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Zoomlion ZT88J-V Service And Maintenance Manual

Mobile elevated work platform
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Service and Maintenance
Service and Maintenance Manual
ZT88J-V
Service and Maintenance Manual
Apr 2024 Version A

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  • Page 1 Service and Maintenance Service and Maintenance Manual ZT88J-V Service and Maintenance Manual Apr 2024 Version A...

  • Page 3: Foreword

    Foreword This Service and Maintenance Manual applies to the ZT88J-V 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 Warning indicates a potential hazardous situation. If not avoided, will result in death or serious injury. Caution indicates a potential hazardous situation. If not avoided, will result in minor or moderate injury. Notice indicates information of property and device damage, or wrong operations. If not avoided, could result in property loss, damage to machine parts or reduced mechanical properties.

  • Page 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 3.1.4 Machine annual inspection ..................3-1 3.1.5 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 ..................3-2 3.2.3 Cleaning ........................3-3 3.2.4 Component disassembly and installation ..............3-3 3.2.5 Component disassembly and reinstallation ..............
  • Page 7 Contents SECTION 4 CHASSIS AND TURNTABLE ................4-1 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 4.14.1 Engine main components ..................4-18 4.14.2 Fuel system ......................4-21 4.14.3 Cool system ......................4-23 4.14.4 Lubrication system....................4-24 4.14.5 Control system ......................4-26 SECTION 5 BOOM AND PLATFORM ................... 5-1 5.1 Platform and Jib ........................5-1 5.1.1 Anti-crushing device ....................5-1 5.1.2 Load cell ........................
  • Page 9 Contents 6.2.3 Minimum value/maximum value ................. 6-1 6.2.4 Polarity......................... 6-1 6.2.5 Range ........................... 6-2 6.2.6 Voltage measurement ....................6-2 6.2.7 Resistance measurement ....................6-2 6.2.8 Conduction test ......................6-3 6.2.9 Current measurement ....................6-3 6.3 DEUTSCH Connector ......................6-4 6.3.1 DT/DTP series connector assembly ................6-4 6.3.2 DT/DTP Series Connector Disassembly ..............
  • Page 11 ·...

  • 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

    down at any time if necessary, and others can conduct inspection or maintenance. Personnel should keep close contact to work safely. Clean the aerial work platform before inspection or maintenance. The dust or debris on the aerial work platform not only makes the faulty components or parts difficult to find, but also can be mixed into the components or parts during operation.
  • 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 Battery fluid contains dilute sulfuric acid. Battery fluid can cause blindness when it enters the eyes, and burns when it comes into contact with the skin. Wear goggles, protective gloves long-sleeved overalls when handling the battery. If the eyes or skin are in contact with the battery fluid, rinse immediately with plenty of water and get medical attention promptly.
  • Page 19 It should always be borne in mind that all maintenance should include mandatory confirmation of normal mechanical movement. Handle hazardous wastes according to law such as oil, fuel, filter, battery, hydraulic oil, etc. Reasonable recycling of used oil, coolant or filter element to save resources and protect the environment.

  • Page 23: Section 2 Technical Parameters

    SECTION 2 TECHNICAL PARAMETERS 2.1 Performance Table 2-1 Performance Platform Capacity 300/ 454kg 660/1000 lbs 45% (platform downhill) Max Travel Speed (on slope) 25% (platform uphill) Max Travel Speed (on side slope) Platform Height 26.7m 87 ft 7 in Horizontal Outreach 22.1m 75 ft 6 in 6.1m (outside)

  • Page 24: Capacity

    2.3 Capacity Table 2-3 Capacity Fuel tank 150 L 39.6 us gal Hydraulic tank 150L 39.6 us gal 2.4 Component data 2.4.1 Engine Table 2-4 Cummins QSF2.8（Cummins, China stage Ⅲ）Engine parameters Type In-line, water-cooled, 4 cylinders 4 strokes Fuel GB 19147, EN590 or ASTM D975 2.1 us gal Engine oil capacity About 8 L...

  • Page 25: Battery

    15-625 Foam-filled 6900kg 10000kg 260±5kg 385/55-24.5 Foam-filled 6900kg 10000kg 260±5kg 2.6 Functional Speed Table 2-9 Functional speed Function ZT88J-V Boom Lifting 100~110 Boom Descending 85~95 Turntable Swing (a round) 100~120 Boom Extending 59~67 Boom Retracting 57~65 Platform Rotation 25~35 Jib Lifting...

  • Page 26: Test Cautions

    Platform Rotation; Platform leveling. Platform reaches extreme position, rotate the platform to reach the extreme position of another side, record the rotating time; rotate the platform to the original position, record the rotating time. Drive (stowed): choose a smooth ground with the main boom less than 7 ° and the extension length less than 1m.

  • Page 27: Lubrication

    Table 2-7 Special toque Requirements Instruction: Torque value (N.m) Time intervals Hub fastening bolt 50 hours after the first run, every 150 hours or 3 months thereafter Traveling reducer connecting 50 hours after the first run, every 150 bolt M16 hours or 3 months thereafter Slew bearing bolt 100 hours after the first run, every 500...

  • 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

    3.1.5 Preventive maintenance Equipment engineers should perform preventive maintenance in conjunction with prescribed inspections. Equipment engineers recognized by our company should have recognized qualifications, certificates, extensive knowledge and experience, and have received relevant training, as well as the ability and level required to maintain, repair and maintain the product models described in this manual.

  • Page 33: Cleaning

    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. This unit has taken preventive measures to protect against such violations. Shields, covers, seals and filters are used to keep the air, diesel and oil supplies clean.

  • Page 34: Washer

    not open the reusable or new bearing packaging until you are ready to install it. Lubricate the new or refurbished bearings before installation. When pressing the bearing into the cage or bore, apply pressure to the outer bearing race. Apply pressure on the inner race when installing the bearing on the shaft.

