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Zoomlion ZT38JE Service And Maintenance Manual

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Service and Maintenance
Service and Maintenance Manual
ZT38JE
Service and Maintenance Manual
Apr 2023 Version A

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Summary of Contents for Zoomlion ZT38JE

  • Page 1 Service and Maintenance Service and Maintenance Manual ZT38JE Service and Maintenance Manual Apr 2023 Version A...

  • Page 3: Foreword

    Foreword This Service and Maintenance Manual applies to the ZT38JE mobile elevated 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 4 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 5: Table Of Contents

    Contents Foreword………….…………….………………………….……………………………...….……I Content………….…………….………………………….…………………………..………..…II 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 ........................1-2 1.2.2 Precautions in maintenance ..................

  • Page 6: Content

    Contents 3.1.6 Preventive maintenance ....................3-2 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 ......................
  • Page 7 Contents 4.1 Tire and wheel ......................... 4-1 4.1.1 Tire inflation ........................ 4-1 4.1.2 Tire damage ......................... 4-1 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 .....................
  • Page 8 Contents 5.2.1 Chain ..........................5-5 5.2.2 Leveling cylinder ......................5-6 5.2.3 Lifting cylinder ......................5-7 5.2.4 Boom ........................... 5-8 5.2.5 Telescopic cylinder ....................5-11 5.2.6 Wire rope pulley disassembly ..................5-13 5.2.7 Wire rope and pulley check ..................5-15 5.3 Load Cell Check........................5-18 5.3.1 Load Cell Check ......................
  • Page 9 Contents 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 ......................7-7 7.5 Hydraulic Schematics ......................7-18...

  • 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.

  • Page 15: Precautions In Maintenance

    or make the floor slippery that results in injury. When cleaning the machine with a high-pressure water gun, it is forbidden to directly align the electrical control box and the connector, otherwise it will cause an electrical short circuit. It is strictly forbidden to align water or water jets with electrical components! Otherwise there is danger of electric shock! Figure 1-2 Mind Electric Shock 1.2.2 Precautions in maintenance...
  • Page 16 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 17 If electrical, circuit or hydraulic components (valves, pumps, etc.) need to be replaced, the replaced parts should be checked and adjusted according to the data on the machine schematic. Manufacturer-approved parts must be used, especially those that affect load bearing performance and safety performance.
  • Page 18 get medical attention promptly. Figure 1-6 Mind battery liquid Use the specified greased items. Use the recommended grade or the same grade of oil and grease when replenishing or replacing. The combination of different grades of grease will result in a chemical reaction that changes the properties of the grease and adversely affects the mechanical properties.
  • Page 19 environment. It is forbidden to dump waste liquid at the sewage pipe, ground surface, river, etc. at will. The waste liquid should be discharged into a suitable container for proper disposal. The disposal of hazardous substances should be in compliance with all environmental regulations, otherwise it will be fined or punished by relevant departments.

  • Page 23: Section 2 Technical Parameters

    SECTION 2 TECHNICAL PARAMETERS 2.1 Performance Table 2-1 Performance Platform Capacity 300kg Max Travel Speed (on slope) 45%(24°） Max Travel Speed (on side slope) 45%(24°） Platform Height 38.22m Horizontal Outreach 22.64m 8.2/10.8m (outside) Turning Radius （working/stowed） 3.3/7.7m (inside) Max Travel Speed 5 km/h Max Hydraulic System Pressure 21 Mpa...

  • Page 24: Capacity

    Rating 8km/h 0km/h wheel) IN445/5 Foam-filled 9250 kg 11500 kg 390±5 kg 0D710 2.6 Functional Speed Table 2-5 Functional speed ZT38JE Function Boom Lifting 120~130 Boom Descending 120~130 Turntable Swing (a round) 135~145 Boom Extending 95~105 Boom Retracting 85~95 Platform Rotation...

  • Page 25: Test Cautions

    right respectively. Boom telescoping: Lifted to highest position. Record boom extending and retracting time respectively. Jib lifting: platform leveling, chassis swing, boom positioned to the center of chassis. Record lifting and descending time respectively. Platform Rotation; Platform leveling. Platform reaches extreme position, rotate the platform to reach the extreme position of another side, record the rotating time;...

  • Page 26: Lubrication

    555 Nm/409.4ftlb 780 Nm/575.3ftlb 705 Nm/520ftlb 992 Nm/731.7ftlb 1032 Nm/761.2ftlb 1450 Nm/1069.5ftlb 1400 Nm/1032.6ftlb 1970 Nm/1453ftlb Note: when maintenance is required or the fasteners are loose, follow the torque gauge to determine the appropriate torque value. Table 2-7 Special toque Requirements Instruction: Torque value (N.m) Time intervals...
  • Page 27 16MPa Jib lifting 21MPa Platform rotation 21MPa Platform leveling 2- 5...

  • Page 31: 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 32: 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 33: Safety And Operating Standards

    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. 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 life.

  • Page 34: Washer

    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). Do not open the reusable or new bearing packaging until you are ready to install it.
  • Page 35 The battery was cleaned with a non-metallic brush and an aqueous solution of sodium bicarbonate. 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 36: Lubrication And Maintenance

    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 Inspection and Maintenance of Hydraulic System 3.3.1 Regular inspection It is necessary to conduct regular maintenance of hydraulic system on time for good performance.
  • Page 37 cap filter Replace return oil Control oil ★(first) ★ filter line element Replace Mandatory hydraulic replacement The following items should note in routine maintenance: Select suitable hydraulic oil for pressure transmitting, lubricating, cooling and sealing. Improper hydraulic oil will cause system fault in early stage and decline in durability. Choose recommended hydraulic oil.

