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Zoomlion ZT22JE Service And Maintenance Manual

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Foreword
This Service and Maintenance Manual applies to the ZT22JE 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. 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 Intelligent Access
Machinery Co., Ltd. does not take the consequence for wrong maintenance.
Users should give top priority to Safety! 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 mobile elevated 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:
I
用户 00757092

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Summary of Contents for Zoomlion ZT22JE

  • Page 1 Foreword This Service and Maintenance Manual applies to the ZT22JE 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 2: 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 3: 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 4: Content

    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 Bearings ........................
  • Page 5 Contents 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 ..................... 4-3 4.2.2 Swing axle lock test .....................
  • Page 6 Contents 5.2.3 Lifting cylinder ......................5-6 5.2.4 Boom ........................... 5-7 5.2.5 Linkage ........................5-10 5.2.6 Telescopic cylinder ....................5-12 5.2.7 Wire rope pulley disassembly ..................5-14 5.3 Load Cell Check........................5-18 5.3.1 Load Cell Check ......................5-18 5.3.2 Platform leveling sensor check .................. 5-19 5.3.3 Boom Tilt Sensor Check ....................
  • Page 7 Contents 7.3.4 HD30/HDP20 Series Connector Removal ..............7-6 7.4 Electrical Schematics ......................7-7 7.5 Hydraulic Schematics ......................7-17 用户 00757092...
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  • Page 11: 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 12: 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 13: 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 14 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 15 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 16 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 17 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.
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  • Page 21: Section 2 Technical Parameters

    SECTION 2 TECHNICAL PARAMETERS 2.1 Performance Table 2-1 Performance Platform Capacity 300/ 454kg 30% (platform uphill) Max Travel Speed (on slope) 45% (platform downhill) Max Travel Speed (on side slope) Platform Height 22.4m Horizontal Outreach 17.9m 5.58m (outside) Turning Radius 2.72m (inside) Max Travel Speed 5.5km/h...

  • Page 22: Capacity

    Rating 8km/h 0km/h wheel) 355/55D-625 Foam-filled 5600 kg 7300 kg 200±5 kg 2.5 Functional Speed Table 2-5 Functional speed Function ZT22JE Boom Lifting 75~95s Boom Descending 80~100s Turntable Swing (a round) 120~150s Boom Extending 60~80s Boom Retracting 60~80s Platform Rotation...

  • Page 23: Test Cautions

    Drive (stowed): choose a smooth ground with the main boom less than 7 ° and the extension length less than 1m. Adjust the speed switch to high speed. Record the time of forward/reverse through 100m. Drive (working): choose a smooth ground with the main boom larger than 7 ° and the extension length greater than 1m.

  • Page 24: Lubrication

    Table 2-7 Special toque Requirements Instruction: Torque value (N.m) Time intervals 50 hours after the first run, every 150 hours or 3 Hub fastening bolt M20 months thereafter 100 hours after the first run, every 500 hours Slew bearing bolt M20 thereafter Slew reducer connecting 100 hours after the first run, every 500 hours...
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  • 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

    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 30: 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 31 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 32: 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 33 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 34: Hydraulic Tank And Hydraulic Oil

    The filter at the filler port of the hydraulic oil tank cannot be removed because of the need to increase the refueling speed; Operators should use clean gloves and work clothes; The cleaning oil of the hydraulic system must use the same type of hydraulic oil used in the system.
  • Page 35 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 36 Breather plug Maintenance point- breather plug of tank Time interval- first 50 hrs after usage, every 2 months or 500 hrs 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 37 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 38 pressure) Mobil SHC Aware H 32 185/ (Environmental friendly) Chevron (Clarity Synthetic EA Hydraulic Oil) Mobil DTE 10 Ultra 22 22.4 Mobil DTE 10 Ultra 32 32.7 Mobil DTE 10 Ultra 46 45.6 Chevron/Caltex Rando HDZ 15 15.7 Chevron/Caltex Rando HDZ 32 Chevron/Caltex Rando HDZ 46 46.7 Chevron/Caltex Rando MV 15...

  • Page 39: Hydraulic System Exhaust

    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 40: Check Hydraulic Hose

    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 41 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 42: 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: ① Avoid overheated surfaces and sharp edges; Avoid friction with components; ② There must be enough free length for bending activities. ③...

  • Page 43: 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 44: 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 45 Door Floor Rotary motor Lanyard anchorage point 1,2,10 1,2,10 Turntable assembly Swing bearing or worm gear 1,2,14 1,2,3,13,14 Swivel joint Turntable drive system Turntable pin 1,2,5 1,2,5 Hood, hood props and hood 1,2,5 latches Chassis assembly Tire 16.17 16,17,18 16,17,18 Wheel nuts/screw Wheel bearing 14,24...
  • Page 46 All system functional test 21, 22 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 47 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...
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  • Page 51: 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 52: 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 53: 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 540 Nm/398ftlb...

