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Zoomlion ZT20J Service And Maintenance Manual

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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
I

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Questions and answers

Александр
March 25, 2025

Рулевая работает,а гидравлика на навеске нет

0
1 comments:
Mr. Anderson
March 25, 2025

The hydraulic system on the Zoomlion ZT20J may not be working while the steering is functioning because the auxiliary power system, which operates using a 12V battery-powered motor/pump unit, only supports returning functional units to the stowed or lowered state and does not support the driving function. If the main power system is not working and the auxiliary power system is being used, the hydraulic system may not function as expected, while steering remains operational.

This answer is automatically generated

0
Ранис Равилевич
April 10, 2025

Где находится горловина двигателя для заливки масла ?

0

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Summary of Contents for Zoomlion ZT20J

  • Page 1 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.

  • Page 2: Foreword

    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.

  • Page 3: Table Of Contents

    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 .....................

  • Page 4: Contents

    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 ......................
  • Page 5 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 Chassis Angle Sensor System ..................4-4 4.4 Auxiliary Power System ....................
  • Page 6 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 .................
  • Page 7 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 Connector Assembly............ 7-5 7.3.4 HD30/HDP20 Series Connector Removal ............. 7-6 7.5 Hydraulic Schematics ....................7-16...

  • Page 10: Section 1 Maintenance Safety Instruction

    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.

  • Page 11: Maintenance Precautions

    Check safety equipment before and after work, perform maintenance according to specified procedures or replacement if necessary. Keep inspection and maintenance records if needed. 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.

  • Page 12: Precautions In Maintenance

    down at any time if necessary, and others can conduct inspection or maintenance. Personnel should keep close contact to work safely. 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.
  • Page 13 Figure 1-3 Beware of Explosion The positive and negative wires of the battery must be removed when welding to prevent the positive and negative poles of the welder from forming a loop with the vehicle body, thereby burning electrical components such as controllers and sensors. The company does not take the consequences for wrong operation.
  • Page 14 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. 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.
  • Page 15 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.
  • Page 16 It is necessary to confirm the machine movement, oil leakage, loose bolts and other problems on the mechanically maintained parts. Restore or reset the safety device and recalibrate the safety device if necessary. Remove the tools and equipment for maintenance, replaced parts and scattered objects, and clean up the site.

  • Page 19: Section 2 Technical Parameters

    SECTION 2 TECHNICAL PARAMETERS 2.1 Performance Table 2-1 Performance 454kg (restricted) 1000lb(restricted) Platform Capacity 300kg (unrestricted) 660lb(unrestricted) 45% (platform uphill) 45% (platform uphill) Max Travel Speed (on slope) 30% (platform downhill) 30% (platform downhill) Max Travel Speed (on side slope) Platform Height 20.75m 68ft...

  • Page 20: Capacity

    2.3 Capacity Table 2-3 Capacity Fuel Tank 130L 34 us gal Hydraulic tank 150L 39.6 us gal 8L (Perkins 2.1 us gal (Perkins 404D-22T) 404D-22T) Engine Oil Capacity 8L (Deutz D2.9L4) 2.1 us gal (Deutz D2.9L4) 15L (Deutz D447-L4) 4 us gal (Deutz D447-L4) 2.4 Components Specification 2.4.1 Engine Table 2-4 D2.9L4 (Deutz) Engine Specification...

  • Page 21: Battery

    Table 2-6 404D-22T (Perkins) Engine Specification Type Electric Control Electric Control Fuel No.0 National IV No.0 National IV Engine Oil Capacity 2.1 us gal 1400 (idle speed) 1400 (idle speed) Rotate Speed 2000 (low speed) 2000 (low speed) 2800 (high speed) 2800 (high speed) Current Output of Generator 12V,65A...

  • Page 22: Functional Speed

    2.6 Functional Speed Table 2-9 Functional speed (unit:s） Function ZT20J Boom Lifting 60~70 s 60~70 s Boom Descending 60~70 s 60~70 s Turntable Swing (a round) 75~85 s 75~85 s Boom Extending 55~65 s 55~65 s Boom Retracting 55~65 s...

  • Page 23: Torque Requirements

    Some flow control functions may be disabled when the speed knob is positioned to low speed. 2.7 Torque Requirements Table 2-10 Toque Requirements Strength Grade and Corresponding Torque Bolt Diameter 8.8 grade 10.9 grade 24.5Nm/18ftlb 34.5 Nm/25.4ftlb 48.3 Nm/35.6ftlb 68 Nm/50.2ftlb 84.3 Nm/62.2ftlb 118 Nm/87ftlb 135 Nm/99.5ftlb...

