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Zoomlion ZA80J Operation And Safety Manual

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ZOOMLION INTELLIGENT ACCESS MACHINERY CO.,LTD.
Add:Tengfei Road 997, Wangcheng District, Changsha, Hunan,PRC
E-mail:awm@zoomlion.com
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.
Zip Code:410200
Tel:400-800-0157
ZA80J
Operation and Safety Manual
NA-OP

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  • Page 1 Add:Tengfei Road 997, Wangcheng District, Changsha, Hunan,PRC E-mail:awm@zoomlion.com Tel:400-800-0157 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.
  • Page 3 Operation and Safety Manual ZA80J Operation and Safety Manual 2022.6 A...
  • Page 5 If there is any change, we will not give further notice. We hope that all users will understand. Thank you very much for your trust and support to Zoomlion products, and sincerely wish you all the best. Zoomlion Intelligent Access Machinery Co., Ltd.
  • Page 6 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.
  • Page 7 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 ........................
  • Page 8 Contents SECTION 4 OPERATION INSTRUCTION ................4-1 4.1 General ............................4-1 4.2 Boom Operation and Restriction ....................4-1 4.2.1 Capacity ........................4-1 4.2.2 Stability characteristics of the machine ..............4-2 4.3 Machine Operation ........................4-3 4.3.1 Engine operation ..................... 4-3 4.3.2 Drive operation ......................
  • Page 9 Contents 5.3 Battery Maintenance........................5-8 5.4 Regular Maintenance ......................... 5-9 5.4.1 Slewing reducer ....................... 5-9 5.4.2 Hydraulic tank ......................5-9 5.4.3 Travelling reducer ....................5-11 5.4.4 Travelling motor ....................5-11 5.4.5 Engine oil and filte ....................5-12 5.4.6 Fuel filter ....................... 5-13 5.4.7 High pressure filter ....................
  • Page 13 1.1 General To Owners/Users/Operators: Zoomlion appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. The following requirements need to be adhere to for the purpose of safety operating: Obey all user rules, job site regulations and governmental regulations;...
  • Page 14 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 to 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.
  • Page 15 Read operational Read service Fire hazard No smoking Explosion hazard manual manual Maintain required Electrocution hazard Burn hazard Prohibit Step on Avoid contact clearance Electrocution hazard Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard Lanyard anchorage Wheel load Wind speed Maximum capacity Tie-down point points...
  • Page 16 No smoking. Runaway hazard Fall Hazards Tire disassembly Explosion hazard No flame. Stop engine. Trained and authorized personnel Platform AC power Prohibit Lifting Lifting point Avoid contact operate the machine only Recovery procedure if tilt alarm sounds while elevated Platform uphill: Platform downhill: Lower the upper...
  • Page 17 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.
  • Page 18 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.
  • Page 19 If the tilt alarm sounds when the platform is raised, use extreme caution. 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. If the tilt alarm sounds with the platform uphill: Lower the upper boom;...
  • Page 20 Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs; Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the boom raised or extended;...
  • Page 21 Model Manual force Maximum occupants ZA80J 400 N/90 lbs force Do not place or attach fixed or overhanging loads to any part of this machine; Do not place ladders or scaffolds in the platform or against any part of this machine;...
  • Page 22 Fall Hazards Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform; Do not sit, stand or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times;...
  • Page 23 Collision Hazard Be aware of limited sight distance and blind spots when driving and operating; Check the work area for overhead obstructions or other possible hazards; Be aware of crushing hazards when grasping the platform guard rail; Be aware of the boom position and tail swing when rotating the turntable; Operators must comply with employer, job site, and governmental rules regarding use of personal protective equipment.
  • Page 24 Do not lower the boom unless the area below is clear of personnel and obstructions. Limit travel speed according to the condition of the ground surface, congestion, slope, location of personnel, and any other factors which may cause collision. Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive and steer functions.
