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Zoomlion ZA10RJE Service And Maintenance 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
ZA10RJE
Service and Maintenance Manual

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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 Service and Maintenance Manual ZA10RJE 2021.03 A...
  • Page 5 This Service and Maintenance Manual applies to the ZA10RJE mobile elevating work platform (hereinafter referred to as the MEWP). 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 6: Foreword

    Foreword Symbols and their description: Danger indicates an imminently dangerous situation. If not avoided, will result in death or 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.

  • Page 7: Table Of Contents

    Contents Foreword ............................I Content ............................III SECTION 1 MAINTENANCE SAFETY INSTRUCTION ............1-1 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 8: Content

    Contents 3.2 Maintenance and Instruction ..................... 3-3 3.2.1 General description ....................3-3 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 9 Contents 4.1.5 Wheel installation ....................4-2 4.2 Chassis Angle Sensor System ....................4-3 4.3 Manual Lowering System ......................4-3 4.4 Traveling Drive System ......................4-4 4.5 Travel Reducer .......................... 4-4 4.5.1 Disassembly ......................4-4 4.5.2 Installation ....................... 4-4 SECTION 5 BOOM AND PLATFORM ..................5-1 5.1 Platform and Jib ........................
  • Page 10 Contents 7.2.8 Conduction test ......................7-3 7.2.9 Current measurement ....................7-3 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 7.4 Electrical Schematics ........................
  • Page 11 履带起重机操作手册 第一章 安全操作说明...

  • Page 13: 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 14: 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.

  • Page 15: Precautions In Maintenance

    of them must be in front of the turntable or platform control panel so that the engine can be shut 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.
  • Page 16 Figure 1-3 Mind 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 unit body, thereby burning electrical components such as controllers and sensors. The company does not take the consequences for wrong operation.
  • Page 17 It is strictly forbidden to disassemble electronic components. Do not allow tools or parts to fall into the inspection hole; do not allow objects to fall into the holes 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;...
  • Page 18 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. Mind battery liquid; Battery fluid contains dilute sulfuric acid.
  • Page 19 Restore or reset the safety device and recalibrate the safety device if necessary; Remove the tools and equipment for maintenance, replace parts and scattered objects, and clean up the site; It should always be borne in mind that all maintenance should include mandatory confirmation of normal mechanical movement.
  • Page 21 履带起重机操作手册 第一章 安全操作说明...

  • Page 23: Section 2 Technical Parameters

    SECTION 2 TECHNICAL PARAMETERS 2.1 Performance Table 2-1 Performance Platform capacity 230 kg 507 lb 35% (platform uphill) Max travel speed (on slope) 25% (platform downhill) Max travel speed (side slope) Platform height 9.55 m 31ft 4in Horizontal outreach 6.85 m 22ft 5in 3.25 m (outside) 10ft 8in (outside)

  • Page 24: Capacity

    7605 lb 50 kg 110 lb 17.75 2.6 Functional Speed Table 2-6 Functional speed (Unit: s) Function ZA10RJE Upper boom lifting 24 s ~30 s Upper boom lowering 24 s ~30 s Turntable swing (a round) 60 s ~70 s...

  • Page 25: Operating Procedure When Testing Speed

    2.6.1 Operating procedure when testing speed Upper boom lifting: telescopic boom retracting. Record lifting and descending time respectively; Turntable swing: upper boom lifted to maximum work height, telescopic boom retracted. Record 360° continuous turntable swing left and right respectively; Upper boom extending: upper boom lifted to maximum work height, telescopic boom retracted. Record telescopic boom extending and retracting time respectively;...

  • Page 26: Lubrication

    Table 2-7 Torque requirements (continuous) Strength grade and corresponding torque Nm Bolt diameter 8.8 grade 10.9 grade 1032 1450 1400 1970 Note: when maintenance is required or the fasteners are loose, follow the torque gauge to determine the appropriate torque value. 2.8 Lubrication 2.8.1 Hydraulic oil Table 2-8 Hydraulic oil specification...
  • Page 27 履带起重机操作手册 第一章 安全操作说明...