  • Page 24: Pressure Setting

    2.9 Pressure Setting Table 2-12 Pressure Setting Main boom lifting: 21MPa Boom telescoping: 21MPa Turntable swing 21MPa Chassis diversion 21MPa Jib lifting 21MPa Platform rotation 21MPa Platform leveling 21MPa 2- 6...

  • Page 27: Section 3 General Introduction

    SECTION 3 GENERAL INTRODUCTION 3.1 Machine Preparation, Inspection and Maintenance 3.1.1 General introduction This section provides the necessary information to the operator responsible for pre-operational inspection and safe operation. In order to obtain the longest service life and ensure safe operation, all necessary inspections and maintenance should be completed before the machine is put into use.

  • Page 28: Preventive Maintenance

    inspection. Please refer to the relevant contents of this manual for maintenance and service procedures. To ensure that safety reports are obtained, our company needs to update the ownership information of each machine. Please inform us of the current machine ownership information each time the machine annual inspection is carried out.

  • Page 29: Safety And Operating Standards

    3.2.2 Safety and operating standards Safety is paramount when performing equipment maintenance. Always pay attention to weight. Never attempt to move heavy parts without mechanical assistance. Do not park heavy objects in unstable locations. Ensure that adequate support is provided when lifting. 3.2.3 Cleaning Prevent dirt or impurities from entering critical parts of the machine for longer service lift.

  • Page 30: Washer

    bearings cannot be rotated. If the bearing race and the steel ball (or roller) are sunken, scratched or burnt, scrap the bearing; If the bearing is still serviceable, apply a layer of oil and wrap it in clean paper (or wax paper). Do not open the reusable or new bearing packaging until you are ready to install it.

  • Page 31: Lubrication And Maintenance

    The battery was cleaned with a non-metallic brush and an aqueous solution of sodium bicarbonate. Then rinse with clean water. When the battery is completely dry, apply the battery terminals with an anti-corrosion compound. 3.2.14 Lubrication and maintenance Parts and components that require lubrication and maintenance refer to the Regular Maintenance in Section 5.
  • Page 32 For special environments or users with special requirements, please contact ZOOMLION or hydraulic oil manufacturers. Note: do not mix different brands or types of oils, and the mixing of additives in different oils will have negative impact.

  • Page 33: Hydraulic Oil Replacement

    more. 3.3.3 Hydraulic oil replacement Good quality hydraulic fluids are critical to machine performance and service life. Unclean hydraulic fluid can affect machine performance and can cause damage to parts if used continuously. This operation should be performed more frequently in adverse working conditions. Regular hydraulic fluid changes are required to use the recommended crankcase or hydraulic fluid.

  • Page 34: Cylinder Drift

    extend the upper boom with the platform capacity and power off. The maximum allowable drift in 10 minutes is 2 inches /5 cm. If the machine fails this test, please conduct the following operation. 3.4.2 Cylinder drift Table 3-3 Cylinder drift Cylinder bore size Maximum acceptable drift value in 10 minutes Millimeter...

  • Page 35: Pin And Bearing Inspection Instructions

    3.5 Pin and Bearing Inspection Instructions 3.5.1 Fiber bearing Disconnect and inspect the connecting pin when one of the following conditions occurs: Joint tilting. Noise is generated at the joint during operation. Fiber bearings should be replaced in one of the following situations: Wear or separate fibers on the surface of the liner.

