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Zoomlion ZT58J Operation And Safety Manual

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Operation and Safety Manual
Operation and Safety Manual
ZT58J
Operation and Safety Manual
Aug 2022 Version A

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Summary of Contents for Zoomlion ZT58J

  • Page 1 Operation and Safety Manual Operation and Safety Manual ZT58J Operation and Safety Manual Aug 2022 Version A...
  • Page 3 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.
  • Page 5 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 Foreword ............................. I Safety Precaution Icons ......................II Content…………………………….……………………………………………………..…………III SECTION ONE SAFETY PRECAUTION ................1-1 1.1 General Description ......................1-1 1.2 Pre-operation cautions ....................... 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 FOUR 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 ....................4-5 4.2.4 Platform rotation ....................4-5 4.2.5 Turntable slewing ....................4-5 4.2.6 Raising and lowering the main boom ...............
  • Page 9 5.2.5 Check hydraulic oil ......................5-5 5.3 Battery Maintenance ......................5-8 5.4 Regular Maintenance ......................5-9 5.4.1 Swing drive…………………………………………………………………………5-9 5.4.2 Hydraulic reservoir…………………………………………………………………5-10 5.4.3 Travel reducer………………………………………………………………………5-11 5.4.4 High pressure filter………………………………………….……………………5-11 5.4.5 Replace engine oil and filter- Cummins QSF 3.8………………………………5-12 5.4.6 Fuel filter –Cummins QSF 3.8…………………………………………………5-12 5.4.7 Air Cleaner …………………………………………………………………………5-13 5.4.8 Engine coolant ……………………………………………………………………5-14 5.4.9 DPF (Diesel Particulate Filter) (Euro stage V/ China Stage IV only)…………5-15...
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  • 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.
  • Page 14 Read, understand and obey all applicable governmental regulations. The operator is properly trained to safely operate the machine. 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.
  • Page 15 Read operational Read service manual Fire hazard No smoking Explosion hazard manual Electrocution Maintain required Burn hazard Prohibit Step on Avoid contact hazard clearance Electrocution Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard hazard Lanyard anchorage Wheel load Wind speed Maximum capacity Tie-down point points Maintain safety...
  • Page 16 No smoking. Tire Runaway hazard Explosion hazard No flame Fall hazards disassembly Stop engine Trained and authorized Crushing hazard Prohibit lifting Lifting point Avoid contact personnel operate the machine only Recovery procedure if tilt alarm sounds while elevated Platform uphill: Platform downhill: 1.
  • 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 the workplace or in the rules of use, the following rules apply. All PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE manufacturer’s instructions.
  • Page 18 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 Maximum platform capacity Maximum Maximum...
  • Page 19 Do not use the tilt alarm as a level indicator. The tilt alarm sounds in the platform only when the machine is on a severe slope. 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.
  • Page 20 Table 1-3 Beaufort scale Beaufort scale Wind speed (m/s) Wind speed (mph) Instruction 0 0-0.2 0.0-0.45 Calm 0.3-1.5 0.67-3.36 Light air 1.6-3.3 3.58-7.38 Light breeze 3.4-5.4 7.61-12.08 Gentle breeze 5.5-7.9 12.3-17.67 Moderate breeze 8.0-10.7 17.9-23.94 Fresh breeze 10.8-13.8 24.16-30.87 Strong breeze 13.9-17.1 31.09-38.25 Moderate gale...
  • Page 21 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.
  • Page 22 Do not transport tools and materials unless they are evenly distributed and can be safely handled by person(s) in the platform. Do not use the machine on a moving or mobile surface or vehicle. Be sure the tires are in good condition and the lug nuts tightened, besides the tightening torque should be 400N/m.
  • Page 23 Do not climb down from the platform when raised. Keep the platform floor clear of debris. Use extreme care while entering or exiting the platform. Do not enter or exit the platform unless the machine is in the stowed position. Enter or exit the platform through the gate only.
  • Page 24 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. Do not lower the boom unless the area below is clear of personnel and obstructions.
  • 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.