  • Page 29: 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 30: Preventive Maintenance

    Refer to the Machine Annual Inspection Form and the Preventive Maintenance Schedule for this 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.

  • Page 31: Maintenance And Instruction

    3.2 Maintenance and Instruction 3.2.1 General description The following information is provided to assist you in the use and application of the repair and maintenance procedures contained in this manual. 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.

  • Page 32: Bearing

    3.2.7 Bearing After removing the bearing, cover it to avoid stains or abrasives. Clean the bearing in a non-flammable cleaning agent and allow it to drip dry. Compressed air can be used, but the 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).

  • Page 33: Battery

    3.2.13 Battery 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. 3.2.13.1 Battery inspection Check the battery appearance. The battery top and terminal connections should be kept clean, free of dust, corrosion and dryness.

  • Page 34: Lubrication And Maintenance

    Prevent the cleaning solution from entering the inside of batteries. Rinse with water, and use cloth to dry it. Coat the terminals with protecting spray (available through local battery dealer). Keep the surrounding area clean and dry. 3.2.14 Lubrication and maintenance Parts and components that require lubrication and maintenance refer to the Lubrication Table in Section 3.3 Lubrication and Information 3.3.1 Hydraulic system...
  • Page 35 3-2 is not used to specify the type and parameters of hydraulic oil). Please select the hydraulic oil of the appropriate brand and technical parameters according to the specific use environment of the equipment. For special environments or users with special requirements, please contact ZOOMLION or hydraulic oil manufacturers.

  • Page 36: Hydraulic Oil Replacement

    of the equipment is higher than the selected hydraulic oil pour point temperature of 25 ℃ or 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.

  • Page 37: Cylinder Drift

    The maximum allowable drift in 10 minutes is 5 cm (2 inches). 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 Inch Millimeter...

  • Page 38: Welding On The Device

    Reassemble the connecting pin with a fiber bearing. The dirt and debris on the housing should be blown off. There must be no foreign objects on the bearings and housings; Bearings and pins should be cleaned with a cleaning agent to remove all grease and lubricant. Fiber bearings do not require lubrication;...
  • Page 39 Table 3-4 Inspection and preventive maintenance schedule Time intervals Pre-delivery Items Every 2 Pre-start Weekly Monthly Annually 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 Cables or wire...
  • Page 40 Table 3-4 Inspection and preventive maintenance schedule (continuous) Time intervals Items Pre-delivery or Every 2 Pre-start Weekly Monthly Annually daily years 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) Function limit or cutout...
  • Page 41 Table 3-4 Inspection and preventive maintenance schedule (continuous) Time intervals Items Pre-delivery or Every 2 Pre-start Weekly Monthly Annually daily years Hydraulic pump 1,2,9 Hydraulic oil tank 1,9,7 1,2,9 1,2,9 Cylinder pinned joints and pins retainer Hydraulic hose and other 1,2,9,12 1,2,9,12 hydraulic fittings...
  • Page 42 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 43 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 履带起重机操作手册 第一章 安全操作说明...

  • Page 47: 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 48: Tire Replacement

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

  • Page 49: Chassis Angle Sensor System

    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 310 Nm...

  • Page 50: Traveling Drive System

    4.4 Traveling Drive System The traveling system is mainly composed of wheels, traveling reducer and traveling motor. Specifically, the two-wheel drive system consists of two motor drivers, two travel motors, and two gear reducers. The walking speed is changed according to the change of the motor speed. Our equipment has three drive modes to choose from at the platform console.
  • Page 51 履带起重机操作手册 第一章 安全操作说明...

  • Page 53: 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 Figure 5-1 Load cell disassembly diagram Retract the tower boom and the upper boom; Disconnect the wiring harness at the platform control box and the load cell, disconnect the pipeline at the platform valve, and mark it at the same time;...