  • Page 38: Hydraulic Tank And Oil

    3.3.2 Hydraulic tank and hydraulic oil 3.3.2.1 Hydraulic tank check There are scales on the side of the hydraulic tank, and the scales have corresponding capacity values. Table 3-4 Oil capacity ZT38JE Model 200L Hydraulic Tank 265KG Oil mass of hydraulic system (including tank) Check the oil capacity before starting the machine.
  • Page 39 Refer to Table 3-5 Hydraulic oil parameters (not for models with specified hydraulic oil) for hydraulic oil types and models. Select suitable hydraulic oil types according to specific application. For special environments or users with special requirements, please contact ZOOMLION or hydraulic oil manufacturers.
  • Page 40 Breather plug Maintenance point- breather plug of tank Time interval- first 50hrs after usage, every 6 months or 1000hrs thereafter Note- remove and replace the wing nut and outer cover. Replacement might be conducted frequently in some circumstances. Please be careful not to reverse the filter inlet and outlet when replacing the filter element, otherwise it will cause serious consequences.
  • Page 41 Refer to Table 3-5 Hydraulic oil parameters (not for models with specified hydraulic oil) for hydraulic oil types and models. Select suitable hydraulic oil types according to specific application. For special environments or users with special requirements, please contact ZOOMLION or hydraulic oil manufacturers.
  • Page 42 pressure) Mobil SHC Aware H 32 185/ (Environmental friendly) Chevron (Clarity Synthetic EA Hydraulic Oil) 22.4 Mobil DTE 10 Ultra 22 32.7 Mobil DTE 10 Ultra 32 45.6 Mobil DTE 10 Ultra 46 15.7 Chevron/Caltex Rando HDZ 15 Chevron/Caltex Rando HDZ 32 46.7 Chevron/Caltex Rando HDZ 46 15.8...
  • Page 43 multiple times. The oil sample can be sent to the hydraulic oil manufacturer or a qualified third-party testing agency for analysis and to determine whether it is still available. 1. The use time of hydraulic oil should not exceed 24 months. After 24 months, it is not recommended to use it even after filtering;...
  • Page 44 should be replaced. When the piston rod is bent and cannot work normally, you should find the manufacturer or professional maintenance personnel to replace the cylinder. Pay attention to the following aspects when using and transporting hydraulic cylinders: Packing should be added during the storage and transportation of the hydraulic cylinder, and protective devices should be added to the oil port joint surface and the exposed part of the piston rod;...
  • Page 45 ③ Hose twisted by 7 ° can reduce the service life of the hose by 10%. Correct Incorrect To have sufficient bending radius: It can ensure smooth fluid flow and effectively avoid pipeline damage; ① Too small bending radius will greatly reduce the life of the hose assembly. ②...

  • Page 46: Cylinder Drift Test

    Use a pipe clamp to ensure the positioning of the hose: Effectively reduce wear between hoses and related components. Incorrect Correct Arrange the hose: Avoid overheated surfaces and sharp edges; ① Avoid friction with components; ② There must be enough free length for bending activities. ③...

  • Page 47: Pin And Bearing Inspection Instructions

    0.009 0.22 152.4 0.006 0.15 177.8 0.005 0.13 203.2 0.0038 0.10 228.6 0.0030 0.08 Use a calibrated dial gauge to measure drift on the cylinder rod. The oil in the cylinder must be in a stable ambient temperature. The cylinder must have the normal load applied by the platform. If the cylinder passes this test, it is acceptable.

  • Page 48: Welding On The Device

    During installation and operation, the pins should be inspected to ensure that there are no burrs, nicks or scratches that could damage the bearings. 3.6 Welding on the device Note: this instruction applies to the repair or adjustment and to the welding of external structures or components on the machine.
  • Page 49 Door Floor Rotary motor 1,2,10 1,2,10 Lanyard anchorage point Turntable assembly 1,2,14 1,2,3,13,14 Swing bearing or worm gear Swivel joint Turntable drive system 1,2,5 1,2,5 Turntable pin Hood, hood props and hood 1,2,5 latches Chassis assembly 16.17 16,17,18 16,17,18 Tire Wheel nuts/screw 14,24 Wheel bearing...
  • Page 50 21, 22 All system functional test Paint 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 51 7 - Clean and free of dirt 8 - Interlock function 9 - Check for signs of leaks 10 - complete and secure decal 11 - Level check 12 - Check for wear and correct routes 13 - Correct tolerance check 14 - Correct lubrication 15 - Reverse to appropriate torque specifications 16 - No boring, excessive wear or bare rope...

  • Page 55: Section 4 Chassis And Turntable

    4.1.1 Tire inflation In order to ensure 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 units or the rim sticker. 4.1.2 Tire damage For pneumatic tires, our company recommends: when any cuts or cracks in the tire are found to expose the sidewalls of the tire or the tread, take immediate action to stop using our products.

  • Page 56: Tire Replacement

    4.1.3 Tire replacement Our company recommends replacing the tires of the same size, grade and brand as the original tires of the machine. Please refer to our company's parts manual for the part number of the certified tire for a specific machine model.

  • Page 57: 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 135 Nm...