  • Page 26 Component Damaged Hazard Do not charge the battery with a charger greater than 12V. Do not use the machine as a ground for welding. Do not charger with unmatched power. Do not use the machine where there may be a strong magnetic field. Battery Safety Burn hazard Batteries contain acid.
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  • Page 29 SECTION 2 MACHINE COMPONENTS AND CONTROLS 2.1 Machine Components Figure 2-1 Components Table 2-1 Component Instruction Item Item Counterweight assembly Cable chain system Turntable assembly Hood assembly Platform console Boom assembly Work platform Slewing mechanism Chassis assembly 2- 1 用户00757092 用户00757092...
  • Page 30 2.2 Machine controls and indicators The manufacturer has no direct control over machine application and operation. Users and operators are responsible for the application and operation in compliance with correct safety regulations. 2.2.1 Ground control console Boom lift, boom extend/retract, 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 Item Jib stow- key switch Turntable slew switch Main boom telescope switch Display Jib extending switch Platform rotary switch Platform leveling switch Jib lift switch Main boom lifting switch Power/Emergency stop switch Charging indicator Three position control switch Engine start/Auxiliary power/Function enable switch Jib stow- key switch...
  • Page 32 Platform rotary switch Provide platform rotate controls. Only use the Platform Leveling Override Function for slight leveling of the platform when platform is lowered. Incorrect use could cause the load/occupants to shift of fail. Failure to do so could result in death or serious injury.
  • Page 33 12) Platform/Ground Select Switch Position the three key control switch to "Platform" (blue), platform mode works only. Position the three key control switch to "Ground" (red), ground mode works only. The three position, key operated switch positions to middle, platform mode and ground mode shut off at the same time. To use auxiliary power, operate a single action only.
  • Page 34 The function classification is as shown below: Figure 2-5 No.1 indicates title; No.2 indicates fault code; No.3 indicates dynamic parameter monitor; No.4 indicates status indicator, stowed position and work station (see details in 2.2.5 Platform Console Indicator Panel); No.5 indicates navigation bar. When the telescopic boom lift is in stowed position with no fault code and engine failure, the interface is as shown below: Figure 2-6...
  • Page 35 Figure 2-7 When the telescopic boom lift is in stowed position with engine failure, but no fault code reveals, the interface is as shown below, and the engine failure icon blinks in real time: Figure 2-8 In this case, press the engine fault button to enter the engine fault page. The engine's fault code can be viewed in real time to facilitate troubleshooting.
  • Page 36 the interface shown in Figure 2-8. When the system alarm occurs, the fault code and its description are displayed in a scrolling manner as shown below: Figure 2-10 22051 indicates fault code, and DTC_GENERATOR_FAULT indicates fault description. When a system failure occurs, the 'Fault Description' button in the navigation bar is activated. Click the button to enter the fault description page and view the fault list in detail, as shown in the following figure: Figure 2-11 2- 8...
  • Page 37 When certain states occur, the status indicator lights up and flashes; When the specific state is released, the turntable indicator light returns to gray, as shown in the following figure: Figure 2-12 2- 9 用户00757092 用户00757092...
  • Page 38 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 2-13 Platform Control Panel (Only the switch number corresponding to the existing function is identified.) Table 2-4 Platform control panel instruction Item Engine start/Auxiliary power switch...
  • Page 39 Power/Emergency stop switch Jib extending switch Drive/Steer controller Engine start/Auxiliary power switch When pushed forward, the switch energizes the starter motor to start the engine. To use auxiliary power, shut off engine and push the switch backward to start auxiliary pump. The function of the auxiliary pump is to provide sufficient oil flow to power-up the basic functions in the event of a main pump or engine failure.
  • Page 40 Main Lift/Swing Controller. Provides main boom lift and platform swing. Push forward to lift the main boom, and pull backward to lower the main boom. Move the handle to the left to swing clockwise, and move right to swing counterclockwise. Note: depress the foot switch before lifting the main boom and swinging the turntable, then move the control handle.
  • Page 41 Platform rotate switch Provide platform rotate controls. 10) Jib lift switch Provide raising and lowering of the jib. 11) Mode switch Free mode: Control system adjusts main boom lifting and extension automatically. Note: Main boom could extend when lifting and retract when lowering. Manual model Operator controls the main boom lifting and extension.