  • Page 35: Lubrication And Information

    2 is not used to specify the type and parameters of hydraulic oil). Please select the hydraulic oil of the appropriate brand and technical parameters according to the specific use environment of the equipment. For special environments or users with special requirements, please contact ZOOMLION or hydraulic oil manufacturers.
  • Page 36 Table 3-2 Hydraulic oil technical parameter Mobil Great Kunlun wall Mobil Mobil Mobil Caltex Caltex Great Great Aware H 4632gr Technical aviation DTE 10 DTE 10 DTE 10 Rando Rando wall L- wall L- ease hydrauli parameter Ultra 22 Ultra 32 Ultra 46 MV 22 MV 32...

  • Page 37: Lubrication Spec

    Regular hydraulic fluid changes are required to use the recommended crankcase or hydraulic fluid. Run for the first time for 50 hours, and the filter element should be replaced every 1,000 hours thereafter. If the hydraulic oil has not been replaced for two years, it should be tested once every quarter, and the hydraulic oil should be replaced if the test fails.

  • Page 38: Cylinder Drift

    3.4.2 Cylinder drift Table 3-3 Cylinder drift Cylinder bore size Maximum acceptable drift value in 10 minutes Millimeter Inch Millimeter Inch 76.2 0.66 0.026 0.48 0.019 101.6 0.38 0.015 0.22 0.009 152.4 0.15 0.006 177.8 0.13 0.005 203.2 0.10 0.0038 228.6 0.08 0.003...

  • Page 39: Welding On The Device

    The surface of the pin has flakes or scratches. The pins in the bearing area are rusty. Reassemble the connecting pin with a fiber bearing. The dirt and debris on the housing should be blown off. There must be no foreign objects on the bearings and housings.

  • Page 40: Engine Electrical System Maintenance

    to use insulating grease for electrical connectors. This procedure applies to all plug connections installed outside the distribution box. Silicone grease is not suitable for use with externally sealed connectors. The silicone grease should be placed around the male and female pins on the inside of the connector before assembly to prevent oxidation.
  • Page 41 Table 3-4 Inspection and preventive maintenance schedule Time intervals Items Pre- Every 2 Pre-start Weekly Monthly Annually delivery or years daily Boom assembly Boom weldment 1,2,4 1,2,4 Oil pipe/wire rope 1,2,9,12 1,2,9,12 Shaft pin and pin Pulley and pulley pins Bearings Wear pad Covers or shields...
  • Page 42 Table 3-4 Inspection and preventive maintenance schedule (continuous) Time intervals Items Pre-start Weekly Monthly Pre-delivery Annually Every 2 or daily years Steer components Drive motor Torque hub Function/Control Platform control Ground control Function control locks, protective device or brake device Foot switch Emergency switch (Ground and platform)
  • Page 43 Table 3-4 Inspection and preventive maintenance schedule (continuous) Time intervals Items Pre- Pre-delivery Weekly Monthly Annually Every 2 years start or daily Exhaust system Batteries Battery fluid Battery charger Fluid reservoir, cap and 11,9 breather Hydraulic/Electrical system Hydraulic pump 1,2,9 Hydraulic oil tank 1,9,7 1,2,9...
  • Page 44 All system functional test 21, 22 Painting and appearance Imprint check date on the frame Notifying Zoomlion machine ownership Footnote: 1. Before daily use or each shift 2. Before each sale, rental or delivery 3. Use 3 months or 150 hours, or idle for more than 3 months, or buy as a used machine 4.
  • Page 45 Performance code: 1 －Confirm that the installation is correct and secure 2 －Visually inspect for damage, cracks, deformation or excessive wear 3 －Check if the adjustment is correct 4 －Check for cracked or damaged welds 5 －Correct operation 6 －Return to neutral of OFF position when released 7 －Clean and free of dirt 8 －Interlock function 9 －Check for signs of leaks...

  • Page 49: 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 50: 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 51: 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 130 Nm/95.7ft·...

  • Page 52: 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 53: Auxiliary Power System

    The preset value of the tilt sensor is 3° 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 54: Traveling Drive System

    1. Bolt 2. Washer 3. 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 55 Figure 4-5 Travel system disassembly diagram 1 Figure 4-6 Travel system disassembly diagram 2...

  • Page 56: Travel Reducer

    1. Bolt 2. Stop pin 3. Pin 4. Right steering knuckle 5. Bolt 6. Washer 7. Main pin cover plate 8. Pin 9. Wear pad 10. Lubrication-free bearing 11. Screw 12. Front axle block 13. Pin 14. Bearing stop plate 15.

  • Page 57: Installation

    4.7.2 Installation Use a suitable lifting device to support the travel reducer (the travel reducer weighs approximately 50kg). Align the mounting holes on the travel reducer with the holes of the reducer mounting plate. The travel reducer is mounted on the axle with M16, and the bolt torque is 310Nm. Connect the hydraulic line that was previously disassembled to the travel motor.

  • Page 58: Installation

    4.8.2 Installation Use a suitable lift to support the walking motor (the weight of the walking motor is approximately 15.4kg). Install the traveling motor on the machine; If the output shaft of the traveling motor is not well aligned, it will cause damage to the output shaft of the traveling motor, and damage to the bearing and sealing ring around it.

  • Page 59: Rotary Reducer

    4.10 Rotary reducer 4.10.1 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

    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. Inject the cleaning fluid into the rotary reducer and brake, install the oil plug, run at high speed for several minutes, and then drain the cleaning fluid The use of aggressive cleaning agents or unsuitable lubrication products will change the characteristics of the oil esters, which will harm the trajectory and related parts.

  • Page 61: Disassembly

    4.11.3 Disassembly Install the appropriate spreader on the turntable and properly tension the spreader. Provide support or obstructions to the boom if possible. Remove the rotary joint hydraulic pipe and properly fix the hydraulic pipe. Remove the rotary reducer and keep it properly. Remove rotary bearing and connecting bolt of turntable.

  • Page 62: Generator

    and even damage to components. If the clearance is too loose, it will cause violent shaking when slewing or braking. Proper gear clearance could guarantee good machine performance and extend the service life of the unit, as such, proper adjustment is necessary. Adjust the clearance as shown below. Motor Rotary reduce...
  • Page 63 Figure 4-12 Motor driving belt Check that the drive belt tension is appropriate for every 250 hours of operation. Every 500 hours; The generator carbon brush and slip ring should be maintained every 500 hours of operation. More frequent maintenance may be required in adverse environments. Figure 4-13 Use a hair dryer to blow the inside of the generator every 500 hours of operation.