  • Page 36: Use Insulating Grease In Electrical Connection Locations

    Ground the hood and weld it in any area other than the turntable. Ground the turntable and weld it in any area other than the turntable. Ground the platform/support and weld it in any area other than the platform/support. Ground a specific boom section and weld it in any area other than the specific boom section. Place pins, wear pads, wire ropes, bearings, gears, seals, valves, electrical wiring or tubing between the grounded location and the weld zone.
  • Page 37 wiring must be checked regularly. The following steps should be taken when checking the electrical system: Check and clean the battery terminal connections to ensure a secure connection. Inspect the battery case for cracks or damage. Check the positive and negative battery cables for corrosion, abrasion or scratches. Check the connection on the chassis to confirm that the connection is secure.
  • Page 38 Table 3-4 Inspection and preventive maintenance schedule Time intervals Items Pre-deliver Every 2 Pre-start Weekly Monthly Annually y or daily years Boom assembly Boom weldment 1,2,4 1,2,4 Oil pipe/wire rope 1,2,9,12 1,2,9,12 Shaft pin and pin Pulley and pulley pins Bearings Wear pad Covers or shields...
  • Page 39 Table 3-4 Inspection and preventive maintenance schedule (continuous) Time intervals Items Pre-start Weekly Monthly Pre-delivery Annually Every 2 or daily years Steer components Drive motor Torque hub Function/Control Platform control Ground control Function control locks, protective device or brake device Foot switch Emergency switch (Ground and platform)
  • Page 40 Table 3-4 Inspection and preventive maintenance schedule (continuous) Time intervals Items Pre-sta Pre-delivery Weekly Monthly Annually Every 2 years or daily Exhaust system Batteries Battery fluid Battery charger Fluid reservoir, cap and 11,9 breather Hydraulic/Electrical system Hydraulic pump 1,2,9 Hydraulic oil tank 1,9,7 1,2,9 1,2,9...
  • Page 41 All system functional test 21, 22 Painting and appearance Imprint check date on the frame Notifying Zoomlion machine ownership Footnote: 1. Before daily use or each shift 2. Before each sale, rental or delivery 3. Use 3 months or 150 hours, or idle for more than 3 months, or buy as a used machine 4.
  • Page 42 Performance code: 1 －Confirm that the installation is correct and secure 2 －Visually inspect for damage, cracks, deformation or excessive wear 3 －Check if the adjustment is correct 4 －Check for cracked or damaged welds 5 －Correct operation 6 －Return to neutral of OFF position when released 7 －Clean and free of dirt 8 －Interlock function 9 －Check for signs of leaks...

  • Page 45: Section 4 Chassis And Turntable

    4.1.1 Tire inflation In order to endure the safety and normal operation, the air pressure of the pneumatic tire must be the same as the air pressure indicated on the side of the Zoomlion machines or the rim sticker. 4.1.2 Tire damage...

  • Page 46: Tire Replacement

    A smooth, uniform cut with a total length of more than 3 inches /7.5cm in the ply. Cracks (uneven edges) in any direction that exceed 1 inch /2.5cm in the ply. Perforations having a diameter of more than 1 inch. Any damage to the ply of the tire bead.

  • Page 47: Swing Axle Exhaust And Locking Test

    Figure 4-2 Wheel fastening nut tightening sequence Nut tightening should be carried out in steps. Please refer to the wheel torque table and tighten the nuts in the recommended order. Table 4-1 Wheel torque table Torque application sequence First step Second step Third step 75 Nm/55ftlb...

  • Page 48: Swing Axle Lock Test

    Place a small bucket or bottle in front of the floating cylinder exhaust valve and insert the cleaning tube. Loosen the exhaust valve and slowly unscrew it counterclockwise. Air is exhausted from the top of the floating cylinder. Use a small bucket or bottle to catch the hydraulic oil that flows out. Close and tighten the exhaust valve at the same time.

  • Page 49: Auxiliary Power System

    4.4 Auxiliary Power System In the event that the main power is not working, the auxiliary power system is used as an alternative to take the operator away from the height of the work to the safe ground. This system uses an electric motor/pump unit powered by a 12V battery.

  • Page 50: Traveling Drive System

    4.6 Traveling Drive System The traveling system is mainly composed of wheels, traveling reducer and traveling motor. Specifically, the four-wheel drive system consists of a variable displacement closed pump, four variable displacement piston motors, four gear reducers, and a split/flow-combining travel control valve. The two-wheel drive system consists of a variable displacement closed pump, two variable displacement piston motors, two gear reducers and a split/flow-combining travel control valve.

  • Page 51: Travel Reducer

    Figure 4-6 Travel system disassembly diagram 2 4.7 Travel Reducer 4.7.1 Disassembly Place the machine on a solid level surface. Remove all hydraulic lines connected to the travel motor on the travel reducer and close the port; Use a suitable lifting device to support the travel reducer (the travel reducer weighs approximately 50kg/110lb).

  • Page 52: Installation

    4.7.2 Installation Use a suitable lifting device to support the travel reducer (the travel reducer weighs approximately 50kg/110lb). Align the mounting holes on the travel reducer with the holes of the reducer mounting plate. The travel reducer is mounted on the axle with six bolts, and the bolt torque is 260Nm. Connect the hydraulic line that was previously disassembled to the travel motor.

  • Page 53: Rotary Motor

    Mounting the traveling motor on the machine. Note: if the travel motor output shaft is not aligned, it will cause damage to the bearings and seals of the traveling motor output shaft and its surroundings. Damage to the seal can cause oil leakage. Make sure that the traveling motor output shaft is properly aligned with the mounting ring gear on the reducer.