  • Page 42 16) Jib Extending Switch Provides jib extension function. 17) Drive/Steer controller Provides drive/steer controls. Push forward to drive forward, and pull backward to drive backward. Steering is accomplished via a thumb-activated rocker switch on the end of the steer handle. 2.2.4 Platform Console Display Figure 2-14 Boot Screen Figure 2-15 Remind Interface...
  • Page 43 Figure 2-16 Main Interface Figure 2-17 Fault Interface Figure 2-18 Fault Interface 2- 15 用户00757092 用户00757092...
  • Page 44 If leveling system fault indicator lights up, shut off the machine and restart. If fault occurs again, retract the platform to stowed position via manual leveling function, and service the leveling system. Leveling system fault indicator Indicates faults in electronic leveling system. Indicator will flash, and alarm will sound.
  • Page 45 If the tilt alarm sounds with the platform downhill: proceed as follows: i. Retract the main boom. ii. Lower the main boom. Main boom system fault indicator Indicates that the length of main boom cannot measure, need check boom length sensor. Creep mode 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.
  • Page 46 10) Drive direction confirm indicator When the boom is swung over the rear tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. This is a signal for the operator to verify that the drive control is being operated in the proper direction (to verify if the machine drive in reversed direction).
  • Page 49 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 50 container located on the machine. Be sure all decals are in place and legible. See Inspections section. Check for hydraulic oil leaks and proper oil level. Add oil if needed. See Maintenance section. Check for battery fluid leaks and proper fluid level. Add oil if needed. See Maintenance section. Check for engine coolant leaks and proper level of coolant.
  • Page 51 Instruction section. 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 52 Start the engine at the ground controls. Do not operate the Function Enable Button. Attempt to activate each boom and platform function button. Check test result: no boom and platform functions should operate. Start the engine at the ground controls. Push and hold the Function Enable Button and maintain the enabled state.
  • Page 53 Pull out the red platform Power/Emergency Stop button to the on position. Do not press down the foot switch. Attempt to start the engine. Check test result: the engine should start. Start the engine at the platform controls. Do not press down the foot switch. Attempt to activate each boom and platform function button.
  • Page 54 Test Drive and Braking Start the engine at the platform controls. Press down the foot switch and activate each boom and platform function button. Move the drive control handle. Release the drive control handle. Check test result: the machine should turn in the direction that the control handle operates. Release the drive handle, the drive function is disabled.
  • Page 55 Attempt to operate drive handle. Check test result: the drive speed should switch to high speed with the main boom retracted to stowed position. Note: the angle between the boom and the horizontal ground is less than 12°, the extension length is less than 1 meter, and it is within ±35°...
  • Page 56 3.3 Workplace Inspection 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. Avoid hazardous situations. Perform a pre-operation inspection at all times. Implement functional test before operating the machine at all times. Inspect job site.
  • Page 57 3.4 Decal Inspection Figure 3-1 Decal Position 3- 9...
  • Page 58 Figure 3-1 Decal Position (continuous) 3- 10...
  • Page 59 Figure 3-1 Decal Position (continuous) 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. 3- 11...
  • Page 60 Table 3-1 Decals Numbers are corresponded to the decal (not all decal are pasted on the machine) Part No. Decal 00773407000201061 Label- Refuel 00773407000401071 Hazard- Electrocution Hazards 00773407000401081 Label- Ground Controls Instruction 00773407010401031 Handle position label 00773407000401151 Caution- disconnect battery 00773407000401511 Cold start 3- 12...
  • Page 61 Table 3-1 Decals (continuous) Part No. Decal 00773407000401171 Hazard- Prohibit contact 00773407000201181 Label- Prohibit Step on 00773407000401191 Danger- smashing hazard 00773407000401201 Caution- Prohibit Lanyard 00773407000401211 Hazard- Crushing Hazard 00773407000201491 Label- High oil level 00773407000401231 Warn- Foot Switch Malfunction 3- 13...
  • Page 62 Table 3-1 Decals (continuous) Part No. Decal 00773407000201241 Label- No hoisting 00773407000401251 Label- Plug Stop Pin when Transporting 00772507000401210 ZT58J Turntable label assembly 00773407000401271 Warn- Prohibit high pressure water-beaktest 3- 14...