  • Page 25 Immediately tag and remove from service a damaged or malfunctioning machine; Be sure all maintenance has been performed as specified in this manual and the appropriate Zoomlion service manual; Be sure all decals are in place and legible; Be sure operator's, safety, and responsibilities manuals are complete, legible, and in the storage container located on the machine.
  • Page 26 Battery Safety Burn hazard Batteries contain acid. Always wear protective clothing and eye wear when working with batteries; Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water; Do not expose the battery or charger in water or rain while charging. Explosion Hazard Keep sparks, flames, and lighted tobacco away from batteries.
  • Page 29 SECTION 2 MACHINE COMPONENTS AND CONTROLS 2.1 Machine Components Figure 2-1 Components Table 2-1 Component instruction Name Name Foot switch Platform console Manual storage container Main boom (upper boom) Sliding mid-rail Tower boom Lanyard anchorage points Ground control console Swing gate Steering tire Non-steering tire Work platform...
  • Page 30 2.2 Machine Controls and Indicators The manufacturer has no direct control over machine application and operation. The user and operator are responsible for conforming with good safety practices. 2.2.1 Ground control console 1.Boom lift, Boom extend/retract, Tower boom lift, Turntable swing, Jib lift, platform leveling, platform rotating device and auxiliary control device both equip with spring so that they will back to neutral when releasing;...
  • Page 31 Table 2-2 Ground Control Panel Instruction Name Turntable slew switch Main boom lift switch Tower boom lift/telescopic switch Main boom telescope switch Jib lift switch Platform rotate switch Platform leveling switch Power/Emergency stop switch Platform/Ground Select Switch Engine Start/ Auxiliary Power/Function Enable Switch Display Turntable slew switch Provide 360°...
  • Page 32 Jib lift switch (if equipped) Provide raising and lowering of the jib. Platform rotate switch Provides platform rotate controls. Only the platform leveling override function for slight leveling of the platform when platform is lowered. Incorrect use could cause the load/occupants to shift or fall. Failure to do so could result in death or serious injury.
  • Page 33 Do not enable any of the above motion functions at the same time when operating auxiliary power. (Operate several movement at the same time will cause auxiliary pump motor overloaded.) 10) Engine/ Auxiliary Power/Function Enable Switch Hold the switch in the UP position to start the engine. Turn off the engine and toggle the switch to DOWN position to active auxiliary pump.
  • Page 34 The function division is shown in the figure below. Figure 2-4 No.1 Indicator display column; No.2 Dynamic parameters monitoring column; No.3 Navigation bar. 1） When some specific status occurs, the status indicator lights up; when the specific status is released, the turntable indicator disappears;...
  • Page 35 Figure 2-5 2.2.3 Platform control console Avoid serious injury, do not operate machine if any control levers or toggle switches controlling platform movement do not return to the off or neutral position when released. Figure 2-12 Platform control panel (Only the switch number corresponding to the existing function is identified.)
  • Page 36 Table 2-3 Platform control panel instruction Name Drive select switch Platform leveling switch Horn switch Power/Emergency stop switch Engine start/Auxiliary power switch Drive direction confirm switch Drive/Steer controller Main boom telescope switch Jib lift switch Platform rotate switch Work light switch Function speed control Main Lift/Swing Controller Tower boom lift switch...
  • Page 37 Platform leveling switch Provide platform leveling controls. This switch is use to adjust platform level in situations such as ascending/descending a grade. Horn switch Horn positioned in turntable sounds when pressed the switch. Power/Emergency stop switch Push in the platform red Emergency Stop button to the off position;Power is shut off to the platform functions.when pull out (on), power turns on to the platform functions.
  • Page 38 Platform rotate switch Provides platform rotate controls Work light switch This switch operates the chassis lights if machine is so equipped. Function speed control This control could adjust the main boom telescoping, tower boom or jib lifting, and the speed of platform rotation. The speed of jib lift and platform rotation speed can only be controlled by the function speed knob.