  • Page 58: Swing Axle Lock Test

    Find the exhaust valve on the opposite side of the floating cylinder and repeat the above steps. 4.2.2 Swing axle lock test Locking system testing must be performed quarterly when components of the locking system are replaced or improper system operation conducted. Note: before starting the floating cylinder test, make sure the boom is fully retracted, lowered and centered in the middle of the two drive wheels.

  • Page 59: Oscillating Axle System

    the primary power source. The auxiliary power system allows all functional units to return to the stowed or lowered state and supports the jib lifting. The auxiliary power system keeps the work platform in a horizontal position when the boom is lowering. However, the auxiliary power system does not support drive function.

  • Page 60: Traveling Drive System

    Figure 4-4 Floating cylinder disassembly diagram 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 61: Travel Reducer

    Steering Tire mounting bolt Traveling reducer Traveling reducer Tire frame motor assembly mounting bolt 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 and mark all hydraulic lines connected to the travel motor on the travel reducer; Use a suitable lifting device to support the travel reducer (the travel reducer weighs approximately 145kg).

  • Page 62: Rotary Motor

    4.8 Rotary Motor This type of rotary motor is a cycloid motor, which is the actuator of the rotary system. Maintenance motor disassembly method: Remove the hydraulic hose connected to the motor, mark it properly and plug it properly, and plug the motor oil port;...

  • Page 63: Slewing Bearing

    Brake oil port Inlet Outlet Figure 4-9 Position of each port of the reducer b) Remove the oil drain plug and oil filling plug, drain the oil in reducer and brake. 1. Clean the inside of rotary reducer and brake before refill. 2.

  • Page 64: Check And Maintenance

    lubrication cycle should be shortened when the unit is located in tropical climates affected by temperature irregularities or sandy or humid areas. Use a grease gun to inject Mobilux EP 2, Shell Alvania EP (LF) 2 grease, etc. into the slewing ring from the grease fitting at the slewing ring until the grease leaks from the seal and fills the ring.

  • Page 65: Slewing Gear Clearance Adjustment

    The bolt of slewing bearing is important to the unit. Do not use the removed bolt, the new bolt should be used. Figure 4-10 Upper part disassembly 4.11 Slewing Gear Clearance Adjustment The gear clearance of slewing mechanism refers to the meshing gap between small gear on the rotary reducer and slewing bearing (large gear).
  • Page 66 Adjust the adjusting bolt and measure the backlash between the slewing gear and the slewing bearing with a plug gauge. Repeatedly adjust and measure the clearance to 0.15-0.25mm. Tighten the mounting bolt with a tightening torque of not less than 520Nm. Hold the adjustment bolt and tighten the locking bolt.

  • Page 69: Section 5 Boom And Platform

    SECTION 5 BOOM AND PLATFORM 5.1 Platform and Jib 5.1.1 Anti-crushing device 5.1.1.1 Disassembly Figure 5-1 Load cell disassembly diagram Disconnect the wiring in anti-crushing device; Remove the bolt 4 connecting steel clamp and platform weldment, then remove the steel clamp;...

  • Page 70: Load Cell

    Check whether the impact rod is bent, broken or otherwise damaged, and replace the it if necessary; Check whether the spring hinge is worn, spring failure or other damage, and replace the spring hinge if necessary; Inspect all threaded parts for damage such as stretching, thread deformation or distortion and replace if necessary.

  • Page 71: Rotary Actuator

    b） Remove the connecting bolts 1, 6 of the bracket and the platform component, and use a suitable lifting device to remove the platform component from the bracket. c） Remove the connecting bolts 4 and 5 of the swing cylinder and the transition base, and use appropriate lifting equipment to remove the bracket and the transition base from the swing cylinder;...

  • Page 72: Jib Lifting Cylinder

    Remove the stop pin and connecting pin of the support and the main boom, and use a suitable lifting device to remove the jib. Remove the connecting bolt 1, the connecting bolt 2 of the swing cylinder and the upper link, and remove the pin, and then the swing cylinder can be removed.

  • Page 73: Boom Assembly

    before installation should be cleaned to prevent contaminants from entering the hydraulic system. A hydraulic system pipes 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.

  • Page 74: Leveling Cylinder

    precautions. Remove the fasten bolt of connecting seat on base boom and telescopic boom. Remove the cable chain from the base boom. 5.2.1.2 Inspection 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.

  • Page 75: Lifting Cylinder

    disassemble the pin shaft 1 and 2, and remove the jib (Follow the jib removal step). Disassembling the pin shaft 3 fixing the upper leveling cylinder on the 4 boom With the aid of the lifting equipment, slowly and carefully remove the upper leveling cylinder from the telescopic boom to avoid damage to the leveling cylinder and the boom.

  • Page 76: Boom

    If the lifting cylinder run normally, fully stow the boom, use appropriate lifting equipment (lifting weight: 5t) to lift the boom. At the same time, appropriate wood or cushion support can be inserted between the boom and the turntable, and between the lifting cylinder and the turntable; If the lifting cylinder cannot run, remove the balance valve on the lifting cylinder, unlock the pressure of the balance valve, use the lifting equipment to lift the boom, make the boom slowly upward to horizontal, and insert appropriate wood or cushion support between the boom and the turntable, and...
  • Page 77 Hoisting point of counter-weight Figure 5-6 Counter-weight 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.
  • Page 78 counterweight to support the counterweight. Loosen the bolts connecting the counterweight to the turntable, slowly and carefully remove the counterweight from the equipment, and place it on the hard ground reliably. Boom pin 1 Turntable Boom assembly Cylinder pin 2 Lifting cylinder Cylinder Pin 3 Figure 5-7 Lifting cylinder disassembly diagram...

