Zoomlion ZT20J Installation and user guide

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

II
Foreword
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 operations. 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.

III
Contents
Foreword....................................................................................................................................I
Contents...................................................................................................................................III
SECTION 1 MAINTENANCE SAFETY INSTRUCTION
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 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 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 inspections.................................................................3-1
3.1.4 Machine annual inspection ............................................................................3-1
3.1.5 Preventive maintenance.................................................................................3-2

IV
Contents
3.2 Maintenance and Instruction............................................................................................3-2
3.2.1 General description........................................................................................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 Instructions ..........................................................................3-9
3.5.1 Fiber bearing..................................................................................................3-9
3.6 Welding on the Device.....................................................................................................3-9
3.6.1 Please perform the following operations when welding on the device..........3-9
3.6.2 Do not perform the following operations when welding on the device.........3-9
3.7 Use Insulating Grease in Electrical Connection Locations............................................3-10
3.8 Engine Electrical System Maintenance..........................................................................3-10
SECTION 4 CHASSIS AND TURNTABLE
4.1 Tire and wheel..................................................................................................................4-1
4.1.1 Tire inflation ..................................................................................................4-1
4.1.2 Tire damage ...................................................................................................4-1

V
Contents
4.1.3 Tire replacement ............................................................................................4-2
4.1.4 Wheel replacement.........................................................................................4-2
4.1.5 Wheel installation ..........................................................................................4-2
4.2 Swing axle 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 ChassisAngle Sensor System..........................................................................................4-4
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...............................................................................................................4-8
4.8.1 Disassembly...................................................................................................4-8
4.8.2 Installation .....................................................................................................4-8
4.9 Rotary Motor....................................................................................................................4-9
4.10 Rotary Reducer ..............................................................................................................4-9
4.10.1 Check and maintenance.................................................................................4-9
4.10.2 Gear oil replacement....................................................................................4-10
4.11 Slewing Bearing...........................................................................................................4-11
4.11.1 Slew bearing lubrication ..............................................................................4-11
4.11.2 Check and maintenance ...............................................................................4-11
4.11.3 Disassembly................................................................................................4-12
4.12 Gear clearance adjustment of slewing mechanism ..........................................................4-12
SECTION 5 BOOM AND PLATFORM
5.1 Platform and Jib...............................................................................................................5-1
5.1.1 Load cell ........................................................................................................5-1
5.1.2 Rotary actuator...............................................................................................5-2
5.1.3 Jib lifting cylinder..........................................................................................5-3
5.2 BoomAssembly...............................................................................................................5-4
5.2.1 Cable..............................................................................................................5-4
5.2.2 Leveling cylinder...........................................................................................5-5
5.2.3 Lower leveling cylinder.................................................................................5-6

VI
Contents
5.2.4 Lifting cylinder..............................................................................................5-8
5.2.5 Boom..............................................................................................................5-9
5.2.6 Telescopic cylinder ......................................................................................5-12
5.2.7 Wire rope pulley disassembly......................................................................5-16
5.2.8 Wire rope and pulley check..........................................................................5-18
5.3 Load Cell Check ............................................................................................................5-20
5.4 Boom Tilt Sensor Check................................................................................................5-21
5.5 Calibration of boom length sensor.................................................................................5-21
5.6 Check of Wire Rope Damage Indication System...........................................................5-22
5.7 Beyond the stowed position-limited speed check..........................................................5-22
SECTION 6 HYDRAULIC AND ELECTRICAL SYSTEM MAINTENANCE..................6-1
6.1 Hydraulic Filter Maintenance ..........................................................................................6-1
6.1.1 High pressure filter ........................................................................................6-1
6.1.2 Oil filling filter...............................................................................................6-1
6.1.3 Return oil filter...............................................................................................6-2
6.2 Pressure Setting................................................................................................................6-2
6.3 Starting Procedure............................................................................................................6-3
6.3.1 Drive pump oiling..........................................................................................6-3
6.3.2 Exhaust air in the pump inlet pipe .................................................................6-3
6.4 Fault code.........................................................................................................................6-4
6.5 Common Faults and Methods........................................................................................6-10
SECTION 7 ELECTRICAL INFORMATION AND SCHEMATIC
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 Resistance measurement................................................................................7-3
7.2.8 Conduction test..............................................................................................7-3
7.2.9 Current measurement.....................................................................................7-4

VII
Contents
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 ConnectorAssembly....................................................7-5
7.3.4 HD30/HDP20 Series Connector Removal.....................................................7-6
7.5 Hydraulic Schematics ....................................................................................................7-16

1-1
SECTION 1 MAINTENANCE SAFETY INSTRUCTION
1.1 Maintenance Personnel Duties, Requirements and Safety Equipment
1.1.1 Duties
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

1-2
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
of them must be in front of the turntable or platform control panel so that the engine can be shut

1-3
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 Welding and repair of every part
of the aerial work platform.