  • Page 54: 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 55: Auxiliary Power System

    value of the tilt sensor is 5° according to the manufacturer default settings. 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 56: Traveling Drive System

    Locknut Washer Float cylinder 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.
  • Page 57 Tire Travel reducer Locknut Figure 4-5 Travel system disassembly diagram 1 Figure 4-6 Travel system disassembly diagram 2 Locknut 2. Tire 3. Traveling reducer 4. Steering knuckle 5. Axle end dam-board 6. Pin 7. Gasket 8. Bearing 9. Lower cover plate 10. Pin 11. Bearing 12. Pin 13. Bearing 14. Steering linkage welds 15.

  • Page 58: Travel Reducer

    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 59: Rotary Reducer

    4.9 Rotary reducer 4.9.1 Check and maintenance Please clean the inside of the reducer and brake with cleaning fluid after 100 hours usage, and replace the oil. Change the oil once every 2000 hours running, or at least once a year; 1.

  • Page 60: 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 61: 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 62: 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 63 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.
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  • Page 67: 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 Platform assembly Transition seat Platform rotary cylinder Stop pin Load cell Tray Stop pin Figure 5-1 Load cell disassembly diagram a） 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 68: Rotary Actuator

    5.1.1.2 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. 5.1.1.2 Installation Follow the reverse steps of disassembly.

  • Page 69: Jib Lifting Cylinder

    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 pipes joint equipped with a sealing device needs to replace a sealing device before the hydraulic line is connected.

  • Page 70: Boom Assembly

    5.2 Boom Assembly Extrusion hazard. If the lifting equipment fails to securely fix the removed parts, the disassembled parts may fall and cause personal injury and equipment damage. When removing, keep personnel away from the area near the boom. 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 71: Leveling Cylinder

    Inspect all threaded parts for damage such as stretching, thread deformation or distortion and replace if necessary. Check the cable structure for bending, cracking, weld separation or other damage and replace the cable structure if necessary. 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.

  • Page 72: Lifting Cylinder

    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 73: 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 4 is completely exposed and in a position that is easy to disassemble.
  • Page 74 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 75 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. Lifting cylinder Boom Pin 2 Upright Pin 1 Joint 2 Pin 3 Upper linkage Joint 3 Turntable Pin 5...

  • Page 76: Linkage

    the boom assembly from the turntable and place it on a suitable support. 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.
  • Page 77 Upright Pin 2 Boom Lifting cylinder Pin 1 Joint 2 Pin 3 Upper linkage Joint 3 Pin 5 Pin 4 Lower linkage Joint 1 Pin 6 a) Remove the hood from the turntable; use a suitable spreader to remove the counterweight from the turntable, the counterweight weighs 5.5t;...

  • Page 78: Telescopic Cylinder

    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. 5.2.4.3 Installation Follow the reverse steps of disassembly.
  • Page 79 assembly on the mounting plate. Use a suitable tool to remove nut 1 to loose the boom retracting wire rope. Use a suitable tool to loosen nut 3, but do not remove nut 3. Remove the cover plate on the side of the base boom end to expose the process hole and pressing plate 3.

  • Page 80: Wire Rope Pulley Disassembly

    Use lifting equipment to support the two ends of the telescopic oil cylinder, and slowly move the telescopic oil cylinder to a suitable support frame. 5.2.6.2 Inspection Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if necessary.
  • Page 81 Remove the bolt 3 and bolt 4, and remove the roller bracket and pulley cover 1. Retracting wire rope 缩臂钢丝绳 Retractable boom pulley 缩臂滑轮 工艺孔 Processing hole 缩臂钢丝绳绳头 Retractable wire rope head 滑轮罩2 螺栓6 螺栓7 销轴3 Pulley cover 2 Bolt 6 Pin 3 Bolt 7 Figure 5-10 Wire rope pulley disassembly diagram...
  • Page 82 Inspect all pulleys for excessive wear, grooves, burrs, or other damage. Use a groove abrasion meter to check whether the pulley is excessively worn, replace pulley if necessary. Check all threaded parts for damage such as stretching, thread deformation or twisting, and replace them if necessary;...
  • Page 83 5.2.8.4 Additional replacement criteria Pulleys and wire ropes must be replaced in sets. Wire rope is rusted or corroded. Wire rope tangled, "knotted" or wrinkled. The adjustment of the steel wire rope has reached the limit adjustment range and cannot be adjusted further.