  • Page 63 Table 3-1 Decals (continuous) Part No. Decal 00771407000401151 Diesel tank 00773407000401321 Warn- collision hazard 00773407000401561 Danger- overturning hazard Ⅲ 00773407000401371 Danger- explosion hazard Ⅰ 00773407000401381 Explosion hazard II 00773407000401391 Keep the manual 00772507000401220 ZT58J platform label assembly 3- 15...
  • Page 64 Table 3-1 Decals (continuous) Part No. Decal 00773407000201411 Label- safety lanyard point 00773407000201421 Label- tie down 00773407000201431 Label- hoisting 00773407000401221 Label- platform indicator 00773407010401021 Mind hand 00773407000401471 Burn hazard 00773407000201481 Low oil level label 3- 16...
  • Page 65 Table 3-1 Decals (continuous) Part No. Decal 00772707000401021 Wheel load 00772507000401050 Overturning hazard label 00772507000401070 Transportation lifting instruction 00771407000401161 Hydraulic tank 00773407000401141 Platform console instruction 00771407000201080 Label- blue arrow 00771407000201090 Label- yellow arrow 3- 17...
  • Page 66 Table 3-1 Decals (continuous) Part No. Decal 00771407000201100 Label- yellow triangle 00771407000201110 Label- blue triangle 00772707000201010 Label－ZOOMLION 00771407000201130 Label－ZOOMLION 00772507000201030 Label－ZT58J 00773407000201010 Zoomlion LOGOⅠ 00773407000201050 Label- Zoomlion 3- 18...
  • Page 67 Table 3-1 Decals (continuous) Part No. Decal 00771409900401043 Nameplate 00771407000201170 Label- environmental protection info 3- 19...
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  • Page 71 SECTION 4 OPERATION INSTRUCTION 4.1 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. Avoid hazardous situations. Perform a pre-operation inspection at all times. Implement functional test before operating the machine at all times.
  • Page 72 If an engine malfunction causes an unscheduled shutdown, determine the cause and correct it before restarting the engine. Consult ZOOMLION customer service to know more about the operation under abnormal conditions. 4.2.1.1 Engine Start Machines with diesel engines. After turning on ignition, operation must wait until glow plug indicator light goes out before cranking engine.
  • Page 73 If engine fails to start promptly, do not crank for an extended period. if engine fail to start once again, allow starter to 'cool off' for 2-3 minutes. if engine fails after several attempts, refer to engine maintenance manual. 4.2.1.2 Engine Shut Down Remove all load and allow engine to operate at low speed for 3-5 minutes;...
  • Page 74 To avoid loss of travel control or upset on grades and side slopes, do not drive machine on grades or side slopes exceeding those specified on machine nameplate. Do not drive on side slopes which exceed 4.5 degrees with platform elevated, do not drive on side slopes which 24 degrees in stowed position.
  • Page 75 Stop: Return the control handle to center or release the foot switch. 4.2.3 Platform Leveling Only use the platform leveling function for slight leveling of the platform when the platform is in low position. Incorrect use could cause the load/occupants to shift or fail. Failure to do so could result in serious injury.
  • Page 76 4.2.6 Raising and lowering the main boom If necessary, place the main boom lift handle on the platform or the main boom lift switch on the ground in the 'up' or 'down' position to operate the boom up and boom down functions until the desired height is reached.
  • Page 77 operation function be restored. 4.2.13 Auxiliary Power Note: When operating on auxiliary power, do not operate more than one function at a time. Compound operation is beyond the capability of auxiliary pump motor. A toggle type auxiliary power control switch is located on the platform control station and another is located on the ground control station.
  • Page 78 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 4- 8 用户00757092...
  • Page 79 machine weight. m) Be sure the machine is on a level surface or secured before releasing the brake. Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating. See Driving on a Slope in the Operating Instructions section. If the slope of the transport vehicle bed exceeds the maximum slope rating, the machine must be loaded and unloaded using a winch as described in the brake release operation.