  • Page 64: Carbon Brush And Slip Ring Maintenance

    Figure 4-15 4.13.2 Carbon brush and slip ring maintenance Check the carbon brush position; Check that the carbon brush is aligned with the slip ring. Check the alignment through the air holes in the stator. The carbon brush should ride completely on the slip ring. Check the carbon brush;...

  • Page 65: Engine System

    4.14 Engine system The engine system generally consists of a fuel system, a cooling system, a control system, and a mounting system, as shown in Figure 4-16. Exhaust system Cooling system Fuel system Control system Intake system Suspension system Figure 4-16 Engine system 4.14.1 Engine components position 4.14.1.1 Cummins engine Figure 4-17 Cummins engine...
  • Page 66 Table 4-2 Main components of Cummins engine Item Function Fuel storage, while suppressing pressure fluctuation due to high High pressure oil rail pressure oil pump and fuel injector, to ensure the system pressure stability. Intake manifold Evenly distribute air to each cylinder High pressure pump Provide enough pressure for fuel to achieve good spray atomization.
  • Page 67 Table 4-3 Main components of Weichai engine Item Function Oil level gauge Check oil level Water temperature Monitor the antifreeze temperature in the engine, and alarm if the sensor temperature is too high. Intake manifold Distribute air evenly to each cylinder. Fuel storage, while suppressing pressure fluctuation due to high High pressure oil rail pressure oil pump and fuel injector, to ensure the system pressure...

  • Page 68: Fuel System

    4.14.2 Fuel system The fuel system consists of fuel system, intake system and exhaust system, including fuel tank, fuel filter, oil-water separator, air filter, muffler and other main components. It can deliver fuel for the engine work, adjust the engine speed according to the actual operation requirements of the whole vehicle, ensure the normal operation of the engine, and reduce the exhaust noise (see Figure 4-19, Figure 4-20, Figure 4-21).
  • Page 69 The common faults and solutions of the fuel system are as follows: Table 4-5 Engine abnormal start Fault Cause Solution Too little oil in fuel tank Add fuel Fuel problem Check fuel composition Air in the fuel system Restart after fully exhausted Fuel wax Add fuel as required by the operation manual Engine abnormal...
  • Page 70 Table 4-8 Engine smoke abnormal fault Fault Cause Solution Add standard fuel according to the operation Use inferior fuel Engine black manual smoke Check whether the intake air is sufficient Insufficient combustion and the fuel injection timing is correct Overfilling oil, burning oil Add oil according to the operation manual Engine blue The gap between the piston ring and...

  • Page 71: Lubrication System

    Figure 4-22 Cooling system Table 4-10 Main components of cooling system Item Function Expansion tank Store antifreeze to provide space for antifreeze to expand when heated. Radiator Cool antifreeze, reduce antifreeze temperature Forced air movement Liquid level Monitors the coolant level in the expansion tank and alarms when it falls sensor below the limit Common faults and solutions of cooling system are shown in Table 4-11:...
  • Page 72 good lubrication effect, reduce the friction between the relatively moving parts, and take away the heat generated. Figure 4-24 Lubricating system Table 4-12 Lubricating system Item Function Oil pan Stores oil, releases heat from oil Oil suction filter Suction and filter sump oil Oil pump Provides power for the flow of oil in the oil passages Oil cooler...