  • Page 54: Gear Oil Replacement

    Check whether there are metal shavings in the reducer and brake. Change the oil when the oil temperature has not cooled, it is more beneficial to drain the oil in the tank at this time. Do not use mixed oil. The rotary reducer is equipped with multiple brakes.

  • Page 55: Slewing Bearing

    Remove the oil drain plug and oil filler plug, drain the oil in the reducer, and drain the oil in the brake. Before injecting new oil, clean the inside of the rotary reducer and brake with cleaning fluid. Inject the cleaning fluid into the rotary reducer and brake, install the oil filling plug, run at high speed for several minutes, and then drain the cleaning fluid.

  • Page 56: Disassembly

    objects from approaching or entering the meshing area. Check the integrity of the slewing bearing seal and repair or replace it in time if damaged. Check the meshing operation of the slewing gear. In order to reduce the wear of the small gear and the large gear, adjust the meshing gap between the small gear and the large gear within the range of (0.15 to 0.25) mm/(0.00591-0.00984)in.
  • Page 57 violently during turning braking. Good gear clearance can make the performance of the machine and extend the life of the machine, so it needs to be adjusted. Adjust as shown in the figure below. Motor Rotary reducer Mounting bolt Adjusting bolt Locknut Figure 4-11 Gear clearance adjustment The adjustment steps are as follows:...

  • Page 60: Section 5 Boom And Platform

    SECTION 5 BOOM AND PLATFORM 5.1 Platform and Jib 5.1.1 Load cell 5.1.1.1 Disassembly Transit Platform Rotary Protec Load cell Pressing Tray Figure 5-1 Load cell disassembly diagram Disconnect the wiring harness at the platform's electrical control box and load cell, disconnect the tubing at the platform valve, collect the hydraulic oil in the pipeline with a suitable container, block the port of the pipeline after the collection, and Make a mark.

  • Page 61: Rotary Actuator

    Check the line for wear and replace the wiring harness if necessary. Check hydraulic oil leaks and replace the line if necessary. Inspect all threaded parts for damage such as stretching, thread deformation or distortion and replace if necessary. 5.1.1.3 Installation Follow the reverse steps of disassembly.

  • Page 62: Jib Lifting Cylinder

    bearing if necessary. Inspect all threaded parts for damage such as stretching, thread deformation or distortion and replace if necessary. 5.1.2.3 Installation Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint and balance valve before installation should be cleaned to prevent contaminants from entering the hydraulic system. A hydraulic system pipe joint equipped with a sealing device needs to replace a sealing device before the hydraulic line is connected.

  • Page 63: Boom Assembly

    5.2 Boom Assembly 5.2.1 Cable 5.2.1.1 Disassembly Moving tube1 Moving tube2 Cable Fixed tube Plastic chain Moving tube Cable Fixed tube Steel cable chain Figure 5-3 Cable system disassembly Adjusting the boom to a fully retracted state. Disconnect the pipeline from the ground control box. After the hydraulic line is disconnected, the port of the pipeline should be blocked immediately to prevent dust and other pollutants from entering the hydraulic system.

  • Page 64: Leveling Cylinder

    container, and seal the port of the pipeline after collecting. Use suitable lifting equipment to hang the ends of the fixed pipe of the cable along the entire length. Remove the bolts 1 fixing the moving pipe 1 on the three-section arm. Remove the bolt 2 supporting the moving pipe 1 on the two-section arm.

  • Page 65: Lower Leveling Cylinder

    Adjust the posture of the boom and the jib to the level. Mark and disconnect the hydraulic line connecting the leveling cylinder balancing valve, collect the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting. Use the appropriate lifting equipment to support the head of the cylinder rod of the leveling cylinder, disassemble the pin shaft 1 and 2, and remove the jib (Follow the jib removal step).
  • Page 66 Base boom Pin 2 Rear linkage Leveling rod Front linkage Pin 1 Lower leveling cylinder Figure 5-5 Lower leveling cylinder disassembly diagram Follow the removal steps to disassemble the working platform, the jib and the upper leveling cylinder. Adjusting the attitude of the boom to a position where the pin 1 and the pin 2 are completely exposed and easy to disassemble.

  • Page 67: Lifting Cylinder

    A hydraulic system pipe joint equipped with a sealing device needs to replace a sealing device before the hydraulic line is connected. Threaded fasteners should be tightened in place according to the torque values in Section 2 Specifications. 5.2.4 Lifting cylinder 5.2.4.1 Disassembly Base boom Lifting cylinder...