  • Page 80 to make the force as uniform as possible to prevent damage to the chain. Figure 4-1 Lifting and Securing Instructions 4.3.4 Securing the platform Be sure the boom and the platform are in stowed position. w) Use the straps between the platform rotary actuator (see Figure below) and platform base to secure the platform.
  • Page 81 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 4-3 Securing the Platform 4- 11 用户00757092 用户00757092...
  • Page 85 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 86 Drive motor/motor. 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 87 5.2 Power and Hydraulic system maintenance 5.2.1 Check the engine oil level Maintaining the engine oil at the proper level is essential to engine service life. Improper oil level will affect the engine’s cooling capability and damage engine components. Note: check the oil level with the engine off. Check the oil level dipstick. Add oil as needed. Figure 5-1 Oil level dipstick Table 5-1 Refuel condition Cummins QSF 3.8 Engine...
  • Page 88 Table 5-2 Fuel Requirement Type Environmental Temperature （-44 ~ -29）℃/(-47~-20)℉ -50# Diesel （-29 ~ -14）℃/(-20~7)℉ -35# Diesel （-14 ~ -5）℃/(7~23)℉ -20# Diesel （-5 ~ 4）℃/(23~39)℉ -10# Diesel （4 ~ 8）℃/(39~46)℉ 0# Diesel 5# Diesel Above 8 ℃/Above46℉ 5.2.3 Check the engine coolant level Maintaining the the proper level of engine coolant is critical to the longevity of the engine.
  • Page 89 （or Adblue） quality is detected the system will attempt to warn the operator of the issue by the use of warning lights and optional audible warnings. If the warnings are ignored the inducement derate will apply.ZOOMLION requires the use of Diesel Exhaust Fluid meeting ISO 22241-1, There is NO acceptable substitute.
  • Page 90 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 91 Table 5-4 Technical Parameters of Hydraulic Oil Great Wa Mobil ll 4632 gr Kunlun 10 Great Great ease non-f Mobil Mobil aviation Technical Aware Mobil Caltex Caltex Wall Wall lammable DTE 10 hydraulic Parameter H 32 DTE 10 Rando Rando DTE 10 hydraulic Ultra...
  • Page 92 25℃/77℉ higher than the pour point of hydraulic oil. Changing Hydraulic Oil We suggest that changing time of the hydraulic oil is as follows: first changing: operating for 500 hrs after commissioning. second and subsequent changing: every 2,000 hrs of operation or every two years. The above recommended intervals are suitable for most applications.
  • Page 93 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 94 Lube Point(s) –Changcheng 7408B-1 Gear Grease. Interval –Every 3 months or 150 hours. Comment –Apply grease and rotate in 90 degree intervals until bearing is completely lubricated. DO NOT over-lubricate the bearings, otherwise it will cause damage to outside seal of casing. 5.4.2 Hydraulic reservoir Liquid Level –220-250L/58.12-66.04us gal.
  • Page 95 Comment –Remove wing nut and cover to replace. Under certain conditions, it may be necessary to replace on a more frequent basis. 5.4.3 Travel Reducer BREVINI Figure 5-6 Travel Reducer Lube Point(s) –Level/Fill Plug. Capacity –About 3.5L/0.85us gal. Gear oil type-SAE80W/90 Industrial Gear Oil for Close Motor. Interval –Check level every 3 months or 150 hours of operation;...
  • Page 96 5.4.5 Replace engine oil and filter- Cummins QSF 3.8 Figure 5-8 Engine oil port Maintenance Point(s) – Replace engine oil Capacity –About 12L Interval –First maintenance after 50 hours of use, then every six months or 500 hours of operation, whichever comes first.
  • Page 97 Maintenance Point(s)-Replaceable Element. Interval –Check water drainage daily; Change every 6 months or 500 hours of operation. Comment –Change in accordance with engine manual. Second class fuel filter Figure 5-11 Second class fuel filter Maintenance Point(s) –Replaceable Element. Interval –Every 6 months or 500 hours of operation. Comment –Change in accordance with engine manual.