  • Page 73: Control System

    4.14.5 Control system The control system is composed of the main components such as throttle motor, throttle motor controller, wiring harness, insurance, relay, switch, etc., which are used to control the start, stop and normal operation of the engine. The electronic control engine fault code table is as follows: WEICHAI WP2.3NG75E441 fault code see Table 4-14, CUMMINS QSF2.8t3TC7 fault code see Table 4-15, and KUBOTA V2607-CR-EW02 fault code see Table 4-16.
  • Page 74 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description The generator voltage is over limit 1795 The generator voltage is below limit 209894 Fuel heating relay/air conditioning compressor /SCR 3597 desulfurization lamp/intake heating relay are short circuit to battery DPF heating relay/stop switch under car/exhaust brake 3598 valve /DPF regeneration stop lamp are short circuit to battery...
  • Page 75 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Coolant sensor voltage exceeds the lower limit Channel 0 receives CAN network information in 522042 non-communication mode Channel 1 receives CAN network information in 522042 non-communication mode Channel 2 receives CAN network information in 522042 non-communication mode Channel 3 receives CAN network information in...
  • Page 76 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description A byte length error occurred in the received tank level 519616 information message No tank level information message has been received 519616 The received driver demand information (inlet 519617 heating, throttle opening, auxiliary braking, etc.) is incorrect The error is set when DCU receives Ack message 519618...
  • Page 77 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description speed information No message containing speed information received 522043 Vehicle -GPS lock vehicle - key verification error 522043 Remote lock car Key receives timeout 522043 Lovol digging machines-Remote lock car execution 523014 failure Vehicle-CAN bus-PTO related message 517128...
  • Page 78 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description brake circuit) Byte length error in message received from air 517139 conditioning compressor (air conditioning compressor outlet pressure) No message received from air conditioning 517139 compressor (air conditioning compressor outlet pressure) Byte length error in message received from adaptive 517132 cruise controller (Cruise control instruction) No message received from adaptive Cruise controller...
  • Page 79 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) The message sent by VCU has not been received (warm 520006 air defrosting working state) The downstream nitrogen and oxygen concentration is...
  • Page 80 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) adaptive Driveline controller No message (torque requirement) received from 519642 adaptive Driveline controller 519644...
  • Page 81 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Reliability failure of speed and torque demand 522044 message sent from ABS Time-out failure of torque demand message sent from 519694...
  • Page 82 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Reliability failure of rotational speed and torque 522044 demand message sent by car body controller Reliability failure of rotational speed and torque 522044...
  • Page 83 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) sensor measured value and the model value is large DOC temperature is too high 4796 Through the key to speed, key error mode error...
  • Page 84 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Overload lamp short circuit to ground Exhaust brake valve open circuit 519660 Overtemperature of exhaust brake valve 519660...
  • Page 85 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Open Load error of Fuel heating relay 4009 Over Temperature error of Fuel heating relay 4009 Short circuit to Battery Error of Fuel heating relay...
  • Page 86 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Intake air heating relay open circuit 2898 Intake air heating relay over temperature 2898 Intake air heating relay short circuit to battery 2898...
  • Page 87 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Six-cylinder diesel engine Engine Fuel 1 Injector Cylinder higher side short circuit 1413 to lower side in Six-cylinder diesel engine（Engine Fuel 1 Injector Cylinder higher side short circuit to lower...
  • Page 88 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Torsion limiting fault with carbon load greater than a 4781 certain value Vehicle -PTO switch signal is abnormal...
  • Page 89 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Short circuit to Battery Error of DPF lamp 4175 Short circuit to Ground error of DPF lamp 4175...
  • Page 90 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) enabled, please go to the service station as soon as possible The differential pressure sensor drifts after it is powered 3251...
  • Page 91 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) 518153 The reflux tube was not cleared of urea，Please stop for 2 minutes before switching off the main power In metering state, the urea pump return pipe is blocked - 518153...
  • Page 92 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Speed governing rate knob original voltage exceeds the 519668 upper limit The accelerator pedal 1 voltage exceeds the lower limit...
  • Page 93 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Deviation of accelerator pedal 1 and accelerator pedal 2 519666 is too large Remote accelerator pedal 1 signal is out of sync with...
  • Page 94 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Throttle valve power supply motor line 2 Short circuit 5375 to ground Throttle valve is closed...
  • Page 95 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) circuit to power source Vehicle - Post processing heating relay short circuit to 4342 the ground SCR heating system pressure tube heating resistance...
  • Page 96 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) and is untrusted The urea pump pressure exceeds the lower limit and is 1387 untrusted The original pressure voltage of the urea pump exceeds...
  • Page 97 Table 4-14 WEICHAI WP2.3NG75E441 fault code Trouble Description Failed to receive message from gearbox controller 517135 (hydraulic/oil temperature) Byte length error in message received from VCU (warm 520005 air defrosting working condition) Warning lamp over temperature 519674 Warning lampshort circuit to battery 519674 Warning lampshort circuit to ground 519674...
  • Page 98 Table4-15 CUMMINS QSF2.8t3TC72 Fault code Trouble Description Engine Control Module Critical Internal Failure - Bad Intelligent Device or Component Engine Magnetic Speed/Position Lost Both of Two Signals -Data erratic, intermittent or incorrect Intake Manifold 1 Pressure Sensor Circuit - Voltage Above Normal or Shorted to High Source Intake Manifold 1 Pressure Sensor Circuit - Voltage Below Normal or Shorted to Low Source...
  • Page 99 Table 4-15 (cont.) CUMMINS QSF2.8t3TC72 Fault code Trouble Description Sensor Supply 2 Circuit - Voltage Below Normal or Shorted to Low Source 3510 Coolant Level Sensor 1 Circuit - Voltage Above Normal or Shorted to High Source Coolant Level Sensor 1 Circuit - Voltage Below Normal or Shorted to Low Source Coolant Level - Data Valid But Below Normal Operating Range - Moderately Severe Level...
  • Page 100 Table 4-15(cont.) CUMMINS QSF2.8t3TC72 Fault code Trouble Description Injector Solenoid Driver Cylinder 6 Circuit - Current Below Normal or Open Circuit Injector Solenoid Driver Cylinder 2 Circuit - Current Below Normal or Open Circuit Injector Solenoid Driver Cylinder 4 Circuit - Current Below Normal or Open Circuit Engine Control Module Warning Internal Hardware Failure - Bad Intelligent Device or Component...
  • Page 101 Table 4-15 (cont.) CUMMINS QSF2.8t3TC72 Fault code Trouble Description Injector Metering Rail 1 Pressure - Data Valid But Above Normal Operating Range - Moderately Severe Level Injector Metering Rail 1 Pressure - Data Valid But Below Normal Operating Range - Moderately Severe Level Engine Starter Motor Relay Circuit - Voltage Above Normal or Shorted to High Source Engine Starter Motor Relay Circuit - Voltage Below Normal or Shorted to Low...
  • Page 102 Table 4-15 (cont.) CUMMINS QSF2.8t3TC72 Fault code Trouble Description Engine Crankshaft Speed/Position - Data Erratic, Intermittent, or Incorrect Engine Camshaft Speed/Position Sensor - Data Erratic, Intermittent, or Incorrect Fan Control Circuit - Voltage Above Normal or Shorted to High Source Injector Solenoid Driver Cylinder 1 - Out of Calibration Injector Solenoid Driver Cylinder 2 - Out of Calibration Injector Solenoid Driver Cylinder 3 - Out of Calibration...
  • Page 103 Table 4-15 (cont.) CUMMINS QSF2.8t3TC72 Fault code Trouble Description Brake Pedal Position - Data erratic, intermittent or incorrect Water in Fuel Indicator - Data Valid But Above Normal Operating Range - Most Severe Level Auxiliary Input/Output 1 - Special Instructions Fan Speed - Data Valid but Above Normal Operational 1639 Range - Most Severe Level...
  • Page 104 Table 4-16 KUBOTA V2607-CR-TI-EW02 Fault code Trouble Description NE-G phase shift NE: Crankshaft position sensor G: Camshaft position sensor Pressure limiter emergency open High rail pressure SCV (MPROP) stuck 1347 Fuel leak (in high pressured fuel system) 1239 Intake air temp. error: Low Intake air temp.
  • Page 105 Table 4-16 (cont.) KUBOTA V2607-CR-TI-EW02 Fault code Trouble Description ECU CPU (Main IC) error 1077 ECU CPU (Monitoring IC) error 523527 Injector charge voltage: Low 523525 Open circuit of SCV (MPROP) 1347 SCV (MPROP) drive system error 1347 +B short circuit of SCV (MPROP) 1347 Injector drive IC error or Open circuit 1077...
  • Page 106 Table 4-16 (cont.) KUBOTA V2607-CR-TI-EW02 Fault code Trouble Description EGR actuator coil short 523574 EGR position sensor failure 523572 Exhaust gas temperature sensor 1: Low 3242 Exhaust gas temperature sensor 1: High 3242 Exhaust gas temperature sensor 0: Low 4765 Exhaust gas temperature sensor 0: High 4765 EEPROM check sum error...
  • Page 107 Table 4-16 (cont.) KUBOTA V2607-CR-TI-EW02 Fault code Trouble Description CAN CM1 (Regen SW) frame error 523592 CAN ETC5 (Neutral SW) frame error 523595 CAN TSC1 frame error 523596 CAN EBC1 frame error 523598 4-59...