  • Page 84: Load Cell Check

    Figure 5-13 Clamping the rope 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.

  • Page 85: Platform Leveling Sensor Check

    5） Platform level-level to 0 °. 6） Platform Rotation-Rotate to 0 °. 7） Load in platform-remove all load items. 8） The machine is on a hard, level surface. b） Start the ground and platform emergency stop switches and turn the key switch to the platform position.

  • Page 86: Calibration Of Boom Length Sensor

    c） Use an angle tester to measure the boom angle to zero degrees and calibrate the zero position of the boom angle sensor. d） Confirm that the angle of the boom on the display is zero degrees. e） Ground mode operates the boom lifting function, and the boom angle value on the display changes. f）...
  • Page 87 e） Raise the boom beyond the stowed position (the boom lifting angle exceeds 7 °). f） Operate the travel function, at this time the two-speed valve will be closed, and the high-speed travel function cannot be enabled. g） Operate the boom to retract to the stowed position, and lower the boom to the stowed position. h）...
  • Page 89 履带起重机操作手册 第一章 安全操作说明 用户 00757092 用户 00757092...
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  • 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 DTC_HIGH_CHARGING_CURRENT_LEVEL1 31079 DTC_HIGH_CHARGING_CURRENT_LEVEL2 21080 DTC_HIGH_DISCHARGING_CURRENT_LEVEL1 31081 DTC_HIGH_DISCHARGING_CURRENT_LEVEL2 21082 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 DTC_LOW_CONSISTENCY_LEVEL2 21090 DTC_HIGH_DIFFERENCE_IN_TEMP_LEVEL1 31091 DTC_HIGH_DIFFERENCE_IN_TEMP_LEVEL2 21092 DTC_LOW_DISCHARGING_TEMP_LEVEL1 31093 DTC_LOW_DISCHARGING_TEMP_LEVEL2 21094 DTC_LOW_CHARGING_TEMP_LEVEL1...
  • Page 93 Table 6-1 Fault Code list (continuous) Item Fault Code Description DTC_MAIN_MOS_SHORT_CIRCUIT 21115 DTC_MAIN_MOS_VOLTAGE_FAULT 21116 DTC_ARST_MOS_OPEN_CIRCUIT 21117 DTC_ARST_MOS_SHORT_CIRCUIT 21118 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 DTC_EPOWER_SYSTEM_FAULT 21126 DTC_FRONT_MAIN_CONTACTOR_DISCONNECT 31127 DTC_BACK_MAIN_CONTACTOR_DISCONNECT Power System 31128 DTC_PUMP_MAIN_CONTACTOR_DISCONNECT 31129 DTC_MOTOR_BRAKE_CLOSE_FAULT_1...
  • Page 94 Table 6-1 Fault Code list (continuous) Item Fault Code Description 22161 DTC_FAULT_SWING_SENSOR DTC_FAULT_LOAD_SENSOR_REDUNDANCY 14162 13163 DTC_BOOM_ANGLE_SINGAL_REDUNDANCY DTC_FAULT_LOAD_SENSOR_OUT_RANGE 14175 31176 DTC_FAULT_STEER_SENSOR_NO_RESPOND 31177 DTC_FAULT_STEER_SENSOR_PARA DTC_FAULT_LIFT_BIG_PRESS_SENSOR 13178 13179 DTC_FAULT_LIFT_LITTLE_PRESS_SENSOR DTC_FAULT_TELE_BIG_PRESS_SENSOR 13180 13181 DTC_FAULT_TELE_LITTLE_PRESS_SENSOR DTC_FAULT_MAIN_VALVE_PRESS_SENSOR 12182 13183 DTC_FAULT_JIB_PROXIMATE_SENSOR1 DTC_FAULT_JIB_PROXIMATE_SENSOR2 13184 14185 DTC_FAULT_WIND_SPEED_SENSOR DTC_FAULT_JIB_LIFT_LENGTH_SENSOR 14186 Sensor 14187 DTC_FAULT_PM_LEVLE_LENGTH_SENSOR...