  • Page 39 Figure 2-13 Platform Control Indicator Panel Table 2-4 Platform Indicator Panel Instruction Name Leveling system fault indicator Platform overload indicator Wire rope loosen indicator Tilt Alarm Warning Light Main boom system fault indicator Creep Speed Indicator Footswitch indicator System fault indicator Glow plug Soft touch indicator Drive direction confirm indicator...
  • Page 40 Platform overload indicator. Indicates the platform has been overloaded. Wire rope loosen indicator (not equipped). Indicates loosen or damage of main boom wire rope, service or adjust it immediately. Tilt Alarm Warning Light. This illuminator indicates that the chassis is on a slope. As long as the tilt angle of the chassis exceeds 4 °, the tilt alarm indicator will flash and a tilt alarm will sound.
  • Page 41 Creep speed indicator. When the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to slowest speed. The light will be on continuously if the operator selects creep speed. Foot switch indicator.
  • Page 42 12) Low fuel indicator. Indicates a low fuel condition in the tank. 13) Limited position indicator. Indicates limited position of boom. 14) Limited position indicator. Indicates limited position of boom. 2.2.5 Safety device The anti-crushing device is installed on the armrest at the platform console to avoid unobserved crushing injuries encountered during the operation of the equipment.
  • Page 45 Section 3 MACHINE INSPECTION 3.1 General An operator must not operate the machine, only if: He has learned and practiced the principles of safe machine operation contained in this operational manual. Only use the machine as it was intended; Know and understand the pre-operation inspection before going on to the next section; Implement functional test before operating the machine at all times;...
  • Page 46 Check for engine oil leak and proper fluid level. Add oil if needed. See Maintenance section; Check for engine coolant leak and proper level of coolant. Add coolant if needed. See Maintenance section; Check the following components or areas for damage, improperly installed, or missing parts and unauthorized modifications: Electrical components, wiring, and electrical cables;...
  • Page 47 3.2 Function Test 3.2.1 Function test principle The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions; A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 48 Attempt to activate each boom and platform function button. Check test result: All boom and platform functions should operate through a full cycle. Test auxiliary power Start the engine at the ground controls; Pull the red Power/Emergency Stop Switch button to on position; Operate Auxiliary Power Switch;...
  • Page 49 Attempt to activate each boom and platform function button. Result: all boom and platform functions except driving and steering should operate at the auxiliary power mode. Test the Horn Press the horn button at the platform controls. Check test result: The horn should sound. Test the Steering Select Platform Mode;...
  • Page 50 Lower the upper boom to stowed position; Extend the upper boom 0.5m; Attempt to operate drive handle; Check test result: the drive speed should switch to low speed with the upper boom extended. Lower the upper boom to stowed position; Attempt to operate drive handle.
  • Page 51 Drop-offs or holes; bumps, floor obstructions, or debris; Sloped surfaces; Unstable or slippery surfaces; Overhead obstructions and high voltage conductors; Hazardous locations; Inadequate surface support to withstand all load forces imposed by the machine; Wind and weather conditions; The presence of unauthorized personnel; Other possible unsafe condition.
  • Page 52 3.4 Decal Inspection Figure 3-1 Decal position Use the pictures on next page to verify that all decals are legible and in place. Below is a numerical list with quantities and descriptions.
  • Page 53 Table 3-1 Decal Numbers are corresponded to the decal (not all decal are pasted on the machine) Code/Content Decal 00771407000201100 Label- Yellow triangle 00773407000401251 Label- Do not insert stop pins 00771407000201090 Label- Yellow arrow 00771407000201110 Label- Blue triangle 00771407000201080 Label- Blue arrow 00773407000401271 Warn- Prohibit high pressure water-bleakest...
  • Page 54 Table 3-1 Decal (continuous) Numbers are corresponded to the decal (not all decal are pasted on the machine) Code/Content Decal 00773407000201421 Label- Tie down 00773407000201241 Label- Prohibit Lifting 00773407000401201 Caution- Prohibit Hand Touch or Lanyard 00773407000401231 Warn- Foot Switch Malfunction 00773407000201411 Label- Lanyard Anchorage Point...