  • Page 79: Telescopic Cylinder

    Extrusion hazard. If the lifting equipment fails to reliably support the boom assembly, when the pin is removed or disassembled, the boom may fall and cause personal injury and equipment damage. When removing, keep personnel away from the area near the boom. 5.2.4.2 Inspection Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if necessary.
  • Page 80 Remove the cables of the wire rope tension sensing assembly, and leave the sensing assembly on the mounting plate; Use suitable tools to unscrew nut 1, but not remove it; Use suitable tools remove cylinder pin 1; Remove the bolt in pressure plate 1, and release the plate; Cylinder pin 2 Pressing plate 2 Cylinder pin 1...

  • Page 81: Wire Rope Pulley Disassembly

    bearing if necessary. Inspect all threaded parts for damage such as stretching, thread deformation or distortion and replace if necessary. 5.2.5.3 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 pipes joint equipped with a sealing device needs to replace a sealing device before the hydraulic line is connected.
  • Page 82 release the 1st retracting wire rope; Drag out the 2 boom section and the wire rope end near the boom from the base boom; Remove nut 6 and fixed pulley 2, and release the 2 retracting wire rope; Figure 5-11 Wire rope pulley disassembly diagram 2 Drag out the boom section and the wire rope end near the boom from the 2 boom...

  • Page 83: Wire Rope And Pulley Check

    Check whether the wire rope is corroded. Check whether the rope is tangled or misused. Install or operate the wire rope not as required, and make the wire rope rotate around its own axis, which may cause tangling when tension the wire rope. Inspect the extended and retracted wire rope pulley bearings for wear, scratches, or other damage, and for ovality.
  • Page 84 After 12 years or 7000 hours of use, the wire rope and pulley must be replaced compulsorily. The ropes and pulleys need to be inspected more often if: The machine is exposed to harsh environments. The boom operation is not smooth or there is abnormal noise. The machine is idle for a long time.
  • Page 85 tightening, clamp the end of the wire rope near the thread to prevent the wire rope from rotating, otherwise it will cause damage to the wire rope. Figure 5-13 Clamp the rope Install adjusting nuts on the outrigger and retracting arm ropes (if readjusting, remove the nylon sleeve lock nut).

  • Page 86: Load Cell Check

    cylinder to limit switch), then extend the boom for 1 to 1.5m again; Check the twisting force of retracting wire rope nut, if the twisting force does not meet the requirements, repeat Step i and Step j, check again until the twist force meets the standard; In order to make all the tension of the wire rope meet the same value, Step i and Step j might need to be repeated.

  • Page 87: Boom Tilt Sensor Check

    b） Check the platform angle sensor wires. c） Confirming that the wiring is correct, then power the unit in turntable control box. d） Check that the platform angle sensor working indicator will flash. e） Observe the platform angle value on the display of turntable electrical control box. f）...

  • Page 88: Drive Speed Limit Check

    c） When the wire rope is loose, a loose alarm will be triggered. d） When the steel wire rope is loose and alarmed, the telescopic function of the operation boom is: the boom is forbidden to extend, only the turtle can retract quickly. e）...
  • Page 89 履带起重机操作手册 第一章 安全操作说明...