  • Page 54: Rotary Actuator

    5.1.1.3 Installation Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint before installation should be cleaned to prevent contaminants from entering the hydraulic system; Threaded fasteners should be tightened in place according to the torque values in Section 2 Specifications.

  • Page 55: Jib Lifting Cylinder

    5.1.3 Jib lifting cylinder 5.1.3.3 Disassembly Mark and disconnect the hydraulic line connecting the jib lifting cylinder balancing valve, collect the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting; Remove the connecting bolts 3 and 5 of the support and the upper and lower links, and remove the pins 4 and 6, so that the jib lifting cylinder can be removed.

  • Page 56: Cable

    5.2.1 Cable 5.2.1.1 Disassembly Figure 5-3 Cable system disassembly Adjusting the boom to a fully retracted state; Disconnect the pipeline from the ground control box; Mark and disconnect the hydraulic lines from upper boom to the control valve. Collect the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting;...

  • Page 57: Leveling Cylinder

    5.2.1.3 Installation Follow the reverse steps of disassembly. The pipe joints of the hydraulic lines 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 58: Lower Leveling Cylinder And Lifting Cylinder

    5.2.2.2 Inspection Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if necessary; 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.
  • Page 59 collecting; Use suitable lifting equipment to hoist the two ends of the leveling cylinder, disassemble the pin shaft 3 and the pin shaft 1, and remove the lower leveling cylinder; Use a suitable lifting device to support the tower boom to prevent the upper boom from falling when disassembling the other cylinder;...

  • Page 60: Upper Boom

    5.2.4 Upper boom 5.2.4.1 Disassembly Figure 5-6 Upper boom disassembly diagram Figure 5-6 Upper boom disassembly diagram Before disassembling the upper boom, it is necessary to disassemble working platform, jib, cable, upper leveling cylinder, counterweight (weight about 3,000kg (6613 lb)) and hood, according to the disassembly steps;...

  • Page 61: Telescopic Cylinder

    5.2.4.2 Inspection Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if necessary; 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.

  • Page 62: Tower Boom And Its Cylinder

    Use a suitable lifting device and fix one end of the rope to the connecting hole on the left side of the telescopic cylinder as shown in the figure; Operate the lifting equipment, slowly and smoothly pull the telescopic cylinder out of base boom, then hoist it on the appropriate support frame;...
  • Page 63 Need to unload the working platform, jib, cable, upper leveling cylinder, counterweight (weight about 3,000kg (6613 lb)), hood and upper boom according to the disassembly steps in advance; Mark and disconnect the hydraulic lines and harnesses connected to the components on the turntable, collect the hydraulic oil in the pipeline with a suitable container, and seal the ports of the pipeline after collection;...

