Zoomlion ZA14J Use and care manual

ZA14J (ZA45J)
Operation and Safety Manual
Zoomlion Heavy Industry Science & Technology Co.Ltd.
Add：No 361South Yinpen Rd Changsha Hunan Province P.R.China 410013
Tel: E-mail:
Postcode:

ZA14J (ZA45J)
Operation and Safety Manual
Standard
2019.5 A
Operation and Safety Manual
Comply with ANSI SAIA_A92.20-2018 and CSA-B354.6-2017

ZOOMLION appreciates your choice of our machine for your application. The Operation and Safety
Manual must be read and understood in its entirety before operating the machine.
This manual introduces you safety information, significant technical specs, safety operation in detail for
working efficiency improving. Keep this manual properly at all times for looking up.
Do not operate the machine if there is any doubt in operation, please consult local service team for
troubleshooting. Zoomlion AWP Machinery Company does not take the consequence for wrong
operation.
This manual should be considered a permanent part of your machine and should remain with the
machine at all times.
This content is under intellectual property protection, permission is required for a copy or other
application.
There might be some tiny differences in details between your machine and the upgraded one due to the
continuous improving. For clarification, questions, or additional information regarding any portions of
this manual, contact Zoomlion AWP Machinery.
Our company reserves the right to modify this manual as technical improvement without notice.
Thank you for your trust and support for Zoomlion products!
I

II
This manual has the following safety precaution icons:
Failure to comply with the safety precautions listed in this
manual could result in personal injury or death.
Failure to comply with the safety precautions listed in this
manual could result in potential personal injury or death.
Failure to comply with the safety precautions listed in this
manual could result in potential mild personal injury.
Indicates risks unrelated with personal injury (such as property
damage).

Contents
Foreword.............................................................................................................................................I
Safety Precaution Icons..................................................................................................................... II
Contents............................................................................................................................................ III
SECTION 1 SAFETY PRECAUTIONS .....................................................................................1-1
1.1 General ......................................................................................................................................1-1
1.2 Pre-operation.............................................................................................................................1-1
1.3 Hazard Classification ................................................................................................................1-2
1.4 Intended Use..............................................................................................................................1-2
1.5 Safety Alert Symbols and Maintenance ....................................................................................1-2
1.6 Safety Operation........................................................................................................................1-5
1.6.1 Operator safaty........................................................................................................1-5
1.6.2 Workplace safety.....................................................................................................1-5
SECTION 2 MACHINE COMPONENTS AND CONTROLS.................................................2-1
2.1 Machine Components................................................................................................................2-1
2.2 Machine Controls and Indicators...............................................................................................2-2
2.2.1 Ground control console...........................................................................................2-2
2.2.2 Ground control indicator panel ...............................................................................2-5
2.2.3 Platform control console .......................................................................................2-10
2.2.4 Platform control indicator panel............................................................................2-13
SECTION 3 MACHINE INSPECTION .....................................................................................3-1
3.1 General ......................................................................................................................................3-1
3.1.1 Pre-start inspection principle...................................................................................3-1
3.1.2 Pre-start inspection..................................................................................................3-1
3.2 Function Check .........................................................................................................................3-3
3.2.1 Pre-start inspection principle...................................................................................3-3
3.2.2 Ground function check............................................................................................3-3
3.2.3 Platform function check..........................................................................................3-4
3.3 Workplace Inspection................................................................................................................3-6
3.3.1 Workplace inspection principle...............................................................................3-6
3.3.2 Workplace inspection ..............................................................................................3-6
3.4 Decal Inspection........................................................................................................................3-7
III

Contents
SECTION 4 OPERATION INSTRUCTION..............................................................................4-1
4.1 General ......................................................................................................................................4-1
4.2 Machine Operation....................................................................................................................4-1
4.2.1 Engine operation .....................................................................................................4-1
4.2.2 Drive operation........................................................................................................4-3
4.2.3 Platform leveling.....................................................................................................4-4
4.2.4 Platform rotating .....................................................................................................4-5
4.2.5 Turntable slewing....................................................................................................4-5
4.2.6 Raise and lowering the upper boom........................................................................4-5
4.2.7 Telescoping the upper boom....................................................................................4-5
4.2.8 Raising and lowering the tower boom.....................................................................4-6
4.2.9 Raising and lowering the jib....................................................................................4-6
4.2.10 Emergency stop.....................................................................................................4-6
4.2.11 Auxiliary power.....................................................................................................4-6
4.2.12 Shut down and park...............................................................................................4-7
4.3 Transport and Lifting.................................................................................................................4-8
4.3.1 Release the brake while towing...............................................................................4-8
4.3.2 Lifting......................................................................................................................4-9
4.3.3 Securing the chassis ................................................................................................4-9
4.3.4 Securing the platform..............................................................................................4-9
SECTION 5 MAINTENANCE ....................................................................................................5-1
5.1 General ......................................................................................................................................5-1
5.1.1 Maintenance symbols legend..................................................................................5-1
5.1.2 Pre-start inspection..................................................................................................5-1
5.1.3 Maintenance hazards...............................................................................................5-2
5.1.4 Body injury hazard..................................................................................................5-2
5.2 Power and Hydraulic System Maintenance...............................................................................5-3
5.2.1 Check the engine oil level.......................................................................................5-3
5.2.2 Check the engine coolant level................................................................................5-3
5.2.3 Check hydraulic oil .................................................................................................5-3
5.3 Battery Maintenance..................................................................................................................5-7
5.4 Regular Maintenance.................................................................................................................5-8
5.5 Tire and Wheel ........................................................................................................................5-14
IV

