
clean up the site;
5) It should always be borne in mind that all maintenance should include mandatory
confirmation of normal mechanical movement.
1. Handle hazardous wastes according to law such as oil, fuel, filter, battery, hydraulic oil, etc.
reasonable recycling of used oil, coolant or filter element to save resources and protect the
environment;
2. It is forbidden to dump waste liquid at the sewage pipe, ground surface, river, etc. at will. The
waste liquid should be discharged into a suitable container for proper disposal;
3. The disposal of hazardous substances should be in compliance with all environmental
regulations, otherwise it will be fined or punished by relevant departments.
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