  • Page 55 Table 3-1 Decal (continuous) Numbers are corresponded to the decal (not all decal are pasted on the machine) Code/Content Decal 00773407010401021 Caution-Risk of Pinching Hand 00773407000401221 Label- Platform Indicator Panel Instruction 02561907001601530 Label-Hood 02561907001601330 Label- Work Platform 00773407000401391 Caution-Preserve the manual 00773407000401511 Caution-Cold starting 00773407000401461...
  • Page 56 Table 3-1 Decal (continuous) Numbers are corresponded to the decal (not all decal are pasted on the machine) Code/Content Decal 00773407000401321 Warn- Crushing hazard 00773407000201181 Label- Prohibit Step on 00771407000401151 Label-Diesel oil tank 00771407000401161 Label-Hydraulic oil tank 00773407000401311 Danger- Tip-over Hazard 00773407000401191 Danger- Crushing Hazard 00773407000201431...
  • Page 57 Table 3-1 Decal (continuous) Numbers are corresponded to the decal (not all decal are pasted on the machine) Code/Content Decal 00773407000401081 Label- Ground Controls Box 02561907001601020 Label -ZOOMLION 00773407000401561 Danger- Tip-over Hazard 00771407001601021 Label- Wheel Load 00773407000201010 Label -ZOOMLION 02561907001601010...
  • Page 58 Table 3-1 Decal (continuous) Numbers are corresponded to the decal (not all decal are pasted on the machine) Code/Content Decal 00773407000401151 Caution- Cut off Battery 00773407000401381 Danger- Explosion Hazard 00771407000401191 QR code 00774007000201081 Label-Noise 00773407000401211 Hazard-Crushing hazard 02561907001601051 Label-Transport and lift instruction 00773707000201101 Label- Minimum fuel level...
  • Page 59 Table 3-1 Decal (continuous) Numbers are corresponded to the decal (not all decal are pasted on the machine) Code/Content Decal 00773707000201111 Label- Maximum fuel level 00773407000401471 Danger–Burn Hazard 00773407000401171 Hazard-Prohibit contact 00773407000201061 Label - Follow instructions to refuel 00773407000401371 Danger –Explosion Hazard 00775607000401321 Warn-Non-insulated 00771409900401042...
  • Page 60 Table 3-1 Decal (continuous) Numbers are corresponded to the decal (not all decal are pasted on the machine) Code/Content Decal 00771407000401350 Precautions for instrument indicator 00771407000401360 Lubricating oil addition 00771407000401211 High temperature warning 00771407000401201 Fuel addition 00771407000401340 Emission control diagnostic system 3-16...
  • Page 63 The equipment is located on a flat, solid and level surface; The load is within the load capacity range specified by the production trademark; All systems of the equipment are working normally; The tire pressure is normal; The equipment keeps the original ZOOMLION equipment.
  • Page 64 4.2.2 Stability characteristics of the machine The stability of the machine is based on the following different positions, called "forward stability" and "backward stability". Figure 4-1 shows the position of the "minimum forward stability" of the machine, and Figure 4-2 and Figure 4-3 show the "position of the minimum backward stability" of the machine. To avoid overturning forward or backward, do not overload the equipment or operate on sloping ground.
  • Page 65 Figure 4-3 Minimum backward stability 4.3 Machine Operation 4.3.1 Engine operation Note: Initial starting should always be performed from the Ground Control station; When operating a machine at high altitudes, a decrease in machine performance may occur due to a decrease in air density. When operating a machine at high ambient temperatures, a decrease in machine performance and increase in engine coolant temperature may occur;...
  • Page 66 Consult ZOOMLION customer service to know more about the operation under abnormal conditions. 4.3.1.1 Engine start Machine with diesel engines. After turning on ignition, operation must wait until glow plug indicator light goes out before cranking engine.
  • Page 67 4.3.1.2 Engine shut down sequence Remove all load and allow engine to operate at low speed for 3-5 minutes. This allows further reduction of internal engine temperature; Push in Power/Emergency Stop switch; Turn the Platform/Ground select switch to Off position. Refer to Engine Manufacture’s manual for detailed information.