  • Page 67: Section 6 Electrical System Maintenance

    SECTION 6 ELECTRICAL SYSTEM MAINTENANCE 6.1 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.
  • Page 68 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 12355 DTC_FAULT_UG_JIB_SWITCH_DOUBLE_POWER_ON 12356 DTC_FAULT_UG_TELESCOPE_DOUBLE_POWER_ON 22357 DTC_FAULT_UG_ROTATE_SWITCH_DOUBLE_POWER_ON 12358 DTC_FAULT_UG_LEVELING_SWITCH_DOUBLE_POWER_ON 22359 DTC_FAULT_UG_SWING_SWITCH_DOUBLE_POWER_ON 22360 DTC_FAULT_UG_ENGINE_SWITCH_DOUBLE_POWER_ON 14361 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_DOUBLE_POWER_ON 14363 DTC_FAULT_PM_JIB_SWITCH_DOUBLE_POWER_ON 14364 DTC_FAULT_PM_TELESCOPE_DOUBLE_POWER_ON 24365 DTC_FAULT_PM_ROTATE_SWITCH_DOUBLE_POWER_ON 14366 DTC_FAULT_PM_LEVELING_SWITCH_DOUBLE_POWER_ON 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...
  • Page 69 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list Switch/handle 14393 DTC_FAULT_PM_ENGINE_SWITCH_DOUBLE_POWER_ON 22551 DTC_DRIVE_FORWARD_VALVE_SHORT_TO_GROUND 12552 DTC_DRIVE_FORWARD_VALVE_SHORT_TO_POWER 22553 DTC_DRIVE_FORWARD_VALVE_OPEN_CIRCUIT 22554 DTC_DRIVE_REVERSE_VALVE_SHORT_TO_GROUND 12555 DTC_DRIVE_REVERSE_VALVE_SHORT_TO_POWER 22556 DTC_DRIVE_REVERSE_VALVE_OPEN_CIRCUIT 22557 DTC_DRIVE_FORWARD_VALVE_FEEDBACK_CURRENT_FAULT 22558 DTC_DRIVE_REVERSE_VALVE_FEEDBACK_CURRENT_FAULT 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...
  • Page 70 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 22588 DTC_4SELECT_MAIN_CONTROL_RIGHT_VALVE_SHORT_TO_GROUND 22589 DTC_4SELECT_MAIN_CONTROL_RIGHT_VALVE_SHORT_TO_POWER 22590 DTC_4SELECT_MAIN_CONTROL_RIGHT_VALVE_OPEN_CIRCIUT 22593 DTC_MAIN_LIFT_UP_VALVE_SHORT_TO_GROUND 12594 DTC_MAIN_LIFT_UP_VALVE_SHORT_TO_POWER 22595 DTC_MAIN_LIFT_UP_VALVE_OPEN_CIRCUIT 22597 DTC_TOWER_LIFT_UP_VALVE_SHORT_TO_GROUND 12598 DTC_TOWER_LIFT_UP_VALVE_SHORT_TO_POWER 22599 DTC_TOWER_LIFT_UP_VALVE_OPEN_CIRCUIT 23601 DTC_TELESCOPE_VALVE_SHORT_TO_GROUND 13602 DTC_TELESCOPE_VALVE_SHORT_TO_POWER 23603 DTC_TELESCOPE_VALVE_OPEN_CIRCUIT 23604 DTC_HAND_LEVELING_VALVE_SHORT_TO_GROUND 13605 DTC_HAND_LEVELING_VALVE_SHORT_TO_POWER 23606 DTC_HAND_LEVELING_VALVE_OPEN_CIRCUIT 23607...
  • Page 71 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 12761 DTC_JIB_ROTATE_VALVE1_SHORT_TO_POWER 22762 DTC_JIB_ROTATE_VALVE1_OPEN_CIRCUIT 22763 DTC_JIB_ROTATE_VALVE2_SHORT_TO_GROUND 12764 DTC_JIB_ROTATE_VALVE2_SHORT_TO_POWER 22765 DTC_JIB_ROTATE_VALVE2_OPEN_CIRCUIT 23775 DTC_LEVEL_SELECT_VALVE_SHORT_TO_GROUND 13776 DTC_LEVEL_SELECT_VALVE_SHORT_TO_POWER 23777 DTC_LEVEL_SELECT_VALVE_OPEN_CIRCUIT 23778 DTC_MAIN_LIFT_DN_VALVE_SHORT_TO_GROUND 13779 DTC_MAIN_LIFT_DN_VALVE_SHORT_TO_POWER 23780 DTC_MAIN_LIFT_DN_VALVE_OPEN_CIRCUIT 23781 DTC_TOWER_DN_RIGHT_VALVE_SHORT_TO_GROUND 13782 DTC_TOWER_DN_RIGHT_VALVE_SHORT_TO_POWER 23783 DTC_TOWER_DN_RIGHT_VALVE_OPEN_CIRCUIT 23784 DTC_TOWER_DN_LEFT_VALVE_SHORT_TO_GROUND 13785...