  • Page 68: Boom

    Use the lifting equipment to support the boom to make the boom slowly swing upward, and adjust the support of the swing cylinder at the same time. During the boom swing upward, one end of the swing cylinder pin will be separated from the base boom.Continue to lift the boom until the pin 2 is completely exposed and in a position that is easy to disassemble.
  • Page 69 Counterweight lifting point Figure 5-8 Counterweight disassembly diagram Tilt hazard The steps of removing the boom include removing the counterweight. Failure to remove the counterweight before removing the boom assembly may cause the device to tip over. Therefore, Please do not remove the boom assembly without removing the counterweight. Tilt hazard When installing the boom, the boom assembly should be assembled first, followed by the counterweight, otherwise the equipment may tip over, causing the risk of personal injury and...
  • Page 70 Remove the work platform, jib, energy chain, leveling cylinder and hood, please follow the removal steps. Fully retract the boom. Use suitable wood to support the rear link (cross the wood across the turntable and place it between the turntable and the rear link). Use suitable wood to support the front link (cross the wood across the turntable and place it between the turntable and the front link).

  • Page 71: Telescopic Cylinder

    The standby power is used to drive the boom lowering function, so that the lifting cylinder is retracted to the head of the piston rod and can be better supported on the boom support base of the turntable. With the assistance of lifting equipment, support the end of the luffing cylinder piston rod on the arm support and protect it.
  • Page 72 The telescopic oil cylinder must be removed with the boom fully retracted. Wrench clamp Nut 1 Nut 2 boom retracting wire rope Figure 5-10 Removal view of the retractable boom rope balancing mechanism Fully retract the boom. Use suitable tools to remove the nut 1 so that the retracted wire rope is in a relaxed state. Use a suitable wrench to be clamped on the wrench, and remove the nut 2.
  • Page 73 Use a suitable tool to loosen nut 3, but do not remove nut 3. Remove the bolt 4 and pull out the wire rope break detection sensor assembly in the direction of the boom tail. When the component leaves the mounting base, move the component toward the head of the boom (make the outrigger wire rope in a relaxed state), and place the wire rope break detection sensor component on the telescopic oil cylinder.
  • Page 74 Bolt 10 stop pin Pin Bolt 9 Limit Figure 5-15 Disassembly of the pin of the telescopic cylinder Remove the bolt 9 and remove the limit block. Remove the bolt 10 and the stopper pin, and pull out the pin shaft with a suitable tool. Cylinder Piston 活塞杆座...

  • Page 75: Wire Rope Pulley Disassembly

    Inspect the inner ring of the bearing for scratches, distortion, wear or other damage and replace the bearing if necessary. Inspect all threaded parts for damage such as stretching, thread deformation or distortion and replace if necessary. Refer to the Pin and Bearing Inspection Instructions in the Section 3 for pin and bearing inspection. 5.2.6.3 Installation Follow the reverse steps of disassembly.
  • Page 76 fabrication hole 1 boom retracting wire rope retracting Pin 3 Bolt 4 Figure 5-18 Removal of the retracting boom wire rope Remove the bolt 4, use a suitable tool to pull out the pin 3, and take out the retractable boom pulley from the end of the base boom.

  • Page 77: Wire Rope And Pulley Check

    5.2.7.3 Installation Please follow the reverse steps of disassembly, the wire rope needs to be lubricated with wire rope lubricant before installation. Threaded fasteners should be tightened in place according to the torque values in Section 2 Specifications. 5.2.8 Wire rope and pulley check 5.2.8.1 Daily inspection Before operation: Fully retract the boom.
  • Page 78 The adjustment of the steel wire rope has reached the limit adjustment range and cannot be adjusted further. The pulley fails to pass the wear gauge inspection. Six wires break in one wire rope, or three wires break in one wire rope, or one valley breaks, or one break occurs at the wire rope joint.

  • Page 79: Load Cell Check

    Install adjusting nuts on the outrigger and retracting arm ropes (if readjusting, remove the nylon sleeve lock nut). At the same time, pre-tighten the nuts of the outrigger and retract arms, and the torque does not exceed 20Nm/15ftlb. Adjust the nut of the retractable wire rope so that the swing boom is parallel to the base boom vertical plate (during use, if the swing arm is not parallel to the vertical plate, it can be determined that the retractable wire rope is loose).