  • Page 68 4.3.2.1Traveling forward and reverse At Platform Controls, pull out Emergency Stop switch, start the engine, and activate foot switch; Position DRIVE/STEER control to “FORWARD” OR “REVERSE” hold for duration of forward or reverse travel desired. This machine is equipped with travelling direction indicator lights. The indicator lights on platform console to inform that upper boom is over front axle (steer wheels), steer and drive controls will move in opposite direction than indicated on machine placards.
  • Page 69 4.3.4 Platform rotation To rotate the platform to the left or right, use the Platform Rotate control switch to select the direction and hold until desired position is reached. 1. Do not swing or raise upper boom above horizontal position when machine is out of level. 2.
  • Page 70 4.3.9 Raising and lowering the jib To raise or lower the Jib, position the Jib Lift to Up or Down until the desired height is reached. 4.3.10 Emergency stop Push in the red “Emergency Stop” button on Ground or Platform Controls to off position to shut off all the functions.
  • Page 71 The transport vehicle must be secured to prevent rolling while the machine is being loaded. Be sure the vehicle capacity, loading surfaces and chains or straps are sufficient to withstand the machine weight. ZOOMLION lifts are very heavy relative to their size. See the serial label for the machine weight.
  • Page 72 towed, the speed must not exceed 3.2 km/h. Securing to Truck or Trailer for Transit Always use the turntable rotation lock pin each time the machine is transported. Panel Cradle Installation Insert the hook piece through the slots in the panel cradle base. Inspect the entire machine for loose or unsecured items.
  • Page 73 4.4.3 Transport Use chains of ample load capacity; Use a minimum of 6 chains; Adjust the rigging to prevent damage to the chains. Figure 4-5 Lifting and Securing Instructions 4.4.4 Securing the platform Be sure the boom and the platform are in stowed position; Use the straps between the platform rotator (see Figure below) and platform base to secure the platform;...
  • Page 74 Figure 4-6 Securing the Platform Use a cable tie or rope to secure the slider to the upper square tube of the work platform to prevent the slider from bumping during transportation. Figure 4-7 Securing the Platform 4-12...
  • Page 77 Disposal of materials should be according to the regulations of government and relevant environmental protection administration; Use only ZOOMLION approved replacement parts. ZOOMLION assumes no responsibility for hazards occurred to equipment and personnel caused by the use of unauthorized parts.
  • Page 78 Wear pads; Tires and wheels; Limit switches and horn; Alarm and indicator (if equipped); Nuts, bolts and other fasteners; Brake release unit. 5.1.3 Maintenance hazards Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs;...
  • Page 79 5.2 Power and Hydraulic System Maintenance 5.2.1 Check the engine oil level Maintaining the engine coolant at the proper level is essential to engine service life. Improper oil level will damage engine performance. Check the oil scale daily, ensure that the oil level is between the highest scale and the lowest scale. Select different types of oil according to the ambient temperature and engine configuration (see Table 5-1).
  • Page 80 Table 5-2 Fuel Requirement Ambient temperature Fuel type （-44 ~ -29）℃ -50# （-29 ~ -14）℃ -35# （-14 ~ -5）℃ -20# （-5 ~ 4）℃ -10# （4 ~ 8）℃ Above 8℃ 5.2.2 Check the engine coolant level Maintaining the engine coolant at the proper level is essential to engine service life. Improper coolant level will affect the engine’s cooling capability and damage engine components.
  • Page 81 Note: DO NOT mix oils of different brands or types, as they contain different additives which may cause negative effects. If mixing of hydraulic oils is unavoidable, permission must be obtained from the hydraulic oil manufacturer. After-sales service of ZOOMLION does not cover machine malfunction caused by hydraulic oil mixing.