  • Page 111: 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 Disassemble Figure 5-1 Load cell disassemble diagram Disconnect the wiring harness at the anti-extrusion device; Remove the connection bolts between the steel pipe clamp and the platform weldment 4, that is, remove the steel pipe clamp;...

  • Page 112: Load Cell

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

  • Page 113: Rotary Actuator

    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; d）...

  • Page 114: Jib Lifting Cylinder

    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. 5.1.3.2 Inspection Check the line for wear and replace the wiring harness if necessary. Check hydraulic oil leaks and replace the line if necessary.

  • Page 115: Boom Assembly

    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. 5.2 Boom Assembly Extrusion hazard.

  • Page 116: Leveling Cylinder

    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. Check the cable structure for bending, cracking, weld separation or other damage and replace the cable structure if necessary.

  • Page 117: Lifting Cylinder

    Use a suitable plug to block the connector of the leveling cylinder balancing valve to prevent dust and other pollutants from entering the oil line. 5.2.2.2 Inspection Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if necessary.
  • Page 118 Until the pin 1 is completely exposed and in a position convenient for disassembly, appropriate lifting equipment (lifting weight greater than 5t) is selected to support the head of the boom, so that the boom cylinder is not stressed; Mark and disconnect the hydraulic pipeline connected to the lifting cylinder, collect the hydraulic oil in the pipeline with a suitable container, and block the port of the pipeline after the collection.
  • Page 119 5.2.4 Boom 5.2.4.1 Disassembly Hoisting point of counter-weight Figure 5-6 Counterweight disassembly diagram Tilt hazard. The steps of removing the boom include removing the counterweight. Failure to remove the counterweight before removing the boom assembly may cause the device to tip over. Therefore, please do not remove the boom assembly without removing the counterweight.
  • Page 120 and carefully remove the counterweight from the equipment, and securely place it on a hard surface; Connect the upright and turntable; Mark and disconnect the wiring harness and hydraulic pipeline connected to the boom, collect the hydraulic oil in the pipeline with a suitable container, and block the port of the pipeline after the collection is completed;...
  • Page 121 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 122: Link

    5.2.5 Link mechanism 5.2.5.1 Disassembly Figure 5-9 Link disassembly Move the hood from the turntable. Use a suitable lifting tool to remove the counterweight (5t) from the turntable. Adjust the boom to the min angle, and the turntable and link support the boom, no weight on the lifting cylinder.
  • Page 123 5.2.5.2 Inspection Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if necessary. Inspect the inner ring of the bearing for scratches, distortion, wear or other damage and replace the bearing if necessary. Inspect all threaded parts for damage such as stretching, thread deformation or distortion and replace if necessary.

  • Page 124: Boom Disassembly

    5.2.6 Boom disassembly 5.2.6.1 Disassembly Disassemble the telescopic cylinder after boom fully retracted. Fully retract the boom; Angle sensor 倾角传感器 拉线传感器 Length sensor 行程开关 Stroke switch Figure 5-9 Sensor disassemble diagram Remove the length sensor and Angle sensor installed at the end of one boom and the stroke switch installed at the boom head of base boom (Note: the pipeline connecting to the boom has been removed).
  • Page 125 When the assembly leaves the mounting seat, move the assembly toward the boom head (make the wire rope in a relaxed state), and place the wire rope break detection sensor assembly on the telescopic cylinder; Processing hole 1 Processing hole 2 工艺孔2 工艺孔1 Pin 1...
  • Page 126 Pin 6 Pin 2 Limit block 限位块 螺钉6 销轴2 Limit gasket 限位垫片 Figure 5-14 Extending cylinder pin disassembling diagram Remove screw 6, take the lower limit gasket and limit block; Select appropriate tools to remove the pin 2; Wire rope break detect sensing assembly Cylinder pin 缸筒销...
  • Page 127 Bolt 7 Guide slider Telescopic pulley 螺栓7 导向滑块 伸臂滑轮 Wire rope break detect sensing assembly Telescopic cylinder 伸缩油缸 钢丝绳断裂检测传感组件 Pin 3 销轴3 伸臂钢丝绳 Extending wire rope Nut 2 螺母2 Pulley cover Bolt 8 螺栓8 伸臂轮护罩 Nut 2 螺母2 Spring Sensor mounting plate 传感器安装板...
  • Page 128 Base boom 一节臂 telescopic boom section 二节臂 Front upper slider 1 前上滑块1 Front side slider 2 Front upper slider 2 前上滑块2 前侧滑块2 三节臂 telescopic boom section Front side slider 1 前侧滑块1 Retracting wire rope 缩臂钢丝绳 Front lower slider 2 前下滑块2 前下滑块1 Front lower slider 1 Figure 5-18 Slider disassembling diagram...
  • Page 129 Remove bolt 9 and bolt 10, and remove the retractable boom wheel guard plate and retractable boom wheel guard; Select appropriate tools to remove the pin 4, remove the telescopic pulley; Put the open cable joint at the tail side of the retracting wire rope back inside the boom through the process hole 1, and pull out the retracting wire rope from the tail of the boom;...