  • Page 95 Table 6-1 Fault Code list (continuous) Item Fault Code Description 12354 DTC_FAULT_UG_TOWER_LIFT_SWITCH_DOUBLE_POWER_ON DTC_FAULT_UG_JIB_SWITCH_DOUBLE_POWER_ON 12355 12356 DTC_FAULT_UG_TELESCOPE_DOUBLE_POWER_ON DTC_FAULT_UG_ROTATE_SWITCH_DOUBLE_POWER_ON 22357 12358 DTC_FAULT_UG_LEVELING_SWITCH_DOUBLE_POWER_ON 22359 DTC_FAULT_UG_SWING_SWITCH_DOUBLE_POWER_ON DTC_FAULT_UG_ENGINE_SWITCH_DOUBLE_POWER_ON 22360 14361 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_DOUBLE_POWER_ON DTC_FAULT_PM_TOWER_LIFT_SWITCH_DOUBLE_POWER_ON 14362 14363 DTC_FAULT_PM_JIB_SWITCH_DOUBLE_POWER_ON DTC_FAULT_PM_TELESCOPE_DOUBLE_POWER_ON 14364 24365 DTC_FAULT_PM_ROTATE_SWITCH_DOUBLE_POWER_ON DTC_FAULT_PM_LEVELING_SWITCH_DOUBLE_POWER_ON 14366 24367 DTC_FAULT_PM_SWING_JOYSTICK_DOUBLE_POWER_ON DTC_FAULT_PM_ENGINE_SWITCH_DOUBLE_POWER_ON 24368 14369 DTC_FAULT_PM_DRIVE_JOYSTICK_DOUBLE_POWER_ON DTC_FAULT_PM_STEER_JOYSTICK_DOUBLE_POWER_ON...
  • Page 96 Table 6-1 Fault Code list (continuous) Item Fault Code Description 12390 DTC_FAULT_UG_JIB_SWING_SWITCH_DOUBLE_POWER_ON DTC_FAULT_PM_JIB_SWING_SWITCH_DOUBLE_POWER_ON Switch/ 14391 Handle 12392 DTC_FAULT_UG_JIB_TELESCOPE_SWITCH_DOUBLE_POWER_ON DTC_FAULT_PM_JIB_TELESCOPE_SWITCH_DOUBLE_POWER_ON 14393 12552 DTC_DRIVE_FORWARD_VALVE_SHORT_TO_POWER 22553 DTC_DRIVE_FORWARD_VALVE_OPEN_CIRCUIT DTC_DRIVE_REVERSE_VALVE_SHORT_TO_GROUND 22554 12555 DTC_DRIVE_REVERSE_VALVE_SHORT_TO_POWE DTC_DRIVE_REVERSE_VALVE_OPEN_CIRCUIT 22556 22557 DTC_DRIVE_FORWARD_VALVE_FEEDBACK_CURRENT_FAULT DTC_DRIVE_REVERSE_VALVE_FEEDBACK_CURRENT_FAULT 22558 21559 DTC_FLOAT_CONTROL_VALVE_SHORT_TO_GROUND DTC_FLOAT_CONTROL_VALVE_SHORT_TO_POWER 21560 21561 DTC_FLOAT_CONTROL_VALVE_OPEN_CIRCUIT DTC_BRAKE_VALVE_SHORT_TO_GROUND 21562 11563...
  • Page 97 Table 6-1 Fault Code list (continuous) Item Fault Code Description 22624 DTC_JIB_FLOW_VALVE_SHORT_TO_GROUND DTC_JIB_FLOW_VALVE_SHORT_TO_POWER 22625 22626 DTC_JIB_FLOW_VALVE_OPEN_CIRCUIT DTC_MAIN_LIFT_UP_FLOW_VALVE_SHORT_TO_GROUND 22627 22628 DTC_MAIN_LIFT_UP_FLOW_VALVE_SHORT_TO_POWER 22629 DTC_MAIN_LIFT_UP_FLOW_VALVE_OPEN_CIRCUIT DTC_MAIN_LIFT_UP_VALVE_SHORT_TO_GROUND 22633 12634 DTC_MAIN_LIFT_UP_VALVE_SHORT_TO_POWER DTC_MAIN_LIFT_UP_VALVE_OPEN_CIRCUIT 22635 22636 DTC_MAIN_LIFT_UP_VALVE_FEEDBACK_CURRENT_FAULT DTC_TELESCOPE_FLOW_VALVE_SHORT_TO_GROUND 22637 22638 DTC_TELESCOPE_FLOW_VALVE_SHORT_TO_POWER DTC_TELESCOPE_FLOW_VALVE_OPEN_CIRCUIT 22639 22640 DTC_TELESCOPE_FLOW_VALVE_FEEDBACK_CURRENT_FAULT DTC_TELESCOPE_IN_VALVE_SHORT_TO_GROUND 22641 12642 DTC_TELESCOPE_IN_VALVE_SHORT_TO_POWER DTC_TELESCOPE_IN_VALVE_OPEN_CIRCUIT...