  • Page 82 Table 5-2 Technical parameters of hydraulic oil Motion Technical Pour Flash Viscosity Parameter Viscosity Point ℃ Point ℃ Viscosity Index Brand cSt(40℃) Great Wall 4632 grease non-flammable 28.8-35.2 hydraulic oil N32(Eco-Friendly) Great Wall Ground — No.10 10.53(50℃) aviation hydraulic fluid Great Wall L -HS 15 Ultra low temperature 15.35...
  • Page 83 Table 5-2 Technical parameters of hydraulic oil (continuous) Motion Technical Pour Flash Viscosity Parameter Viscosity Point ℃ Point ℃ Viscosity Index Brand cSt(40℃) Mobil SHC Aware H 28.8-35.2 32 (Eco-Friendly) Chevron Clarity — Synthetic EA Hydraulic 10.53(50℃) Mobil DTE 10 Ultra 22 15.35 Mobil DTE 10 Ultra 32 31.35...
  • Page 84 meeting the aforementioned requirements for the use of hydraulic oil. Cleanliness of the hydraulic oil upon delivery is NAS9 (ISO4406 18/15), and for normal operation, the cleanliness should not be lower than NAS10 (ISO4406 19/16). We suggest that the hydraulic oil should be checked every 6 months, and the oil should be sampled at least once upon the time for oil changing.
  • Page 85 Body injury hazard Batteries contain acid.Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. Note: the battery should be fully charged before this inspection. Only qualified riggers should rig the machine; Only certified crane operators should lift the machine and only in accordance with the applicable crane regulations;...
  • Page 86 DO NOT over-lubricate the bearings, otherwise it will cause damage to outside seal of casing. 5.4.2 Hydraulic Tank Liquid Level –120-150 L (32-40 us gal). Interval –Check level daily;Change every year or 2,000 hours of operation. Comment –On new machines, those recently overhauled, or after changing hydraulic oil, operate all system a minimum of two complete cycles and recheck oil level in reservoir.
  • Page 87 5.4.3 Travelling reducer Lube Point(s) –Level/Fill Plug. Capacity –1.5 L (0.4 us gal). Model:SAE80W/90 Industrial Gear Oil for Close Motor. Interval – Check level every 3 months or 150 hours of operation;change every year or 2,000 hours of operation. 5.4.4 Travelling motor Lube Point(s) –Fill Plug.
  • Page 88 5.4.5 Engine oil and filte CUMMINS QSF2.8t3TC72 KUBOTA V3307 WEICHAI WP2.3NG75E441 KUBOTA V2607-CR-TI-EW02 Fig. 5-7 Engine oil port Maintenance point – replace engine oil. CUMMINS QSF2.8t3TC72 about 8L； WEICHAI WP2.3NG75E441 about 11L； KUBOTA V3307 about 11L；KUBOTA V2607-CR-TI-EW02 about 10L。 Interval – 50hrs of operation for first maintenance, then service it every half year or 500hrs ofoperation, whichever comes first.
  • Page 89 5.4.6 Fuel filter a) First class fuel filter CUMMINSQSF2.8t3TC72 WEICHAI WP2.3NG75 E441 KUBOTA V3307 KUBOTA V2607-CR-TI-EW02 Fig.5-9 First class fuel filter Maintenance point – replace filter element. Interval – Check drainage daily, then service it every half year or 500hrs ofoperation, whichever comes first. Replace according to engine maintenance manual.
  • Page 90 b) Second class fuel filter CUMMINSQSF2.8t3TC72 WEICHAIWP2.3NG75E441 KUBOTA V3307 KUBOTA V2607-CR-TI-EW02 Fig.5-10 Second class fuel filter Maintenance point – replace filter element. Interval –every half year or 500hrs ofoperation, whichever comes first. Replace according to engine maintenance manual. 5.4.7 High pressure filter Maintenance point- Replaceable element.
  • Page 91 5.4.8 Low pressure filter Maintenance point- Replaceable element. Interval- Replace every half year or 1,000hrs of operation. 5.4.9 Air filter (1) Air filter main body (2) Lid (3) Safety filter (4) Main filter element (5) Dust valve Fig.5-13 Air filter Maintenance Point(s) –Replaceable Element.