  • Page 130: Wire Rope Pulley

    Pulley and wire rope must be replaced in sets. 5.2.6.3 Installation Please follow the opposite steps of disassembly, and clean the joints of hydraulic pipelines and the interfaces of balance valves before installation to prevent pollutants from entering the hydraulic system;...
  • Page 131 The wire rope is rusted or corroded; Tangling, "knotting" or wrinkling of the wire rope; The adjustment of the wire rope has reached the limit adjustment range and cannot be adjusted further; The pulley fails to pass the wear meter inspection; 6 wires are broken in a wire rope, or 3 wires are broken in a wire rope strand, or 1 valley is broken, or 1 break occurs at the wire rope junction.

  • Page 132: Load Cell Check

    Enable the telescopic function of the boom, extend the boom 1~1.5m, alternately twist the two nuts of the wire rope of the tightening arm (nut 1 in Figure 5-10), tighten the nuts of the wire rope of the tightening arm to 23Nm with a torque wrench (pay attention to limit the rotation of the wire rope when tightening); Enable the telescopic function of the boom to retract about 0.5-0.8m (do not retract the telescopic cylinder to the limit position), alternately tighten the two nuts of the steel wire rope of the overhang arm (nut 2 in Figure 5-11), and tighten the nuts of the extending wire rope of 23Nm with a torque wrench;...

  • Page 133: Platform Leveling Sensor Check

    e） After calibrating the zero-point position, increase the load on the work platform to 340kg to full load. f） Under the overload condition, the overload indicator of the platform and the ground is continuously lit, and the alarm is issued. g）...

  • Page 134: Check Of Wire Rope Damage Indication System

    Extend the boom 1m/3.28ft, record the length of the boom on the display screen. Compare the boom length values twice. The absolute value should be 1m/3.28ft. Extend the boom horizontally to the limit position, and confirm the boom length of 20.6m on display. 5.3.5 Check of Wire Rope Damage Indication System a）...
  • Page 135 function cannot be enabled. Wear a seat belt when performing a speed limit check. Do not lift the boom to an excessively high position for testing, and pay attention to driving safety to avoid accidents. 5-25...
  • Page 137 履带起重机操作手册 第一章 安全操作说明...

  • Page 139: Section 6 Electrical System Maintenance

    SECTION 6 ELECTRICAL SYSTEM MAINTENANCE 6.1 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 140: Range

    6.2.5 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. For example:1.2 kΩ ＝1200Ω For example:50 mA = 0.05 amps. 6.2.6 Voltage measurement Figure 7-1 Voltage measurement (direct current) If the multimeter cannot automatically adjust the range, set the correct range (refer to the multimeter...

  • Page 141: Conduction Test

    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). Make sure the multimeter leads are securely connected. 6.2.8 Conduction test Figure 7-3 Conduction test The multimeter needs to use a separate button to initiate the continuity test of the beep.

  • Page 142: Deutsch Connector

    6.3 DEUTSCH Connector 6.3.1 DT/DTP series connector assembly Figure 7-5 DT/DTP contact installation Pinch the crimped contact about 25mm behind the contact cylinder. Hold the connector so that the rear guard ring faces toward you. Push the contacts into the retaining ring in a straight line until you hear a slight click, and pull gently to confirm that the connector is completely locked.

  • Page 143: Hd30/Hdp20 Series Connector Assembly

    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. Hold the rear seal, otherwise the seal may be displaced when the contact is removed.

  • Page 144: Hd30/Hdp20 Series Connector Removal

    6.3.4 HD30/HDP20 Series Connector Removal Figure 7-9 HD/HDP contact removal With the rear insert facing the side, select the appropriate size of the insertion and removal tool to clamp the wire of the contact to be removed. Slide the tool into the cavity of the insert until the tool catches the contact and feels stressed. Pull the contact wire assembly out of the connector.
  • Page 145 Figure 6-11. Control system frame The control system can be accessed through a display screen on the ground control box. Functions include data monitoring, information query, parameter management, sensor calibration and fault diagnosis.

  • Page 146: Electrical Components Position

    6.4.2 Electrical components position Anti-crushing Platform angle sensor device Platform Main boom extending console limit switch Pedal Load cell Figure 6-12 Platform electrical components Table 6-1 Platform electrical components instruction Electrical Function components Platform angle To detect the platform tilting angle, it is necessary to connect the cable sensor bundle of the platform and re-calibrate after replacement Main...
  • Page 147 Wire rope loose detection switch Main boom sensor Main boom length sensor Figure 6-13 Boom electrical components Table 6-2 Boom electrical components instruction Electrical Functions components Rope loosening Check the loose state of wire rope detection switch Main boom angle The lifting angle of the boom shall be detected, and the lifting function sensor of the boom shall be re-calibrated and tested after replacement...
  • Page 148 Table 6-3 Turntable electrical components instruction Electrical components Function Turntable rotary limit Test the rotating position of the turntable, and test the driving switch confirmation function after replacement The horizontal state of the frame should be detected, and the tilt Turntable angle sensor alarm function should be re-calibrated and tested after replacement Flash warning while working.

  • Page 149: Display Function And Operation

    6.4.3 Display function and operation The display is located on the panel of the ground control box and can be used with the power on. Display Up key Right key Enter key Figure 6-16 Ground console The display is operated by four function keys and four arrow keys at the bottom of the screen. The functions of function keys on each interface are not fixed.
  • Page 150 Figure 6-18 Display interface Figure 6-19 Main menu operating system Figure 6-20 Menu column Figure 6-21 Parameter management 6-12...

  • Page 151: Data Monitoring And Info Query

    Figure 6-22 Dynamic status operating system 6.4.4 Data monitoring and info query Click the "Main Menu" button from the "Home Interface" and then select "System Monitoring" to view the "input parameter monitoring" and "Output parameter monitoring". Figure 6-23 System monitoring Select Input Parameter Monitoring to view the input values of various operation switches, detection switches, and sensors.
  • Page 152 Figure 6-25 Input parameter monitoring (2) Figure 6-26 Input parameter monitoring (3) Select Output Parameter Monitoring to view the output current value of various solenoid valves and the operating status of the actuator Figure 6-27 Output parameter monitoring (1) 6-14...
  • Page 153 Figure 6-28 Output parameter monitoring (2) Click "Fault Query" from the "Main menu" to view "Current fault" Figure 6-29 Current fault To view historical faults, tap Historical Faults on the Current Fault or Main Menu screen Figure 6-30 Historical fault 6-15...