  • Page 72 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 12809 DTC_AUX_POWER_SHORT_TO_POWER 12810 DTC_AUX_POWER_OPEN_CIRCUIT 34811 DTC_PM_BUZZER_SHORT_TO_GROUND 34812 DTC_PM_BUZZER_SHORT_TO_POWER 34813 DTC_PM_BUZZER_OPEN_CIRCUIT 14814 DTC_PLATFORM_SW_POWER_SHORT_TO_GROUND 14815 DTC_PLATFORM_SW_POWER_SHORT_TO_POWER 14816 DTC_PLATFORM_SW_POWER_OPEN_CIRCUIT 14817 DTC_JIB_LEFT_VALVE_SHORT_TO_GROUND 14818 DTC_JIB_LEFT_VALVE_SHORT_TO_POWER 14819 DTC_JIB_LEFT_VALVE_OPEN_CIRCUIT 14820 DTC_JIB_RIGHT_VALVE_SHORT_TO_GROUND 14821 DTC_JIB_RIGHT_VALVE_SHORT_TO_POWER 14822 DTC_JIB_RIGHT_VALVE_OPEN_CIRCUIT 14823 DTC_JIB_TELESCOPE_OUT_VALVE_SHORT_TO_GROUND 14824...
  • Page 73 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 24855 DTC_LEVELING_FAULT 23856 DTC_SHORT_ROPE_FAULT 23857 DTC_MAIN_LIFT_CONTROL_SYSTEM_FAULT 41858 DTC_LOWER_SPEED_FAULT 32859 DTC_SYSTEM_FAULT 34860 DTC_SOFT_TOUCH_FAULT Device status 32861 DTC_ALTERNATOR_FAULT 32862 DTC_GLOW_PLUG_FAULT 12863 DTC_TILT_FAULT 32864 DTC_LOW_FUEL_FAULT 14865 DTC_ANTI_CRUSH_ALARM 12866 DTC_SYSTEM_INITIAL_FAULT 12867 DTC_INH_FAULT System 22951 DTC_CONTROL_READ_PARA_ERROR...
  • Page 74 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 1056 DTC_MAIN_CONTACTOR_WELDED_1 1057 DTC_MAIN_CONTACTOR_DID_NOT_CLOSE_1 1065 DTC_THROTTLE_WIPER_HIGH_1 1066 DTC_THROTTLE_WIPER_LOW_1 1067 DTC_POT2_WIPER_HIGH_1 1068 DTC_POT2_WIPER_LOW_1 1069 DTC_POT_LOW_OVERCURRENT_1 1070 DTC_EEPROM_FAILURE_1 1071 DTC_HPD_SEQUENCING_FAULT_1 1073 DTC_PARAMETER_CHANGE_FAULT_1 1104 DTC_VCL_RUN_TIME_ERROR_1 1105 DTC_EXTERNAL_SUPPLY_OUT_OF_RANGE_1 1113 DTC_OS_GENERAL_1 1114 DTC_PDO_TIMEOUT_1 1115 DTC_STALL_DETECTED_1 1116...
  • Page 75 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 2035 DTC_UNDERVOLTAGE_CUTBACK_2 2036 DTC_OVERVOLTAGE_CUTBACK_2 2037 DTC_SUPPLY_5V_FAILURE_2 2038 DTC_DO6_OPEN_OR_SHORT_2 2039 DTC_DO7_OPEN_OR_SHORT_2 2040 DTC_MOTOR_TEMP_HOT_CUTBACK_2 2041 DTC_MOTOR_TEMP_SENSOR_FAULT_2 2049 DTC_MAIN_OPEN_SHORT_2 2050 DTC_EMBRAKE_OPEN_SHORT_2 2051 DTC_COIL3_DRIVER_OPEN_SHORT_2 2052 DTC_COIL4_DRIVER_OPEN_SHORT_2 2053 DTC_PD_OPEN_SHORT_2 2054 DTC_ENCODER_FAULT_2 2055 DTC_MOTOR_OPEN_2 2056 DTC_MAIN_CONTACTOR_WELDED_2 2057...