  • Page 91: Fault Code

    SECTION 6 ELECTRICAL SYSTEM MAINTENANCE 6.1 Fault code If the unit fails, please check the fault code indicated on the display of turntable control box. If the following code displays, please remove the fault condition and restart the device before continuing the device operation.
  • Page 92 Table 6-1 Fault Code list (continuous) Item Fault Code Description 21078 DTC_LOW_SOC_LEVEL2 31079 DTC_HIGH_CHARGING_CURRENT_LEVEL1 21080 DTC_HIGH_CHARGING_CURRENT_LEVEL2 31081 DTC_HIGH_DISCHARGING_CURRENT_LEVEL1 21082 DTC_HIGH_DISCHARGING_CURRENT_LEVEL2 31083 DTC_HIGH_CELL_VOLTAGE_LEVEL1 21084 DTC_HIGH_CELL_VOLTAGE_LEVEL2 31085 DTC_LOW_CELL_VOLTAGE_NORMAL_TEMP_LEVEL1 31086 DTC_LOW_CELL_VOLTAGE_LOW_TEMP_LEVEL1 21087 DTC_LOW_CELL_VOLTAGE_LOW_TEMP_LEVEL2 21088 DTC_LOW_CELL_VOLTAGE_NORMAL_TEMP_LEVEL2 31089 DTC_LOW_CONSISTENCY_LEVEL1 21090 DTC_LOW_CONSISTENCY_LEVEL2 31091 DTC_HIGH_DIFFERENCE_IN_TEMP_LEVEL1 21092 DTC_HIGH_DIFFERENCE_IN_TEMP_LEVEL2 31093 DTC_LOW_DISCHARGING_TEMP_LEVEL1 21094...
  • Page 93 Table 6-1 Fault Code list (continuous) Item Fault Code Description 21114 DTC_MAIN_MOS_OPEN_CIRCUIT 21115 DTC_MAIN_MOS_SHORT_CIRCUIT 21116 DTC_MAIN_MOS_VOLTAGE_FAULT 21117 DTC_ARST_MOS_OPEN_CIRCUIT 21118 DTC_ARST_MOS_SHORT_CIRCUIT 31119 DTC_ARST_HIGH_TEMP 31120 DTC_ARST_COMM_FAULT 21121 DTC_DRIVER_COMM_FAULT_1 21122 DTC_DRIVER_COMM_FAULT_2 21123 DTC_DRIVER_COMM_FAULT_3 21124 DTC_DRIVER_COMM_FAULT_4 21125 DTC_DRIVER_COMM_FAULT_5 21126 DTC_EPOWER_SYSTEM_FAULT 31127 DTC_FRONT_MAIN_CONTACTOR_DISCONNECT 31128 Power System DTC_BACK_MAIN_CONTACTOR_DISCONNECT 31129 DTC_PUMP_MAIN_CONTACTOR_DISCONNECT...
  • Page 94 Table 6-1 Fault Code list (continuous) Item Fault Code Description 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 14162 DTC_FAULT_LOAD_SENSOR_REDUNDANCY 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 DTC_FAULT_AIR_FILTER_SENSOR 32169 DTC_FAULT_OIL_WATER_SEPARATION_SENSOR 32170 DTC_FAULT_HYDRAULIC_OIL_FILTER_SENSOR 21171 DTC_FAULT_LEFT_FRONT_WHEEL_ANGEL_SENSOR 21172 DTC_FAULT_RIGHT_FRONT_WHEEL_ANGEL_SENSOR 21173 DTC_FAULT_LEFT_REAR_WHEEL_ANGEL_SENSOR 21174...
  • Page 95 Table 6-1 Fault Code list (continuous) Item Fault Code Description 11194 DTC_FAULT_LEFT_FRONT_AXLE_SENSOR 11195 DTC_FAULT_RIGHT_FRONT_AXLE_SENSOR 11196 DTC_FAULT_LEFT_REAR_AXLE_SENSOR 11197 DTC_FAULT_RIGHT_REAR_AXLE_SENSOR 13198 DTC_TOWER_ANGLE_SENSOR_COMM_ERROR 13199 DTC_TOWER_ANGLE_SINGAL_REDUNDANCY 11200 DTC_FAULT_FLOAT_PRESSURE_SENSOR_COMM 11201 DTC_FAULT_FLOAT_VALVE_FAILURE 12202 DTC_SWING_VALVE_STUCKED_MOVEMENT 31203 DTC_FAULT_INSPECT_VALVE_PRESS_SENSOR 13225 Sensor DTC_BOOM_LENGTH_SENSOR_COMM 11226 DTC_INCLINE_SENSOR_REDUNDANCY 13227 DTC_FAULT_TOWER_LENGTH_SENSOR_COMM 13228 DTC_FAULT_TOWER_LENGTH_SENSOR_REDUNDANT 14229 DTC_FAULT_ANTI_COLLISION_SYSTEM_COMM 14230 DTC_FAULT_ANTI_COLLISION_SENSOR_FAULT_1...
  • Page 96 Table 6-1 Fault Code list (continuous) Item Fault Code Description 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 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 Switch/ 24380 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_MEDIUM_OFFSET Handle 24381 DTC_FAULT_PM_DRIVE_JOYSTICK_UP_LIMIT 24382 DTC_FAULT_PM_DRIVE_JOYSTICK_DN_LIMIT 24383...
  • Page 97 Table 6-1 Fault Code list (continuous) Item Fault Code Description 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 DTC_SWING_LEFT_VALVE_SHORT_TO_POWER 22576 DTC_SWING_LEFT_VALVE_OPEN_CIRCUIT 22577 DTC_SWING_RIGHT_VALVE_SHORT_TO_GROUND 22578...
  • Page 98 Table 6-1 Fault Code list (continuous) Item Fault Code Description 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 22650 DTC_SWING_FLOW_VALVE_FEEDBACK_CURRENT_FAULT 23651 DTC_MAIN_LIFT_DN_FLOW_VALVE_SHORT_TO_GROUND 23652 DTC_MAIN_LIFT_DN_FLOW_VALVE_SHORT_TO_POWER 23653 DTC_MAIN_LIFT_DN_FLOW_VALVE_OPEN_CIRCUIT 23654 DTC_MAIN_LIFT_DN_VALVE_SHORT_TO_GROUND 13655 DTC_MAIN_LIFT_DN_VALVE_SHORT_TO_POWER 23656 DTC_MAIN_LIFT_DN_VALVE_OPEN_CIRCUIT 23657 DTC_MAIN_LIFT_DN_VALVE_FEEDBACK_CURRENT_FAULT 24658 DTC_JIB_UNLOAD_VALVE_SHORT_TO_GROUND 24659 DTC_JIB_UNLOAD_VALVE_SHORT_TO_POWER 24660 DTC_JIB_UNLOAD_VALVE_OPEN_CIRCUIT 24661...