  • Page 80: Boom Tilt Sensor Check

    Set the device to the following status position: Boom-lower. Telescopic-retract. Jib-adjusted to 0 ° . Turntable-turn to 0 ° . Platform level-level to 0 ° . Platform Rotation-Rotate to 0 ° . Load in platform-remove all load items. The machine is on a hard, level surface. Start the ground and platform emergency stop switches and turn the key switch to the platform position.

  • Page 81: Check Of Wire Rope Damage Indication System

    Calibrate the zero position of the boom length sensor, and record the initial value of the boom length on the display screen. Extend the boom 1m, record the length of the boom on the display screen. Compare the boom length values twice. The absolute value should be 1m. 5.6 Check of Wire Rope Damage Indication System A limit switch is installed at the end of the boom to detect the loose state of the wire rope.
  • Page 82 Wear a seat belt when performing a speed limit check. Do not lift the boom to an excessively high position for testing, and pay attention to driving safety to avoid accidents. 5-23...

  • Page 85: Hydraulic Filter Maintenance

    SECTION 6 HYDRAULIC AND ELECTRICAL SYSTEM MAINTENANCE 6.1 Hydraulic Filter Maintenance 6.1.1 High pressure filter Time intervals Run for the first time for 50 hours, and the filter element should be replaced every 300 hours thereafter. 6.1.2 Oil filling filter Time intervals Run for the first time for 50 hours, and the filter element should be replaced every 300 hours thereafter.

  • Page 86: Return Oil Filter

    6.1.3 Return oil filter Time intervals Run for the first time for 50 hours, and the filter element should be replaced every 300 hours thereafter. 6.2 Pressure Setting Low temperatures can seriously affect the accuracy of pressure gauge readings. Preheat the hydraulic system to normal operating temperature before starting the unit when testing the pressure.

  • Page 87: Starting Procedure

    6.3 Starting Procedure 6.3.1 Drive pump oiling Machine without hydraulic oil cooler: When filling hydraulic oil, fill it all the way to the top of the tank. This creates sufficient outlet pressure from the hydraulic tank to fill the housing that drives the pump. Excess hydraulic fluid will be used to fill the individual cylinders during start-up.