  • Page 154: Parameters Management And Password Tool

    Click "Information Query" on the Main Menu interface to view the device number, program version, and GPS status. Figure 6-31 Info query 6.4.5 Parameter management and password tools The Parameter Management page is displayed on the Main Menu page. Figure 6-32 Dynamic password Dynamic password is set in Parameter Management.
  • Page 155 When it is necessary to use the display screen for debugging, all the service engineers at the stagnation point of Zoomlion can obtain the password. The random code can be unlocked by contacting the service engineers at any time through telephone, wechat and other means, and the remote guidance can be used to solve the problem.
  • Page 156 Figure 6-35 Turntable rotary parameter Figure 6-36 Main boom lifting parameter Figure 6-37 Main boom extending parameter 6-18...
  • Page 157 Figure 6-38 Jib lifting parameter Figure 6-39 Platform rotary parameter Figure 6-40 Platform leveling parameter 6-19...

  • Page 158: Sensor Calibration

    Figure 6-41 Auto-leveling setting Term explanation Target current: operate this action target current; Actual current: real-time current detected by the controller; Acceleration time: the time from minimum current to maximum current; Deceleration time: the time from the maximum current to the minimum current reduction; Minimum current: the current value at the beginning of acceleration and the current value at the end of deceleration, generally the valve opening current;...
  • Page 159 Zoomlion can obtain the password. The random code can be unlocked by contacting the service engineers at any time through telephone, wechat and other means, and the remote guidance can be used to solve the problem.
  • Page 160 Sensor mounting device Load sensor Main boom length sensor Figure 6-43 Load cell position Joystick and function speed knob Traveling Front and rear: boom lifting joystick Function speed knob joystick Left and Right: Turntable rotary joystick Figure 6-44 Joystick and function knob layout 6-22...
  • Page 161 6.4.6.1 Load cell calibration Figure 6-45 Load cell calibration 1. The main boom is retracted to the position, the angle is about 0 degrees, and the platform is adjusted to the horizontal position to ensure that it will not touch the ground or force against other objects; 2.
  • Page 162 1. The main arm is retracted in place and the angle is about 0° . 2. Select the "Main Boom Length Sensor" page; 3. Press the left button for more than 3 seconds and release the button to clear the weight of channel 1 and calibrate the zero of the main arm length sensor;...
  • Page 163 1. Carry out joystick calibration in platform mode, the corresponding position will light up green if the modification is successful; 2. When the lifting/rotating joystick is placed naturally, press the up button for 3 seconds to set the minimum lifting speed of the main boom; 3.
  • Page 164 6.4.6.5 Turntable rotary joystick calibration Figure 6-49 Turntable rotary joystick calibration 1. Carry out joystick calibration in platform mode, the corresponding position will light up green if the modification is successful; 2. When the lifting/turning joystick is placed naturally, press the up button for 3 seconds to set the minimum turning speed;...

  • Page 165: Fault Analysis And Solution

    1. When the speed knob is calibrated in platform mode, the corresponding position will light up green after successful modification; 2. Turn the knob to the left to the limit position and press the left button for 3 seconds to set the minimum function speed;...
  • Page 166 6. Oil pressure is too low 6. Add engine oil 7. Low fuel level 7. Add fuel Overload 1. Platform overload 1. Remove platform load alarm 2. Load cell communication 2 .Check load cell harness or replace fault sensor 1. Chassis tilt exceeds setting 1.
  • Page 167 If you encounter any equipment failure, you can call Zoomlion. The company will solve the equipment failure for you in time. If you are not absolutely sure about the solution of the fault, please contact Zoomlion or Zoomlion's dealer for solution.