  • Page 98 Table 6-1 Fault Code list (continuous) Item Fault Code Description 24663 DTC_PM_ROTATE_LEFT_VALVE_OPEN_CIRCUIT DTC_PM_ROTATE_RIGHT_VALVE_SHORT_TO_GROUND 24664 24665 DTC_PM_ROTATE_RIGHT_VALVE_SHORT_TO_POWER DTC_PM_ROTATE_RIGHT_VALVE_OPEN_CIRCUIT 24666 24667 DTC_PM_LEVELING_UP_VALVE_SHORT_TO_GROUND 14668 DTC_PM_LEVELING_UP_VALVE_SHORT_TO_POWER DTC_PM_LEVELING_UP_VALVE_OPEN_CIRCUIT 24669 24670 DTC_PM_LEVELING_DN_VALVE_SHORT_TO_GROUND DTC_PM_LEVELING_DN_VALVE_SHORT_TO_POWER 14671 24672 DTC_PM_LEVELING_DN_VALVE_OPEN_CIRCUIT DTC_PM_LEVELING_UP_VALVE_FEEDBACK_CURRENT_FAULT 24673 24674 DTC_PM_LEVELING_DN_VALVE_FEEDBACK_CURRENT_FAULT DTC_JIB_UP_VALVE_SHORT_TO_GROUND 24675 14676 DTC_JIB_UP_VALVE_SHORT_TO_POWER DTC_JIB_UP_VALVE_OPEN_CIRCUIT 24677 24678 DTC_JIB_DN_VALVE_SHORT_TO_GROUND DTC_JIB_DN_VALVE_SHORT_TO_POWER...
  • Page 99 Table 6-1 Fault Code list (continuous) Item Fault Code Description 21699 DTC_LEFT_REAR_STEER_OUT_VALVE_SHORT_TO_GROUND DTC_LEFT_REAR_STEER_OUT_VALVE_SHORT_TO_POWER 11700 21701 DTC_LEFT_REAR_STEER_OUT_VALVE_OPEN_CIRCUIT DTC_LEFT_REAR_STEER_IN_VALVE_SHORT_TO_GROUND 21702 11703 DTC_LEFT_REAR_STEER_IN_VALVE_SHORT_TO_POWER 21704 DTC_LEFT_REAR_STEER_IN_VALVE_OPEN_CIRCUIT DTC_RIGHT_REAR_STEER_OUT_VALVE_SHORT_TO_GROUND 21705 11706 DTC_RIGHT_REAR_STEER_OUT_VALVE_SHORT_TO_POWER DTC_RIGHT_REAR_STEER_OUT_VALVE_OPEN_CIRCUIT 21707 21708 DTC_RIGHT_REAR_STEER_IN_VALVE_SHORT_TO_GROUND DTC_RIGHT_REAR_STEER_IN_VALVE_SHORT_TO_POWER 11709 21710 DTC_RIGHT_REAR_STEER_IN_VALVE_OPEN_CIRCUIT DTC_REAR_AXLE_OUT_VALVE_SHORT_TO_GROUND 21711 11712 DTC_REAR_AXLE_OUT_VALVE_SHORT_TO_POWER DTC_REAR_AXLE_OUT_VALVE_OPEN_CIRCUIT 21713 21714 DTC_REAR_AXLE_IN_VALVE_SHORT_TO_GROUND DTC_REAR_AXLE_IN_VALVE_SHORT_TO_POWER...
  • Page 100 Table 6-1 Fault Code list (continuous) Item Fault Code Description 22735 DTC_PM_FLOW_VALVE_SHORT_TO_GROUND DTC_PM_FLOW_VALVE_SHORT_TO_POWER 12736 22737 DTC_PM_FLOW_VALVE_OPEN_CIRCUIT DTC_DUMP_VALVE_SHORT_TO_GROUND 22738 12739 DTC_DUMP_VALVE_SHORT_TO_POWER 22740 DTC_DUMP_VALVE_OPEN_CIRCUIT DTC_BOOM_UP_VALVE_STUCKED 22741 22742 DTC_BOOM_DN_VALVE_STUCKED DTC_LEVEL_UP_VALVE_STUCKED 24743 24744 DTC_LEVEL_DN_VALVE_STUCKED DTC_FRONT_LEG_VALVE_SHORT_TO_GROUND 21745 11746 DTC_FRONT_LEG_VALVE_SHORT_TO_POWER DTC_FRONT_LEG_VALVE_OPEN_CIRCUIT 21747 21748 DTC_REAR_LEG_VALVE_SHORT_TO_GROUND DTC_REAR_LEG_VALVE_SHORT_TO_POWER 11749 21750 DTC_REAR_LEG_VALVE_OPEN_CIRCUIT DTC_PM_REVERSE_VALVE_SHORT_TO_GROUND...
  • Page 101 Table 6-1 Fault Code list (continuous) Item Fault Code Description 12807 DTC_GROUND_SW_POWER_OPEN_CIRCUIT DTC_AUX_POWER_SHORT_TO_GROUND 12808 12809 DTC_AUX_POWER_SHORT_TO_POWER DTC_AUX_POWER_OPEN_CIRCUIT 12810 34811 DTC_PM_BUZZER_SHORT_TO_GROUND 34812 DTC_PM_BUZZER_SHORT_TO_POWER DTC_PM_BUZZER_OPEN_CIRCUIT 34813 14814 DTC_PLATFORM_SW_POWER_SHORT_TO_GROUND DTC_PLATFORM_SW_POWER_SHORT_TO_POWER 14815 14816 DTC_PLATFORM_SW_POWER_OPEN_CIRCUIT DTC_JIB_LEFT_VALVE_SHORT_TO_GROUND 14817 14818 DTC_JIB_LEFT_VALVE_SHORT_TO_POWER DTC_JIB_LEFT_VALVE_OPEN_CIRCUIT 14819 14820 DTC_JIB_RIGHT_VALVE_SHORT_TO_GROUND DTC_JIB_RIGHT_VALVE_SHORT_TO_POWER 14821 14822 DTC_JIB_RIGHT_VALVE_OPEN_CIRCUIT DTC_JIB_TELESCOPE_OUT_VALVE_SHORT_TO_GROUND...