  • Page 76 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 2145 DTC_VCL_OS_MISMATCH_2 2146 DTC_EM_BRAKE_FAILED_TO_SET_2 2147 DTC_ENCODER_LOS_2 2148 DTC_EMR_REV_TIMEOUT_2 2152 DTC_ILLEGAL_MODEL_NUMBER_2 2153 DTC_DUALMOTOR_PARAMETER_MISMATCH_2 3018 DTC_CONTROLLER_OVERCURRENT_3 3019 DTC_CURRENT_SENSOR_FAULT_3 3020 DTC_PRECHARGE_FAILED_3 3021 DTC_CONTROLLER_SEVERE_UNDERTEMP_3 3022 DTC_CONTROLLER_SEVERE_OVERTEMP_3 3023 DTC_SEVERE_UNDERVOLTAGE_3 3024 DTC_SEVERE_OVERVOLTAGE_3 3034 DTC_CONTROLLER_OVERTEMP_CUTBACK_3 3035 DTC_UNDERVOLTAGE_CUTBACK_3 3036...
  • Page 77 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 3071 DTC_HPD_SEQUENCING_FAULT_3 3073 DTC_PARAMETER_CHANGE_FAULT_3 3104 DTC_VCL_RUN_TIME_ERROR_3 3105 DTC_EXTERNAL_SUPPLY_OUT_OF_RANGE_3 3113 DTC_OS_GENERAL_3 3114 DTC_PDO_TIMEOUT_3 3115 DTC_STALL_DETECTED_3 3116 DTC_FAULT_ON_OTHER_TRACTION_CONTROLLER_3 3117 DTC_DUAL_SEVERE_FAULT_3 3119 DTC_SUPERVISOR_FAULT_3 3120 DTC_SUPERVISOR_INCOMPATIBLE_3 3135 DTC_MOTOR_CHARACTERIZATION_FAULT_3 3136 DTC_ENCODER_PULSE_ERROR_3 3137 DTC_MOTOR_TYPE_FAULT_3 3145 DTC_VCL_OS_MISMATCH_3 3146...
  • Page 78 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 4050 DTC_EMBRAKE_OPEN_SHORT_4 4051 DTC_COIL3_DRIVER_OPEN_SHORT_4 4052 DTC_COIL4_DRIVER_OPEN_SHORT_4 4053 DTC_PD_OPEN_SHORT_4 4054 DTC_ENCODER_FAULT_4 4055 DTC_MOTOR_OPEN_4 4056 DTC_MAIN_CONTACTOR_WELDED_4 4057 DTC_MAIN_CONTACTOR_DID_NOT_CLOSE_4 4065 DTC_THROTTLE_WIPER_HIGH_4 4066 DTC_THROTTLE_WIPER_LOW_4 4067 DTC_POT2_WIPER_HIGH_4 4068 DTC_POT2_WIPER_LOW_4 4069 DTC_POT_LOW_OVERCURRENT_4 4070 DTC_EEPROM_FAILURE_4 4071 DTC_HPD_SEQUENCING_FAULT_4 4073...
  • Page 79 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 5020 DTC_PRECHARGE_FAILED_5 5021 DTC_CONTROLLER_SEVERE_UNDERTEMP_5 5022 DTC_CONTROLLER_SEVERE_OVERTEMP_5 5023 DTC_SEVERE_UNDERVOLTAGE_5 5024 DTC_SEVERE_OVERVOLTAGE_5 5034 DTC_CONTROLLER_OVERTEMP_CUTBACK_5 5035 DTC_UNDERVOLTAGE_CUTBACK_5 5036 DTC_OVERVOLTAGE_CUTBACK_5 5037 DTC_SUPPLY_5V_FAILURE_5 5038 DTC_DO6_OPEN_OR_SHORT_5 5039 DTC_DO7_OPEN_OR_SHORT_5 5040 DTC_MOTOR_TEMP_HOT_CUTBACK_5 5041 DTC_MOTOR_TEMP_SENSOR_FAULT_5 5049 DTC_MAIN_OPEN_SHORT_5 5050 DTC_EMBRAKE_OPEN_SHORT_5 5051...
  • Page 80 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 5117 DTC_DUAL_SEVERE_FAULT_5 5119 DTC_SUPERVISOR_FAULT_5 5120 DTC_SUPERVISOR_INCOMPATIBLE_5 5135 DTC_MOTOR_CHARACTERIZATION_FAULT_5 5136 DTC_ENCODER_PULSE_ERROR_5 5137 DTC_MOTOR_TYPE_FAULT_5 Driver 5145 DTC_VCL_OS_MISMATCH_5 5146 DTC_EM_BRAKE_FAILED_TO_SET_5 5147 DTC_ENCODER_LOS_5 5148 DTC_EMR_REV_TIMEOUT_5 5152 DTC_ILLEGAL_MODEL_NUMBER_5 5153 DTC_DUALMOTOR_PARAMETER_MISMATCH_5 6-14...