  • Page 99 Table 6-1 Fault Code list (continuous) Item Fault Code Description 21681 DTC_LEFT_FRONT_STEER_OUT_VALVE_SHORT_TO_GROUND 11682 DTC_LEFT_FRONT_STEER_OUT_VALVE_SHORT_TO_POWER 21683 DTC_LEFT_FRONT_STEER_OUT_VALVE_OPEN_CIRCUIT 21684 DTC_LEFT_FRONT_STEER_IN_VALVE_SHORT_TO_GROUND 11685 DTC_LEFT_FRONT_STEER_IN_VALVE_SHORT_TO_POWER 21686 DTC_LEFT_FRONT_STEER_IN_VALVE_OPEN_CIRCUIT 21687 DTC_RIGHT_FRONT_STEER_OUT_VALVE_SHORT_TO_GROUND 11688 DTC_RIGHT_FRONT_STEER_OUT_VALVE_SHORT_TO_POWER 21689 DTC_RIGHT_FRONT_STEER_OUT_VALVE_OPEN_CIRCUIT 21690 DTC_RIGHT_FRONT_STEER_IN_VALVE_SHORT_TO_GROUND 11691 DTC_RIGHT_FRONT_STEER_IN_VALVE_SHORT_TO_POWER 21692 DTC_RIGHT_FRONT_STEER_IN_VALVE_OPEN_CIRCUIT 21693 DTC_FRONT_AXLE_OUT_VALVE_SHORT_TO_GROUND 11694 DTC_FRONT_AXLE_OUT_VALVE_SHORT_TO_POWER 21695 DTC_FRONT_AXLE_OUT_VALVE_OPEN_CIRCUIT 21696 DTC_FRONT_AXLE_IN_VALVE_SHORT_TO_GROUND 11697...
  • Page 100 Table 6-1 Fault Code list (continuous) Item Fault Code Description 21717 DTC_LEFT_DRIVE_FWD_VALVE_SHORT_TO_GROUND 11718 DTC_LEFT_DRIVE_FWD_VALVE_SHORT_TO_POWER 21719 DTC_LEFT_DRIVE_FWD_VALVE_OPEN_CIRCUIT 21720 DTC_LEFT_DRIVE_REV_VALVE_SHORT_TO_GROUND 11721 DTC_LEFT_DRIVE_REV_VALVE_SHORT_TO_POWER 21722 DTC_LEFT_DRIVE_REV_VALVE_OPEN_CIRCUIT 21723 DTC_RIGHT_DRIVE_FWD_VALVE_SHORT_TO_GROUND 11724 DTC_RIGHT_DRIVE_FWD_VALVE_SHORT_TO_POWER 21725 DTC_RIGHT_DRIVE_FWD_VALVE_OPEN_CIRCUIT 21726 DTC_RIGHT_DRIVE_REV_VALVE_SHORT_TO_GROUND 11727 DTC_RIGHT_DRIVE_REV_VALVE_SHORT_TO_POWER 21728 DTC_RIGHT_DRIVE_REV_VALVE_OPEN_CIRCUIT 22729 DTC_CHASSIS_FLOW_VALVE_SHORT_TO_GROUND 12730 DTC_CHASSIS_FLOW_VALVE_SHORT_TO_POWER 22731 DTC_CHASSIS_FLOW_VALVE_OPEN_CIRCUIT 22732 DTC_EMG_LIFT_DN_VALVE_SHORT_TO_GROUND 12733...
  • Page 101 Table 6-1 Fault Code list (continuous) Item Fault Code Description 24753 DTC_PM_REVERSE_VALVE_OPEN_CIRCUIT 22754 DTC_PM_CONTROL_VALVE_1_SHORT_TO_GROUND 12755 DTC_PM_CONTROL_VALVE_1_SHORT_TO_POWER 22756 DTC_PM_CONTROL_VALVE_1_OPEN_CIRCUIT 22757 DTC_PM_CONTROL_VALVE_2_SHORT_TO_GROUND 12758 DTC_PM_CONTROL_VALVE_2_SHORT_TO_POWER 22759 DTC_PM_CONTROL_VALVE_2_OPEN_CIRCUIT 22796 DTC_ENGINE_START_SHORT_TO_GROUND 22797 DTC_ENGINE_START_SHORT_TO_POWER 22798 DTC_ENGINE_START_OPEN_CIRCUIT 32799 DTC_ALARM_SHORT_TO_GROUND 32800 DTC_ALARM_SHORT_TO_POWER 32801 DTC_ALARM_OPEN_CIRCUIT 32802 DTC_LIGHT_SHORT_TO_GROUND 32803 DTC_LIGHT_SHORT_TO_POWER 32804 DTC_LIGHT_OPEN_CIRCUIT 12805...
  • Page 102 Table 6-1 Fault Code list (continuous) Item Fault Code Description 14824 DTC_JIB_TELESCOPE_OUT_VALVE_SHORT_TO_POWER 14825 DTC_JIB_TELESCOPE_OUT_VALVE_OPEN_CIRCUIT 14826 DTC_JIB_TELESCOPE_IN_VALVE_SHORT_TO_GROUND 14827 DTC_JIB_TELESCOPE_IN_VALVE_SHORT_TO_POWER 14828 DTC_JIB_TELESCOPE_IN_VALVE_OPEN_CIRCUIT 13829 DTC_LIFT_VALVE_STUCKED_MOVEMENT 13830 DTC_TELESCOPE_VALVE_STUCKED_MOVEMENT 14831 DTC_LEVELING_VALVE_STUCKED_MOVEMENT 12832 DTC_MAIN_LIFT_SAFETY_VALVE_SHORT_TO_GROUND Valve 12833 DTC_MAIN_LIFT_SAFETY_VALVE_SHORT_TO_POWER 12834 DTC_MAIN_LIFT_SAFETY_VALVE_OPEN_CIRCUIT 12835 DTC_MAIN_TELE_SAFETY_VALVE_SHORT_TO_GROUND 12836 DTC_MAIN_TELE_SAFETY_VALVE_SHORT_TO_POWER 12837 DTC_MAIN_TELE_SAFETY_VALVE_OPEN_CIRCUIT 12838 DTC_SWING_SAFETY_VALVE_SHORT_TO_GROUND 12839 DTC_SWING_SAFETY_VALVE_SHORT_TO_POWER...
  • Page 103 Table 6-1 Fault Code list (continuous) Item Fault Code Description 11868 DTC_LEG_EXTENTED 21869 FRONT_WHEEL_STEER_ERROR 21870 REAR_WHEEL_STEER_ERROR 23878 DTC_BOOM_TELESCOPE_CYLINDER_LEAKAGE 23879 DTC_BOOM_LIFT_CYLINDER_LEAKAGE 22880 DTC_SWING_LEFT_VALVE_STUCKED 22881 DTC_SWING_RIGHT_VALVE_STUCKED 21882 DTC_TRANSPORT_DRIVE_WITHOUT_FLOAT 11883 DTC_WORK_POSITION_WITH_FLOAT 31884 DTC_DC_ENBLE_SHORT_TO_GROUND 31885 DTC_DC_ENBLE_SHORT_TO_POWER 31886 DTC_DC_ENBLE_OPEN_CIRCUIT 12887 DTC_CHASIS_CUT_OFF_VALVE_SHORT_TO_GROUND 12888 DTC_CHASIS_CUT_OFF_VALVE_SHORT_TO_POWER 12889 DTC_CHASIS_CUT_OFF_VALVE_OPEN_CIRCUIT 12890 DTC_GROUND_SWITCH_SHORT_TO_POWER 14891...