  • Page 102 Table 6-1 Fault Code list (continuous) Item Fault Code Description 33851 DTC_STEEL_WIRE_ROPE_LOOSE DTC_DRIVE_DIRECTION_REVERSE 41852 24853 DTC_OVER_LOAD DTC_RESTRICT_OR_UNRESTRICT 23854 24855 DTC_LEVELING_FAULT 23856 DTC_SHORT_ROPE_FAULT DTC_MAIN_LIFT_CONTROL_SYSTEM_FAULT 23857 41858 DTC_LOWER_SPEED_FAULT DTC_SYSTEM_FAULT 32859 34860 DTC_SOFT_TOUCH_FAULT DTC_ALTERNATOR_FAULT 32861 32862 DTC_GLOW_PLUG_FAULT DTC_TILT_FAULT 12863 32864 DTC_LOW_FUEL_FAULT DTC_ANTI_CRUSH_ALARM 14865 12866 DTC_SYSTEM_INITIAL_FAULT DTC_INH_FAULT...
  • Page 103 Table 6-1 Fault Code list (continuous) Item Fault Code Description 1018 DTC_CONTROLLER_OVERCURRENT_1 DTC_CURRENT_SENSOR_FAULT_1 1019 1020 DTC_PRECHARGE_FAILED_1 DTC_CONTROLLER_SEVERE_UNDERTEMP_1 1021 1022 DTC_CONTROLLER_SEVERE_OVERTEMP_1 1023 DTC_SEVERE_UNDERVOLTAGE_1 DTC_SEVERE_OVERVOLTAGE_1 1024 1034 DTC_CONTROLLER_OVERTEMP_CUTBACK_1 DTC_UNDERVOLTAGE_CUTBACK_1 1035 1036 DTC_OVERVOLTAGE_CUTBACK_1 DTC_SUPPLY_5V_FAILURE_1 1037 1038 DTC_DO6_OPEN_OR_SHORT_1 DTC_DO7_OPEN_OR_SHORT_1 1039 1040 DTC_MOTOR_TEMP_HOT_CUTBACK_1 DTC_MOTOR_TEMP_SENSOR_FAULT_1 1041 1049 DTC_MAIN_OPEN_SHORT_1 DTC_EMBRAKE_OPEN_SHORT_1...
  • Page 104 Table 6-1 Fault Code list (continuous) Item Fault Code Description 1105 DTC_EXTERNAL_SUPPLY_OUT_OF_RANGE_1 DTC_OS_GENERAL_1 1113 1114 DTC_PDO_TIMEOUT_1 DTC_STALL_DETECTED_1 1115 1116 DTC_FAULT_ON_OTHER_TRACTION_CONTROLLER_1 1117 DTC_DUAL_SEVERE_FAULT_1 DTC_SUPERVISOR_FAULT_1 1119 1120 DTC_SUPERVISOR_INCOMPATIBLE_1 DTC_MOTOR_CHARACTERIZATION_FAULT_1 1135 1136 DTC_ENCODER_PULSE_ERROR_1 DTC_MOTOR_TYPE_FAULT_1 1137 1145 DTC_VCL_OS_MISMATCH_1 DTC_EM_BRAKE_FAILED_TO_SET_1 1146 1147 DTC_ENCODER_LOS_1 DTC_EMR_REV_TIMEOUT_1 Driver 1148 1152 DTC_ILLEGAL_MODEL_NUMBER_1...
  • Page 105 Table 6-1 Fault Code list (continuous) Item Fault Code Description 2038 DTC_DO6_OPEN_OR_SHORT_2 DTC_DO7_OPEN_OR_SHORT_2 2039 2040 DTC_MOTOR_TEMP_HOT_CUTBACK_2 DTC_MOTOR_TEMP_SENSOR_FAULT_2 2041 2049 DTC_MAIN_OPEN_SHORT_2 2050 DTC_EMBRAKE_OPEN_SHORT_2 DTC_COIL3_DRIVER_OPEN_SHORT_2 2051 2052 DTC_COIL4_DRIVER_OPEN_SHORT_2 DTC_PD_OPEN_SHORT_2 2053 2054 DTC_ENCODER_FAULT_2 DTC_MOTOR_OPEN_2 2055 2056 DTC_MAIN_CONTACTOR_WELDED_2 DTC_MAIN_CONTACTOR_DID_NOT_CLOSE_2 2057 2065 DTC_THROTTLE_WIPER_HIGH_2 DTC_THROTTLE_WIPER_LOW_2 2066 2067 DTC_POT2_WIPER_HIGH_2 DTC_POT2_WIPER_LOW_2...