  • Page 81: Common Faults And Solutions

    Replace controller 1. If you encounter any equipment failure, contact Zoomlion for timely troubleshooting; 2. If there is no absolute understanding of the fault resolution, please contact Zoomlion or Zoomlion dealers to solve it; 3. It is forbidden to open the electric control cabinet to change the wire.
  • Page 83 履带起重机操作手册 第一章 安全操作说明...

  • Page 85: Section 7 Electrical Information And Schematic

    SECTION 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 not be corrected by the listed solutions, occur, you should obtain authoritative technical guidance before performing maintenance.

  • Page 86: 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 87: Conduction Test

    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; If the multimeter cannot automatically adjust the range, set the correct range (refer to the multimeter operation manual).

  • Page 88: Deutsch Connector

    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; If the multimeter cannot automatically adjust the range, set the correct range (refer to the multimeter operation manual).

  • Page 89: Dt/Dtp Series Connector Disassembly

    7.3.2 DT/DTP Series Connector Disassembly Figure 7-6 DT/DTP contact removal When disassembling, use a non-toothed nose pliers or hook line to pull the wedge locker vertically; Use a screwdriver to remove the retaining finger from the contact, release the retaining finger, and gently pull the wire to remove the contact;...

  • Page 90: Hd30/Hdp20 Series Connector Removal

    Hold the connector so that the rear guard ring faces toward you; Push the contact straight into the retaining ring until the main motion stops. Gently pull to confirm that the connector is fully locked. Figure 7-8 HD/HDP lock contact position Note: for unused wire cavities, a sealing plug should be inserted to achieve complete isolation from the environment.
  • Page 91 Figure 7-10 HD/HDP non-locking contact Note: for unused wire cavities, a sealing plug should be inserted to achieve complete isolation from the environment.

  • Page 92: Electrical Schematics

    7.4 Electrical Schematics Figure 7-11 Electrical Schematics (Figure1/7) 7- 8...
  • Page 93 Figure 7-12 Electrical Schematics (Figure 2/7)
  • Page 94 Figure 7-13 Electrical Schematics (Figure3/7) 7- 10...
  • Page 95 Figure 7-14 Electrical Schematics (Figure 4/7) 7-11...
  • Page 96 Figure 7-15 Electrical Schematics (Figure 5/7) 7- 12...
  • Page 97 Figure 7-16 Electrical Schematics (Figure 6/7) 7-13...
  • Page 98 Figure 7-17 Electrical Schematics (Figure 7/7) 7- 14...

  • Page 99: Hydraulic Schematics

    7.5 Hydraulic Schematics Figure 7-17 Hydraulic Schematics 7-15...

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