1-4
Figure 1-3 Beware of Explosion
The positive and negative wires of the batterymust be removed when welding to prevent the positive
and negative poles of the welder from forming a loop with the vehicle 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 Caution Hot
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.
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

1-5
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
a. 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.
b. Remove the cable from the battery before inspecting or maintaining the electrical system.

1-6
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.
c. 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 the 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 liquid
d. 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 chemicalreaction 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 thoroughlybefore adding new grease.
Figure 1-7 Prohibition of mixing oil
e. Support the boom and platform during maintenance. Maintenance is prohibited when the platform
is in the raised position. If there is special demand, the boom and platform should have reliable
support to ensure the safety and reliability during maintenance.
f. Precautions after maintenance:
1) After maintenance, the operation function must be confirmed to detect the oil leakage or
malfunction in the early stage.

1-7
2) It is necessary to confirm the machine movement, oil leakage, loose bolts and other problems
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, replaced 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.
The disposal of hazardous substances should be in compliance with all environmental regulations,
otherwise it will be fined or punished by relevant departments.

2-1
SECTION 2 TECHNICAL PARAMETERS
2.1 Performance
Table 2-1 Performance
Platform Capacity
454kg (restricted)
300kg (unrestricted)
1000lb(restricted)
660lb(unrestricted)
Max Travel Speed (on slope)
45% (platform uphill)
30% (platform downhill)
45% (platform uphill)
30% (platform
downhill)
Max Travel Speed (on side slope)
17%
17%
Platform Height
20.75m
68ft
Horizontal Outreach
16.8m
55ft
Turning Radius
5.4m (outside)
2.4m (inside)
17ft8in (outside)
7ft10in (inside)
Max Travel Speed
6 km/h
3.73mph
Max Hydraulic System Pressure
21Mpa
21Mpa
Max Wind Speed
12.5m/s (force 6 wind)
28mph(force 6 wind)
Max Working Force
400N
90lb
Electrical System Pressure
12V DC
12V DC
Gross Weight
12200kg
26896lb
*In stowed position
2.2 Specification and Performance
Table 2-2 Specification and Performance
Turntable Swing
360°
360°
Tail Swing
1.45m
4ft9in
Platform Dimension
2.44×0.91 m
8×3ft
Width
2.49m
8ft2in
Stowed Height
2.78m
9ft1in
Stowed Length
10.36m
34ft
Wheelbase
2.52 m
8ft3in
Ground Clearance
415mm
1ft4in
Travel Speed
6 km/h (stowed)
1 km/h (working)
3.73mph (stowed)
0.62mph (working)
Ground Bearing Stress
0.49MPa
0.49MPa
Max Tire Capacity
7110kg
15675lb

2- 2
2.3 Capacity
Table 2-3 Capacity
Fuel Tank
130L
34 us gal
Hydraulic tank
150L
39.6 us gal
Engine Oil Capacity
8L (Perkins
404D-22T)
8L (Deutz D2.9L4)
15L (Deutz D447-L4)
2.1 us gal (Perkins
404D-22T)
2.1 us gal (Deutz D2.9L4)
4 us gal (Deutz D447-L4)
2.4 Components Specification
2.4.1 Engine
Table 2-4 D2.9L4 (Deutz) Engine Specification
Type
Electric Control
Electric Control
Fuel
No.0 National IV
No.0 National IV
Engine Oil Capacity
8L
2.1 us gal
Rotate Speed
1200 (idle speed)
2000 (low speed)
2600 (high speed)
1200 (idle speed)
2000 (low speed)
2600 (high speed)
Current Output of Generator
14V,95A
14V,95A
Horsepower
49
49
Coolant
Cold water, 11L
Cold water, 2.9 us gal
Table 2-5 D447L4 (Deutz) Engine Specification
Type
Electric Control
Electric Control
Fuel
No.0 National IV
No.0 National IV
Engine Oil Capacity
15L
4 us gal
Rotate Speed
1200 (idle speed)
2000 (low speed)
2500 (high speed)
1200 (idle speed)
2000 (low speed)
2500 (high speed)
Current Output of Generator
14V,55A
14V,55A
Horsepower
49
49
Coolant
Cold oil, 15L
Cold oil, 4 us gal