  • Page 106 Table 6-1 Fault Code list (continuous) Item Fault Code Description 2148 DTC_EMR_REV_TIMEOUT_2 DTC_ILLEGAL_MODEL_NUMBER_2 2152 2153 DTC_DUALMOTOR_PARAMETER_MISMATCH_2 DTC_COMMUNICATION_TIMEOUT_2 2084 3018 DTC_CONTROLLER_OVERCURRENT_3 3019 DTC_CURRENT_SENSOR_FAULT_3 DTC_PRECHARGE_FAILED_3 3020 3021 DTC_CONTROLLER_SEVERE_UNDERTEMP_3 DTC_CONTROLLER_SEVERE_OVERTEMP_3 3022 3023 DTC_SEVERE_UNDERVOLTAGE_3 DTC_SEVERE_OVERVOLTAGE_3 3024 3034 DTC_CONTROLLER_OVERTEMP_CUTBACK_3 DTC_UNDERVOLTAGE_CUTBACK_3 3035 3036 DTC_OVERVOLTAGE_CUTBACK_3 DTC_SUPPLY_5V_FAILURE_3 3037 3038 DTC_DO6_OPEN_OR_SHORT_3 DTC_DO7_OPEN_OR_SHORT_3...
  • Page 107 Table 6-1 Fault Code list (continuous) Item Fault Code Description 3070 DTC_EEPROM_FAILURE_3 DTC_HPD_SEQUENCING_FAULT_3 3071 3073 DTC_PARAMETER_CHANGE_FAULT_3 DTC_VCL_RUN_TIME_ERROR_3 3104 3105 DTC_EXTERNAL_SUPPLY_OUT_OF_RANGE_3 3113 DTC_OS_GENERAL_3 DTC_PDO_TIMEOUT_3 3114 3115 DTC_STALL_DETECTED_3 DTC_FAULT_ON_OTHER_TRACTION_CONTROLLER_3 3116 3117 DTC_DUAL_SEVERE_FAULT_3 DTC_SUPERVISOR_FAULT_3 3119 3120 DTC_SUPERVISOR_INCOMPATIBLE_3 DTC_MOTOR_CHARACTERIZATION_FAULT_3 3135 3136 DTC_ENCODER_PULSE_ERROR_3 DTC_MOTOR_TYPE_FAULT_3 3137 3145 DTC_VCL_OS_MISMATCH_3 DTC_EM_BRAKE_FAILED_TO_SET_3...
  • Page 108 Table 6-1 Fault Code list (continuous) Item Fault Code Description 4049 DTC_MAIN_OPEN_SHORT_4 DTC_EMBRAKE_OPEN_SHORT_4 4050 4051 DTC_COIL3_DRIVER_OPEN_SHORT_4 DTC_COIL4_DRIVER_OPEN_SHORT_4 4052 4053 DTC_PD_OPEN_SHORT_4 4054 DTC_ENCODER_FAULT_4 DTC_MOTOR_OPEN_4 4055 4056 DTC_MAIN_CONTACTOR_WELDED_4 DTC_MAIN_CONTACTOR_DID_NOT_CLOSE_4 4057 4065 DTC_THROTTLE_WIPER_HIGH_4 DTC_THROTTLE_WIPER_LOW_4 4066 4067 DTC_POT2_WIPER_HIGH_4 DTC_POT2_WIPER_LOW_4 4068 4069 DTC_POT_LOW_OVERCURRENT_4 DTC_EEPROM_FAILURE_4 4070 4071 DTC_HPD_SEQUENCING_FAULT_4 DTC_PARAMETER_CHANGE_FAULT_4...
  • Page 109 Table 6-1 Fault Code list (continuous) Item Fault Code Description 5019 DTC_CURRENT_SENSOR_FAULT_5 DTC_PRECHARGE_FAILED_5 5020 5021 DTC_CONTROLLER_SEVERE_UNDERTEMP_5 DTC_CONTROLLER_SEVERE_OVERTEMP_5 5022 5023 DTC_SEVERE_UNDERVOLTAGE_5 5024 DTC_SEVERE_OVERVOLTAGE_5 DTC_CONTROLLER_OVERTEMP_CUTBACK_5 5034 5035 DTC_UNDERVOLTAGE_CUTBACK_5 DTC_OVERVOLTAGE_CUTBACK_5 5036 5037 DTC_SUPPLY_5V_FAILURE_5 DTC_DO6_OPEN_OR_SHORT_5 5038 5039 DTC_DO7_OPEN_OR_SHORT_5 DTC_MOTOR_TEMP_HOT_CUTBACK_5 5040 5041 DTC_MOTOR_TEMP_SENSOR_FAULT_5 DTC_MAIN_OPEN_SHORT_5 5049 5050 DTC_EMBRAKE_OPEN_SHORT_5 DTC_COIL3_DRIVER_OPEN_SHORT_5...
  • Page 110 Table 6-1 Fault Code list (continuous) Item Fault Code Description 5116 DTC_FAULT_ON_OTHER_TRACTION_CONTROLLER_5 DTC_DUAL_SEVERE_FAULT_5 5117 5119 DTC_SUPERVISOR_FAULT_5 DTC_SUPERVISOR_INCOMPATIBLE_5 5120 5135 DTC_MOTOR_CHARACTERIZATION_FAULT_5 5136 DTC_ENCODER_PULSE_ERROR_5 DTC_MOTOR_TYPE_FAULT_5 Driver 5137 5145 DTC_VCL_OS_MISMATCH_5 DTC_EM_BRAKE_FAILED_TO_SET_5 5146 5147 DTC_ENCODER_LOS_5 DTC_EMR_REV_TIMEOUT_5 5148 5152 DTC_ILLEGAL_MODEL_NUMBER_5 DTC_DUALMOTOR_PARAMETER_MISMATCH_5 5153 6-20 用户 00757092 用户...