  • Page 88: Fault Code

    6.4 Fault code When the unit fails, check the fault message indicated by the display on the ground console.If the display on the ground console indicates the following fault code, remove the fault condition and restart the device before continuing operation. Fault code Table 6-1 Fault code Classification...
  • Page 89 Table 6-1 Fault code(continuous) Classification Fault code Fault code list 24153 DTC_FAULT_PLATFORM_HIT_GROUND 11154 DTC_INCLINE_SENSOR_OUT_OF_RANGE 11155 DTC_INCLINE_SENSOR_COMM_ERROR 11156 DTC_INCLINE_SENSOR_NOT_STANDARDIZATION 13157 DTC_BOOM_ANGLE_SENSOR_OUT_OF_RANGE 13158 DTC_BOOM_ANGLE_SENSOR_COMM_ERROR 13159 DTC_BOOM_ANGLE_SENSOR_NOT_STANDARDIZATION 13160 DTC_FAULT_LIFT_WIRE_ROPE_SENSOR_LOOSE 22161 DTC_FAULT_SWING_SENSOR DTC_FAULT_PM_TOWER_LIFT_SWITCH_DOUBLE_POWE Sensor 14162 R_ON 13163 DTC_BOOM_ANGLE_SINGAL_REDUNDANCY 13164 DTC_BOOM_LENGTH_SENSOR_NO_RESPOND 13165 DTC_BOOM_LENGTH_SENSOR_ERROR_DETECTION 14166 DTC_LEVELING_SENSOR_COMM_ERROR 13167 DTC_BOOM_LENGTH_SENSOR_REDUNDANCY 32168...
  • Page 90 Table 6-1 Fault code(continuous) Classification Fault code Fault code list 24365 DTC_FAULT_PM_ROTATE_SWITCH_DOUBLE_POWER_ON DTC_FAULT_PM_LEVELING_SWITCH_DOUBLE_POWER_O 14366 24367 DTC_FAULT_PM_SWING_JOYSTICK_DOUBLE_POWER_ON 24368 DTC_FAULT_PM_ENGINE_SWITCH_DOUBLE_POWER_ON 14369 DTC_FAULT_PM_DRIVE_JOYSTICK_DOUBLE_POWER_ON 14370 DTC_FAULT_PM_STEER_JOYSTICK_DOUBLE_POWER_ON 14371 DTC_FAULT_UG_FOOTSWITCH_CLOSED 14372 DTC_FAULT_FOOTSWITCH_FUNCTION 14373 DTC_FAULT_PM_DRIVE_DIRECTION_CONFIRM_SWITCH Switch/handle 24374 DTC_FAULT_PM_DRIVE_SPEED_GEER_SWITCH 24375 DTC_FAULT_PM_SWING_JOYSTICK_UP_LIMIT 24376 DTC_FAULT_PM_SWING_JOYSTICK_DN_LIMIT 24377 DTC_FAULT_PM_SWING_JOYSTICK_MEDIUM_OFFSET 24378 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_UP_LIMIT 24379 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_DN_LIMIT DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_MEDIUM_OFFSE 24380...
  • Page 91 Table 6-1 Fault code(continuous) Classification Fault code Fault code list 21559 DTC_FLOAT_CONTROL_VALVE_SHORT_TO_GROUND 21560 DTC_FLOAT_CONTROL_VALVE_SHORT_TO_POWER 21561 DTC_FLOAT_CONTROL_VALVE_OPEN_CIRCUIT 21562 DTC_BRAKE_VALVE_SHORT_TO_GROUND 11563 DTC_BRAKE_VALVE_SHORT_TO_POWER 21564 DTC_BRAKE_VALVE_OPEN_CIRCUIT 21565 DTC_2SPEED_VALVE_SHORT_TO_GROUND 21566 DTC_2SPEED_VALVE_SHORT_TO_POWER 21567 DTC_2SPEED_VALVE_OPEN_CIRCUIT 22568 DTC_STEER_LEFT_VALVE_SHORT_TO_GROUND 12569 DTC_STEER_LEFT_VALVE_SHORT_TO_POWER 22570 DTC_STEER_LEFT_VALVE_OPEN_CIRCUIT 22571 DTC_STEER_RIGHT_VALVE_SHORT_TO_GROUND 12572 DTC_STEER_RIGHT_VALVE_SHORT_TO_POWER 22573 DTC_STEER_RIGHT_VALVE_OPEN_CIRCUIT 22574 DTC_SWING_LEFT_VALVE_SHORT_TO_GROUND 22575...
  • Page 92 Table 6-1 Fault code(continuous) Classification Fault code Fault code list 22638 DTC_TELESCOPE_FLOW_VALVE_SHORT_TO_POWER 22639 DTC_TELESCOPE_FLOW_VALVE_OPEN_CIRCUIT DTC_TELESCOPE_FLOW_VALVE_FEEDBACK_CURRENT 22640 _FAULT 22641 DTC_TELESCOPE_IN_VALVE_SHORT_TO_GROUND 12642 DTC_TELESCOPE_IN_VALVE_SHORT_TO_POWER 22643 DTC_TELESCOPE_IN_VALVE_OPEN_CIRCUIT 22644 DTC_TELESCOPE_OUT_VALVE_SHORT_TO_GROUND 12645 DTC_TELESCOPE_OUT_VALVE_SHORT_TO_POWER 22646 DTC_TELESCOPE_OUT_VALVE_OPEN_CIRCUIT 22647 DTC_SWING_FLOW_VALVE_SHORT_TO_GROUND 22648 DTC_SWING_FLOW_VALVE_SHORT_TO_POWER 22649 DTC_SWING_FLOW_VALVE_OPEN_CIRCUIT DTC_SWING_FLOW_VALVE_FEEDBACK_CURRENT_FA 22650 DTC_MAIN_LIFT_DN_FLOW_VALVE_SHORT_TO_GROU 23651 DTC_MAIN_LIFT_DN_FLOW_VALVE_SHORT_TO_POWE Valve 23652 23653...
  • Page 93 Table 6-1 Fault code(continuous) Classification Fault code Fault code list 14668 DTC_PM_LEVELING_UP_VALVE_SHORT_TO_POWER 24669 DTC_PM_LEVELING_UP_VALVE_OPEN_CIRCUIT 24670 DTC_PM_LEVELING_DN_VALVE_SHORT_TO_GROUND 14671 DTC_PM_LEVELING_DN_VALVE_SHORT_TO_POWER 24672 DTC_PM_LEVELING_DN_VALVE_OPEN_CIRCUIT DTC_PM_LEVELING_UP_VALVE_FEEDBACK_CURRENT 24673 _FAULT DTC_PM_LEVELING_DN_VALVE_FEEDBACK_CURRENT 24674 _FAULT 24675 DTC_JIB_UP_VALVE_SHORT_TO_GROUND 14676 DTC_JIB_UP_VALVE_SHORT_TO_POWER 24677 DTC_JIB_UP_VALVE_OPEN_CIRCUIT Valve 24678 DTC_JIB_DN_VALVE_SHORT_TO_GROUND 14679 DTC_JIB_DN_VALVE_SHORT_TO_POWER 24680 DTC_JIB_DN_VALVE_OPEN_CIRCUIT 22741 DTC_BOOM_UP_VALVE_STUCKED 22742 DTC_BOOM_DN_VALVE_STUCKED...