  • Page 92 5.4.10 Engine coolant Fig.5-14 Engine coolant Maintenance Point(s) –Add/replace anti-freezing solution. Refilling requirements: After running the engine for 5 minutes, the coolant level in the cooling water tank is between the MIN and MAX scale lines. Recommended capacity: CUMMINS QSF2.8t3TC72 about 13L; WEICHAI WP2.3NG75E441 about 12L; KUBOTA V3307 about 9L;...
  • Page 93 The replacement should be operated by professional maintenance personnel. 5.4.12 DPF parking regeneration（for WEICHAI WP2.3NG75E441/KUBOTA ） V2607-CR-TI-EW02 KUBOTAV2607-CR-TI-EW02 WEICHAI WP2.3NG75E441 Fig.5-16 Regenaration monitoring (in English) Fig.5-17 DPF regeneration prohibition button and regeneration button Maintenance point: DPF parking regeneration. Interval: Whenever the regeneration request light is on. Operation method: Park the vehicle where there is no risk of fire.
  • Page 94 "0". The whole vehicle will not be affected in the regeneration process. 5.4.14 Common filter element Table 5-5 CUMMINSQSF2.8t3TC72 filter element Filter element Part No. Zoomlion code Oil filter element 5266016 1009900947 First level fuel filter FS20019...
  • Page 95 Table 5-7 WEICHAI WP2.3NG75E441 filter element Filter element Part No. Zoomlion code Oil filter element 1000491060 1009806741 First level fuel filter 1000700908 1009806735 element Second level fuel filter Z20140023 1010601542 element Air filter element P827653 1000100310 Table 5-8 KUBOTA V2607-CR-TI-EW02 filter element Filter element Part No.
  • Page 96 Fig.5-18 Glow plug indicator (in English) b） After starting the engine, idle for 10 minutes before other operations. Do not start the engine frequently to avoid irreversible damage to the engine. When the ambient temperature is lower than -20° C, additional auxiliary starting equipment (such as electric heater) is required to start.
  • Page 97 ZOOMLION recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the ZOOMLION Parts Manual for the part number of the approved tires for a particular machine model. If not using a ZOOMLION approved replacement tire, we recommend that replacement tires have the following characteristics: Equal or greater ply/load rating and size of original;...
  • Page 98 larger or smaller diameter, etc., without written factory recommendations, may result in an unsafe condition regarding stability. Wheel installation It is extremely important to apply and maintain proper wheel mounting torque. Wheel nuts must be installed and maintained at the proper torque to prevent loose wheels, broken studs, and possible dangerous separation of wheel from the axle.
  • Page 101 SECTION 6 STORAGE AND EX-FACTORY TEST 6.1 Storage Conditions Ambient temperature for machine storage and transportation should be between -20℃/-4℉ and 40℃/104℉, with relative humidity not greater than 85% and 100% only for short-term. 6.2 Ex-factory Test Items Machine must complete testing items in the following table before delivery: Table 6-1 Testing Items Before Delivery Tests Items Load Testing...
  • Page 105 SECTION 7 TECHNICAL PARAMETER Table 7-1 Technical Parameters Model ZA80J Parameters Platform Height 24.23m 79ft 5in Horizontal Outreach 18.9m 62ft Up and Over Height 9.29m 30ft 5in Overall Length 11.2m 36ft 9in Dimension Overall Width 2.49m 8ft 2in Overall Height 2.85m...
  • Page 106 Table 7-1 Technical Parameters (Continuous) Model ZA80J Parameters Platform Rotation ± 90° Jib Working Range -65° ~70° Upper Boom Working -35° ~65° Range of Range Motion Upper Boom Telescopic 5980mm 19ft 7in. Tower Boom Working -1.5° ~70° Range Turntable Swing 360°...
  • Page 107 Figure 7-1 ZA80J Range of Motion...
  • Page 108 Figure 7-2 ZA80J Dimension in Traveling Mode...