Contents
SECTION 6 STORAGE AND EX-FACTORY TEST................................................................6-1
6.1 Storage Conditions....................................................................................................................6-1
6.2 Ex-factory Test Items ................................................................................................................6-1
SECTION 7 TECHNICAL PARAMETER.................................................................................7-1
V

SAFETYPRECAUTIONS
SECTION 1 SAFETY PRECAUTIONS
1.1 General
To Owner/Users/Operations:
Zoomlion appreciates your choice of our machine for your application. Safety is the number one priority,
which is best achieved by our joint efforts. The following requirements need to be adhere to for the
purpose of safety operating.
a) Obey all user rules, job site regulations and governmental regulations;
b) Read, understand and obey all operating instructions on the machine and in this manual;
c) Keep good safety operating convention;
d) Allow only those authorized and qualified personnel to operate the machine under the supervision
of an experienced and qualified operator;
e) An operator must not operate the machine if he has any doubts.
Zoomlion appreciates your choice of our machine for your application.
1.2 Pre-Operation
Failure to comply with the safety precautions listed in this manual could result in personal injury
or death.
An operator must not operate the machine, only if:
a) He has learned and practiced the principles of safe machine operation contained in this operational
manual:
1) Avoid hazardous situations;
2) Be aware of safety rules before further operation;
3) Perform a pre-operation inspection at all times;
4) Implement functional test before operating the machine at all times;
5) Inspect job site;
6) Only use the machine as it was intended.
b) Read, understand and obey the manufacturer’s instructions and safety rules-safety and operator’s
manuals and machine decals;
c) Read, understand and obey employer’s safety rules and work site regulations;
d) Read, understand and obey all applicable governmental regulations;
e) The operator is properly trained to safely operate the machine.
1-1

SAFETYPRECAUTIONS
1.3 Hazard Classification
Decals on this machine use symbols, color coding, and signal words to identify the following:
Safety alert symbol - used to alert you potential personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided, will result in death or serious injury. This
decal will have a red background.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. This
decal will have an orange background.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
This decal will have a yellow background.
Indicates a property damage message. This decal will have a blue background.
1.4 Intended Use
This machine is intended to be used only to lift personnel, along with their tools, and materials to an
aerial work site.
1.5 Safety Alert Symbols and Maintenance
Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap
and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety
sign material.
1-2

SAFETYPRECAUTIONS
Read operational
manual
Read service manual Fire hazard No smoking Explosion hazard
Electrocution hazard Burn hazard Prohibit step on Avoid contact
Maintain required
clearance
Electrocution hazard Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard
Wheel load Wind speed Maximum capacity Tie-down point Lanyard anchorage points
Crushing hazard Disconnect battery Manual force Collision hazard Maintain safety distance
Figure 1-1 Symbol and hazard pictorials definitions
1-3

SAFETYPRECAUTIONS
Runaway hazard Fall hazard Tire disassembly Explosion hazard
No smoking
No flame
Stop engine
Platform AC power Prohibit lifting Lifting point Avoid contact
Trained and authorized
personnel operates the
machine only
Recovery procedure if tilt alarm sounds while elevated
Platform uphill:
1. Lower the upper boom;
2. Lower the tower boom;
3. Retract the upper boom.
Platform downhill:
1. Retract upper boom;
2. Lower the tower boom;
3. Lower the upper boom.
Prohibit high
pressure water-beak
test
Prohibit modify the limit
switches Color coded direction arrows
Collision hazard
High temperature surface
Avoid contact
Fill fuel oil
Crushing hazard
Figure 1-1 Symbol and hazard pictorials definitions (continuous)
1-4