  • Page 104 Table 6-1 Fault Code list (continuous) Item Fault Code Description 21911 DTC_EMERGENCY_STOP_DRIVE Unit Condition 22951 DTC_CONTROL_READ_PARA_ERROR 1018 DTC_CONTROLLER_OVERCURRENT_1 1019 DTC_CURRENT_SENSOR_FAULT_1 1020 DTC_PRECHARGE_FAILED_1 1021 DTC_CONTROLLER_SEVERE_UNDERTEMP_1 1022 DTC_CONTROLLER_SEVERE_OVERTEMP_1 1023 DTC_SEVERE_UNDERVOLTAGE_1 1024 DTC_SEVERE_OVERVOLTAGE_1 1034 DTC_CONTROLLER_OVERTEMP_CUTBACK_1 1035 DTC_UNDERVOLTAGE_CUTBACK_1 1036 DTC_OVERVOLTAGE_CUTBACK_1 1037 DTC_SUPPLY_5V_FAILURE_1 1038 DTC_DO6_OPEN_OR_SHORT_1 1039 DTC_DO7_OPEN_OR_SHORT_1 1040...
  • Page 105 Table 6-1 Fault Code list (continuous) Item Fault Code Description 1113 DTC_OS_GENERAL_1 1114 DTC_PDO_TIMEOUT_1 1115 DTC_STALL_DETECTED_1 1116 DTC_FAULT_ON_OTHER_TRACTION_CONTROLLER_1 1117 DTC_DUAL_SEVERE_FAULT_1 1119 DTC_SUPERVISOR_FAULT_1 1120 DTC_SUPERVISOR_INCOMPATIBLE_1 1135 DTC_MOTOR_CHARACTERIZATION_FAULT_1 1136 DTC_ENCODER_PULSE_ERROR_1 1137 DTC_MOTOR_TYPE_FAULT_1 1145 DTC_VCL_OS_MISMATCH_1 1146 DTC_EM_BRAKE_FAILED_TO_SET_1 1147 DTC_ENCODER_LOS_1 1148 DTC_EMR_REV_TIMEOUT_1 1152 DTC_ILLEGAL_MODEL_NUMBER_1 1153 DTC_DUALMOTOR_PARAMETER_MISMATCH_1 2018...
  • Page 106 Table 6-1 Fault Code list (continuous) Item Fault Code Description 2054 DTC_ENCODER_FAULT_2 2055 DTC_MOTOR_OPEN_2 2056 DTC_MAIN_CONTACTOR_WELDED_2 2057 DTC_MAIN_CONTACTOR_DID_NOT_CLOSE_2 2065 DTC_THROTTLE_WIPER_HIGH_2 2066 DTC_THROTTLE_WIPER_LOW_2 2067 DTC_POT2_WIPER_HIGH_2 2068 DTC_POT2_WIPER_LOW_2 2069 DTC_POT_LOW_OVERCURRENT_2 2070 DTC_EEPROM_FAILURE_2 2071 DTC_HPD_SEQUENCING_FAULT_2 2073 DTC_PARAMETER_CHANGE_FAULT_2 2104 DTC_VCL_RUN_TIME_ERROR_2 2105 DTC_EXTERNAL_SUPPLY_OUT_OF_RANGE_2 2113 DTC_OS_GENERAL_2 2114 DTC_PDO_TIMEOUT_2 2115...
  • Page 107 Table 6-1 Fault Code list (continuous) Item Fault Code Description 3024 DTC_SEVERE_OVERVOLTAGE_3 3034 DTC_CONTROLLER_OVERTEMP_CUTBACK_3 3035 DTC_UNDERVOLTAGE_CUTBACK_3 3036 DTC_OVERVOLTAGE_CUTBACK_3 3037 DTC_SUPPLY_5V_FAILURE_3 3038 DTC_DO6_OPEN_OR_SHORT_3 3039 DTC_DO7_OPEN_OR_SHORT_3 3040 DTC_MOTOR_TEMP_HOT_CUTBACK_3 3041 DTC_MOTOR_TEMP_SENSOR_FAULT_3 3049 DTC_MAIN_OPEN_SHORT_3 3050 DTC_EMBRAKE_OPEN_SHORT_3 3051 DTC_COIL3_DRIVER_OPEN_SHORT_3 3052 DTC_COIL4_DRIVER_OPEN_SHORT_3 3053 DTC_PD_OPEN_SHORT_3 3054 DTC_ENCODER_FAULT_3 3055 DTC_MOTOR_OPEN_3 3056...
  • Page 108 Table 6-1 Fault Code list (continuous) Item Fault Code Description 3136 DTC_ENCODER_PULSE_ERROR_3 3137 DTC_MOTOR_TYPE_FAULT_3 3145 DTC_VCL_OS_MISMATCH_3 3146 DTC_EM_BRAKE_FAILED_TO_SET_3 3147 DTC_ENCODER_LOS_3 3148 DTC_EMR_REV_TIMEOUT_3 3152 DTC_ILLEGAL_MODEL_NUMBER_3 3153 DTC_DUALMOTOR_PARAMETER_MISMATCH_3 4018 DTC_CONTROLLER_OVERCURRENT_4 4019 DTC_CURRENT_SENSOR_FAULT_4 4020 DTC_PRECHARGE_FAILED_4 4021 DTC_CONTROLLER_SEVERE_UNDERTEMP_4 4022 DTC_CONTROLLER_SEVERE_OVERTEMP_4 4023 DTC_SEVERE_UNDERVOLTAGE_4 4024 DTC_SEVERE_OVERVOLTAGE_4 4034 DTC_CONTROLLER_OVERTEMP_CUTBACK_4 4035...
  • Page 109 Table 6-1 Fault Code list (continuous) Item Fault Code Description 4069 DTC_POT_LOW_OVERCURRENT_4 4070 DTC_EEPROM_FAILURE_4 4071 DTC_HPD_SEQUENCING_FAULT_4 4073 DTC_PARAMETER_CHANGE_FAULT_4 4104 DTC_VCL_RUN_TIME_ERROR_4 4105 DTC_EXTERNAL_SUPPLY_OUT_OF_RANGE_4 4113 DTC_OS_GENERAL_4 4114 DTC_PDO_TIMEOUT_4 4115 DTC_STALL_DETECTED_4 4116 DTC_FAULT_ON_OTHER_TRACTION_CONTROLLER_4 4117 DTC_DUAL_SEVERE_FAULT_4 4119 DTC_SUPERVISOR_FAULT_4 4120 DTC_SUPERVISOR_INCOMPATIBLE_4 4135 DTC_MOTOR_CHARACTERIZATION_FAULT_4 4136 DTC_ENCODER_PULSE_ERROR_4 4137 DTC_MOTOR_TYPE_FAULT_4 4145...
  • Page 110 Table 6-1 Fault Code list (continuous) Item Fault Code Description 5041 DTC_MOTOR_TEMP_SENSOR_FAULT_5 5049 DTC_MAIN_OPEN_SHORT_5 5050 DTC_EMBRAKE_OPEN_SHORT_5 5051 DTC_COIL3_DRIVER_OPEN_SHORT_5 5052 DTC_COIL4_DRIVER_OPEN_SHORT_5 5053 DTC_PD_OPEN_SHORT_5 5054 DTC_ENCODER_FAULT_5 5055 DTC_MOTOR_OPEN_5 5056 DTC_MAIN_CONTACTOR_WELDED_5 5057 DTC_MAIN_CONTACTOR_DID_NOT_CLOSE_5 5065 DTC_THROTTLE_WIPER_HIGH_5 5066 DTC_THROTTLE_WIPER_LOW_5 5067 DTC_POT2_WIPER_HIGH_5 5068 DTC_POT2_WIPER_LOW_5 5069 DTC_POT_LOW_OVERCURRENT_5 5070 DTC_EEPROM_FAILURE_5 5071...