  • 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 113 用户 00757092 用户 00757092...
  • Page 114 用户 00757092...

  • Page 115: 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 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 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 7.4 Electrical Schematics Figure 7-11 Electrical Schematics (CE) 1/10 7- 7 用户 00757092 用户 00757092...
  • Page 122 Figure 7-12 Electrical Schematics (CE) 2/10 7- 8 用户 00757092 用户 00757092...
  • Page 123 Figure 7-13 Electrical Schematics (CE) 3/10 7- 9 用户 00757092 用户 00757092...
  • Page 124 Figure 7-14 Electrical Schematics (CE) 4/10 7- 10 用户 00757092 用户 00757092...
  • Page 125 Figure 7-15 Electrical Schematics (CE) 5/10 7- 11 用户 00757092 用户 00757092...
  • Page 126 Figure 7-16 Electrical Schematics (CE) 6/10 7- 12 用户 00757092 用户 00757092...
  • Page 127 Figure 7-17 Electrical Schematics (CE) 7/10 7- 13 用户 00757092 用户 00757092...
  • Page 128 Figure 7-18 Electrical Schematics (CE) 8/10 7- 14 用户 00757092 用户 00757092...
  • Page 129 Figure 7-19 Electrical Schematics (CE) 9/10 7- 15 用户 00757092 用户 00757092...
  • Page 130 Figure 7-20 Electrical Schematics (CE) 10/10 7- 16 用户 00757092 用户 00757092...
  • Page 131 7.5 ydraulic Schematics Figure 7-23 Hydraulic Schematics 7- 17 用户 00757092 用户 00757092...
  • Page 133 Add:Tengfei Road 997 , Wangcheng District, Changsha, Hunan,PRC Tel:400-800-0157 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.

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