SAFETYPRECAUTIONS
1.6 Safety Operation
1.6.1 Operator safety
Personal Fall Protection
Personal fall protection equipment (PFPE) is required when operating this machine. If PFPE is required
in job site or in operator’s manual, the following rule should be complied with:
All PFPE must comply with applicable governmental regulations, and must be inspected and used in
accordance with the PFPE manufacturer’s instructions.
1.6.2 Workplace safety
This machine is not electrically insulated and will not provide protection from contact with or
proximity to electrical current.
a) Obey all local and governmental regulations regarding required clearance from electrical power
lines. At a minimum, the required clearance contained in the table below must be followed. Allow
for platform movement, electrical line sway or sag, and beware of strong or gusty winds;
Table 1-1 Required clearance
No. Line Voltage Required Clearance
1 0 to 50KV 3.05 m 10ft
2 50 to 200KV 4.60 m 15ft 1in
3 200 to 350KV 6.10 m 20ft
4 350 to 500KV 7.62 m 25ft
5 500 to 750KV 10.67m 35ft
6 750 to 1000KV 13.72m 45ft
1-5

SAFETYPRECAUTIONS
b) Allow for platform movement, electrical line sway or sag, and beware of strong or gusty winds;
c) Keep away from the machine if it contacts energized power lines. Personnel on the ground or in the
platform must not touch or operate the machine until energized power lines are shut off.
Do not operate the machine during lightning or storms.
Do not use the machine as a ground for welding.
Tip-over hazard
Occupants, equipment and materials shall not exceed the maximum platform capacity.
Table 1-2 Rated load
Maximum platform capacity
Unrestricted range of motion
300 kg/660lb
Maximum occupants
2
a) Do not exceed the maximum platform capacity;
b) Do not attach a platform rated at 300kg/660lb to machines with any other rated load. See the serial
label for the maximum rated capacity;
c) The weight in options and accessories (such as pipe, panel bracket and welder) will reduce rated
platform capacity and must be factored into total platform load. See the decals with the options and
accessories;
d) If using accessories, read, understand and obey the decals and instructions with the accessory;
e) Do not raise or extend the boom unless the machine is on a firm, level surface.
Do not use the tilt alarm as a level indicator. The tilt alarm sounds in the platform only when the
1-6

SAFETYPRECAUTIONS
machine is on a severe slope.
If the tilt alarm sounds when the platform is raised, be extremely careful. Identify the condition of the
boom on the slope as shown below. Follow the steps to lower the boom before moving to a firm, level
surface. Do not rotate the boom while lowering.
a) If the tilt alarm sounds with the platform uphill:
1) Lower the upper boom;
2) Lower the tower boom;
3) Retract the upper boom.
b) If the tilt alarm sounds with the platform downhill:
1) Retract the upper boom;
2) Lower the tower boom;
3) Lower the upper boom.
Do not raise the boom when wind speeds may exceed 12.5m/s (28mph).
If wind speeds exceed 12.5m/s (28mph) when the boom is raised, lower the boom and do not continue
to operate the machine. Do not operate the machine in strong or gusty winds. Do not increase the
surface area of the platform or the load. Increasing the area exposed to the wind will decrease machine
stability.
Table 1-3 Beaufort scale
Beaufort scale Wind speed Instruction
0
0 0-0.2 m/s
0-0.45mph
Calm
1
0.3-1.5 m/s
0.67-3.36mph
Light air
2
1.6-3.3 m/s
3.58-7.38mph
Light breeze
3
3.4-5.4 m/s
7.61-12.08mph
Gentle breeze
4
5.5-7.9 m/s
12.30-17.67mph
Moderate breeze
5
8.0-10.7 m/s
17.90-23.94mph
Fresh breeze
6
10.8-13.8 m/s
24.16-30.87mph
Strong breeze
7
13.9-17.1 m/s
31.09-38.25mph
Moderate gale
8
17.2-20.7 m/s
38.48-46.30mph
Fresh gale
9
20.8-24.4 m/s
46.53-54.58mph
Strong gale
1-7

SAFETYPRECAUTIONS
a) Be extremely careful and slow speeds while driving the machine in the stowed position across
uneven terrain, debris, unstable or slippery and near holes and drop-offs;
b) Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous
conditions with the boom raised or extended;
c) Never attempt to use the machine as a crane;
d) Do not push the machine or other objects with the boom;
e) Do not contact adjacent structures with the boom;
f) Do not tie the boom or platform to adjacent structures;
g) Do not place loads outside the platform perimeter;
h) Do not alter or disable machine components that in any way affect safety and stability;
i) Do not replace items critical to machine stability with items of different weight or specification;
j) Do not replace factory-installed tires with tires of different specification or ply rating;
k) Do not use air-filled tires. These machines are equipped with foam-filled tires. Wheel weight is
critical to stability;
l) Do not use the platform controls to free a platform that is caught, snagged, or otherwise prevented
from normal motion by an adjacent structure. All personnel must be removed from the platform
before attempting to free the platform using the ground controls;
m) Do not modify or alter an aerial work platform without prior written permission from the
manufacture. Mounting attachments for holding tools or other materials onto the platform, toe
boards, or guard rail system can increase the weight in the platform and the surface area of the
platform or the load;
n) Do not push off or pull toward any object outside of the platform.
1-8