  • Page 98 (1) Cover (2) Air cleaner main filter element (3) Safety filter element (4) Air cleaner housing (5) Dust discharge valve Figure 5-13 Air cleaner During the 500h maintenance cycle, the main filter element can be purged with compressed air, but the pressure must be lower than 205kPa, and the number of purges should not exceed 6 times.
  • Page 99 water tank is between the MIN and MAX scale lines. Capacity –About 13 L. Interval –Check oil level daily, change every 2000 hours or one year (whichever come first). Note: Antifreeze is poisonous, if it comes into contact with the human body, please rinse it with water immediately;...
  • Page 100 the equipment enters the flammable and explosive area, the regeneration prohibition switch should be turned on to avoid fire 5.4.10 SCR system (Selective Catalytic Reduction System)( Euro Stage V only) Adding Diesel Exhaust Fluid that does not meet the standard requirements will lead to the failure of the after-treatment (EAT) system, resulting in illegal or economic losses.
  • Page 101 Fig 5-20 DEF tank Connections Failure to replenish Diesel Exhaust Fluid in time will cause illegal or economic losses. Fig 5-21 Supply Modules filter Maintenance point: Replace the Supply Modules filter element. Interval: CUMMINS F3.8 every 4000 hrs of operation 5.5 Engine Cold Start When the ambient temperature is lower than 10°C, the equipment needs to be preheated when starting 5- 17...
  • Page 102 a) When the ambient temperature is lower than 10°C, after the whole vehicle is powered on, the engine will automatically open the glow plug for preheating, and the working time is about 8s. If it cannot be started within 8s, it can be powered on again 2 to 3 times. The relationship between the heating time of the glow plug and the temperature is shown in Table 5-5.
  • Page 103 5.6 Fuel System Deglassing The fuel system needs to be vented in the following situations: a) After disassembly and reassembly of the fuel filter and fuel pipe; b) After the fuel tank is empty; c) Before preparing the engine for use after long periods of non-use. Deglassing operation: 1.
  • Page 104 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 105 The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in an unsafe condition regarding stability.
  • Page 106 Table 5-6 Wheel Torque Table Torque Sequence 1st Stage 2nd Stage 3rd Stage 75 Nm 155 Nm 320 Nm Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check and torque every 3 months or 150 hours of operation. Table 5-7 Tire Tire Model...
  • Page 107 The boom is exposed to an arc, and the inside of the wire rope may fuse together. 5.10.4 Additional replacement criteria Pulleys and wire ropes must be replaced in sets. Wire rope is rusted or corroded. Wire rope tangled, "knotted" or wrinkled. The adjustment of the steel wire rope has reached the limit adjustment range and cannot be adjusted further.
  • Page 108 Figure 5-30 Clamping the rope Install adjusting nuts on the outrigger and retracting arm ropes (if readjusting, remove the nylon sleeve lock nut). Pre-tighten the nut of the extension and retractable wire rope, the torque of the first extension wire rope is 60Nm, the torque of the first retractable wire rope is 80Nm, the torque of the second extension wire rope is 50Nm, the torque of the second retractable wire rope is 60Nm, and the torque of the third extension wire rope is 45Nm, and the torque of the third retractable wire rope is 45Nm;...
  • Page 109 a torque of 45Nm; Check the torque of the retracted boom rope. If the torque does not meet the requirements, repeat steps g to step n, and check again until the torque reaches the standard. After all wire ropes are properly tightened, install nylon sleeve lock nuts. Remove all clamping devices and install all covers and guards.
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  • Page 113 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 117 SECTION 7 TECHNICAL PARAMETER Table 7-1 ZT58J Technical parameter Model ZT58J Work Height 58.8 m Platform Height 56.8 m Horizontal Outreach 25.5 m Overall Length (Stowed) 14.4 m Size Overall Width (Stowed) 2.5 m Overall Height (Stowed) 3.06 m Platform Length 2.44 m...
  • Page 118 Platform Vibration 2.5m/s2 acceleration Work Noise Tire Tires Type 445/50 D710 foam-filled Weight Gross 29600 kg Max Work Height 58.80m Max Horizontal Reach 25.50m...
  • Page 119 Figure 7-1 ZT58J Range of Motion Figure 7-2 ZT58J Dimension (stowed) 7- 3...
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