  • Page 94: Common Faults And Methods

    Table 6-1 Fault code(continuous) Classification Fault code Fault code list 32861 DTC_ALTERNATOR_FAULT DTC_GLOW_PLUG_FAULT 32862 12863 DTC_TILT_FAULT Unit Condition 32864 DTC_LOW_FUEL_FAULT DTC_ANTI_CRUSH_ALARM 14865 DTC_SYSTEM_INITIAL_FAULT 12866 DTC_INH_FAULT 12867 6.5 Common Faults and Methods Table 6-2 Common faults and methods Fault Fault Cause Solution Feature Remove the battery or replace it with a new...
  • Page 95 2. Replace controller If you encounter any equipment failure, contact Zoomlion for timely troubleshooting. If there is no absolute understanding of the fault resolution, please contact Zoomlion or Zoomlion dealers to solve it. It is forbidden to open the electric control cabinet to change the wire.

  • Page 98: Section 7 Electrical Information And Schematic

    SECTION 7 ELECTRICAL INFORMATION AND SCHEMATIC 7.1 General Introduction This section introduces basic electrical information and schematics for locating and correcting most operational problems that may arise. If problems that are not listed in this section, or problems that cannot be corrected by the listed solutions, occur, you should obtain authoritative technical guidance before performing maintenance.

  • Page 99: Range

    leads are reversed. Check the voltage prediction value, signal position, and whether the lead is properly connected to the device under test. Also check that the lead of the COM port is grounded or the negative signal is connected, and that the lead of the other port is connected to the positive signal. 7.2.5 Range M = mega = 1,000,000 * (displayed number).

  • Page 100: Resistance Measurement

    7.2.7 Resistance measurement Figure 7-2 Resistance measurement First test the multimeter and leads by touching the two leads. The result should show a short circuit of resistance (very low resistance). The circuit power must be turned off before testing the resistor. Disconnect each component from the circuit before testing.

  • Page 101: Current Measurement

    First test the multimeter and leads by touching the two leads. The multimeter should alarm and display continuity. 7.2.9 Current measurement Figure 7-4 Current measurement (direct current) Set the expected current range of the multimeter. Verify that the multimeter leads and jacket are properly connected within the current range of your choice.

  • Page 102: Dt/Dtp Series Connector Disassembly

    Pinch the crimped contact about 25mm/0.984in behind the contact cylinder. Hold the connector so that the rear guard ring faces toward you. Push the contacts straight into the retaining ring until you hear a slight click. Gently pull to confirm that the connector is fully locked.

  • Page 103: Hd30/Hdp20 Series Connector Removal

    Figure 7-7 HD/HDP contact installation Pinch the contact piece about 25 mm/0.984in after the crimping cylinder. Hold the connector so that the rear guard ring faces toward you. Push the contacts straight into the retaining ring until you hear a slight click. Gently pull to confirm that the connector is fully locked.
  • Page 104 Figure 7-9 HD/HDP contact removal With the rear insert facing the side, select the appropriate size of the insertion and removal tool to clamp the wire of the contact to be removed. Slide the tool into the cavity of the insert until the tool catches the contact and feels stressed. Pull the contact wire assembly out of the connector.
  • Page 105 Figure 7-11 Electrical Schematics Figure 1/6-Perkins engine 7- 8...
  • Page 106 Figure 7-12 Electrical Schematics Figure 1/6-Deutz D447 engine...
  • Page 107 Figure 7-13 Electrical Schematics Figure 1/6-Deutz D2.9 engine 7- 10...
  • Page 108 Figure 7-14 Electrical Schematics Figure 2/6 7-11...
  • Page 109 Figure 7-14 Electrical Schematics Figure 3/6 7- 12...
  • Page 110 Figure 7-16 Electrical Schematics Figure 4/6 7-13...
  • Page 111 Figure 7-17 Electrical Schematics Figure 5/6 7- 14...
  • Page 112 Figure 7-18 Electrical Schematics Figure 6/6 7-15...

  • Page 113: Hydraulic Schematics

    7.5 Hydraulic Schematics Figure 7-19 Hydraulic Schematics Figure 7- 16...

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