  • Page 111: Common Faults And Solutions

    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 115: General Introduction

    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 116: Range

    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). k = thousand = 1,000 * (displayed number). m = milli = (displayed number) /1,000. μ= micro = (displayed number) /1,000,000.

  • Page 117: Conduction Test

    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 118: 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 119: 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 120: Hd30/Hdp20 Series Connector Removal

    Push the contacts straight into the retaining ring until they are obstructed. Pull gently to confirm that the connector is fully locked. Locking fingers Contact Unlocked position Contact locked in position 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 121: Electrical Schematics

    7.4 Electrical Schematics Figure 7-11 Electrical Schematics (CE) 1/11 7- 7...
  • Page 122 Figure 7-12 Electrical Schematics (GB) 2/11 7- 8...
  • Page 123 Figure 7-13 Electrical Schematics 3/11 7- 9...
  • Page 124 Figure 7-14 Electrical Schematics 4/11 7- 10...
  • Page 125 Figure 7-15 Electrical Schematics 5/11 7- 11...
  • Page 126 Figure 7-16 Electrical Schematics 6/11 7- 12...
  • Page 127 Figure 7-17 Electrical Schematics 7/11 7- 13...
  • Page 128 Figure 7-18 Electrical Schematics 8/11 7- 14...
  • Page 129 Figure 7-19 Electrical Schematics 9/11 7- 15...
  • Page 130 Figure 7-20 Electrical Schematics 10/11 7- 16...
  • Page 131 Figure 7-21 Electrical Schematics 11/11 7- 17...

  • Page 132: Hydraulic Schematics

    7.5 Hydraulic Schematics Figure 7-23 Hydraulic Schematics 7- 18...
  • Page 133 Add:701 Xulong Nan Lu, Xiangjiang New District, Changsha, Hunan. 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.

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