  • Page 168: Fault Code

    6.6 Fault code When the device is faulty, check the fault information displayed on the screen of the turntable electric cabinet. If the display on the turntable electric cabinet indicates the following fault code, remove the fault condition and restart the device before continuing to operate the device. Display fault code Figure 6-51 Ground console...
  • Page 169 Table 6-6 Fault code list (cont.) Item Fault code Fault info list 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 Switch/Joystick 22351 DTC_FAULT_UG_FUNCTION_SWITCH_CLOSED 24352 DTC_FAULT_PM_FUNCTION_SWITCH_CLOSED 12353 DTC_FAULT_UG_MAIN_LIFT_SWITCH_DOUBLE_POWER_ON 12355 UG_TOWER_LIFT_SWITCH_DOUBLE_POWER_ON 12356 DTC_FAULT_UG_JIB_SWITCH_DOUBLE_POWER_ON 22357 DTC_FAULT_UG_TELESCOPE_DOUBLE_POWER_ON...
  • Page 170 Table 6-6 Fault code list (cont.) Item Fault code Fault info list Switch/joystick 24380 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_MEDIUM_OFFSET 24381 DTC_FAULT_PM_DRIVE_JOYSTICK_UP_LIMIT 24382 DTC_FAULT_PM_DRIVE_JOYSTICK_DN_LIMIT 24383 DTC_FAULT_PM_DRIVE_JOYSTICK_MEDIUM_OFFSET 24384 DTC_FAULT_PM_STEER_JOYSTICK_UP_LIMIT 24385 DTC_FAULT_PM_STEER_JOYSTICK_DN_LIMIT 24386 DTC_FAULT_PM_STEER_JOYSTICK_MEDIUM_OFFSET 22389 DTC_FAULT_KEY_SWITCH Valve 22551 DTC_DRIVE_FORWARD_VALVE_SHORT_TO_GROUND 12552 DTC_DRIVE_FORWARD_VALVE_SHORT_TO_POWER 22553 DTC_DRIVE_FORWARD_VALVE_OPEN_CIRCUIT 22554 DTC_DRIVE_REVERSE_VALVE_SHORT_TO_GROUND 12555 DTC_DRIVE_REVERSE_VALVE_SHORT_TO_POWER 22556 DTC_DRIVE_REVERSE_VALVE_OPEN_CIRCUIT 22557...
  • Page 171 Table 6-6 Fault code list (cont.) Item Fault code Fault info list Valve 22579 DTC_SWING_RIGHT_VALVE_OPEN_CIRCUIT 22624 DTC_JIB_FLOW_VALVE_SHORT_TO_GROUND 22625 DTC_JIB_FLOW_VALVE_SHORT_TO_POWER 22626 DTC_JIB_FLOW_VALVE_OPEN_CIRCUIT 22627 DTC_MAIN_LIFT_UP_FLOW_VALVE_SHORT_TO_GROUND 22628 DTC_MAIN_LIFT_UP_FLOW_VALVE_SHORT_TO_POWER 22629 DTC_MAIN_LIFT_UP_FLOW_VALVE_OPEN_CIRCUIT 22633 DTC_MAIN_LIFT_UP_VALVE_SHORT_TO_GROUND 12634 DTC_MAIN_LIFT_UP_VALVE_SHORT_TO_POWER 22635 DTC_MAIN_LIFT_UP_VALVE_OPEN_CIRCUIT 22636 DTC_MAIN_LIFT_UP_VALVE_FEEDBACK_CURRENT_FAULT 22637 DTC_TELESCOPE_FLOW_VALVE_SHORT_TO_GROUND 22638 DTC_TELESCOPE_FLOW_VALVE_SHORT_TO_POWER 22639 DTC_TELESCOPE_FLOW_VALVE_OPEN_CIRCUIT 22640 DTC_TELESCOPE_FLOW_VALVE_FEEDBACK_CURRENT_FAULT...
  • Page 172 Table 6-6 Fault code list (cont.) Item Fault code Fault info list Valve 24662 DTC_PM_ROTATE_LEFT_VALVE_SHORT_TO_POWER 24663 DTC_PM_ROTATE_LEFT_VALVE_OPEN_CIRCUIT 24664 DTC_PM_ROTATE_RIGHT_VALVE_SHORT_TO_GROUND 24665 DTC_PM_ROTATE_RIGHT_VALVE_SHORT_TO_POWER 24666 DTC_PM_ROTATE_RIGHT_VALVE_OPEN_CIRCUIT 24667 DTC_PM_LEVELING_UP_VALVE_SHORT_TO_GROUND 14668 DTC_PM_LEVELING_UP_VALVE_SHORT_TO_POWER 24669 DTC_PM_LEVELING_UP_VALVE_OPEN_CIRCUIT 24670 DTC_PM_LEVELING_DN_VALVE_SHORT_TO_GROUND 14671 DTC_PM_LEVELING_DN_VALVE_SHORT_TO_POWER 24672 DTC_PM_LEVELING_DN_VALVE_OPEN_CIRCUIT 24673 DTC_PM_LEVELING_UP_VALVE_FEEDBACK_CURRENT_FAULT 24674 DTC_PM_LEVELING_DN_VALVE_FEEDBACK_CURRENT_FAULT 24675 DTC_JIB_UP_VALVE_SHORT_TO_GROUND 14676 DTC_JIB_UP_VALVE_SHORT_TO_POWER...
  • Page 173 Table 6-6 Fault code list (cont.) Item Fault code Fault info list Valve 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 12840 DTC_SWING_SAFETY_VALVE_OPEN_CIRCUIT 22738 DTC_DUMP_VALVE_SHORT_TO_GROUND 12739 DTC_DUMP_VALVE_SHORT_TO_POWER 22740 DTC_DUMP_VALVE_OPEN_CIRCUIT Machine 33851 DTC_STEEL_WIRE_ROPE_LOOSE condition 41852 DTC_DRIVE_DIRECTION_REVERSE 24853 DTC_OVER_LOAD 23854 DTC_RESTRICT_OR_UNRESTRICT 24855 DTC_LEVELING_FAULT 23856 DTC_SHORT_ROPE_FAULT...

  • Page 174: Electrical Schematics

    6.7 Electrical schematics Figure 6-52 Electrical schematics – KUBOTA engine V2607-CR-TI-EW02 6-36...
  • Page 175 Figure 6-53 Electrical schematics 6-37...
  • Page 176 Figure 6-54 Electrical schematics 6-38...
  • Page 177 Figure 6-55 Electrical schematics 6-39...
  • Page 178 Figure 6-56 Electrical schematics 6-40...
  • Page 179 Figure 6-57 Electrical schematics 6-41...

  • Page 181: Section 7 Hydraulic System Maintenance

    Section 7 Hydraulic System Maintenance...

  • Page 183: Hydraulic System Safety

    SECTION SEVEN HYDRAULIC SYSTEM MAINTENANCE 7.1 Hydraulic system safety The hydraulic system of the machine works under dangerous pressure. Therefore, the system should be relieved as much as possible before disassembly or removing a part of the system. When the engine is off and the power switch is on, the proper control is operated several times to release system pressure and channel all pipeline pressure back to the tank.
  • Page 184 After shutting down the equipment, conduct a good preventive maintenance measure to inspect all hydraulic components, lines, joints, etc., and implement functional inspection of each system before restart.

  • Page 185: Hydraulic Components

    7.5 Hydraulic components Figure 7-1 Hydraulic components Figure 7-2 Hydraulic components...

  • Page 186: Function Of Hydraulic Components

    7.6 Function of hydraulic components Table 7-1 Hydraulic components function Hydraulic components Function Main valve Control boom, rotation and steering, and provide oil to platform and chassis Traveling splite-flow valve Distribute flow of traveling pump to traveling motor Traveling control valve Control float, brake and two-speed Platform select valve Switch jib lifting and platform rotation...

  • Page 187: Hydraulic Schematics

    7.8 Hydraulic schematics...
  • Page 188 Figure 7-3-1 Hydraulic schematics – platform movement Figure 7-3-2 Hydraulic schematics – main valve movement...
  • Page 189 Figure 7-4-1 Hydraulic schematics - traveling Figure 7-4-2 Hydraulic schematics - traveling...
  • Page 190 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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