Zoomlion ZS1930E Series Service And Maintenance Manual

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Operation and safety manual (101 pages)

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ervice and Maintenance Manual

ZOOMLION

ZS1930E Series

ZS1530E Series

Service and Maintenance Manual

Oct 2023 Version A

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Page 1 Maintenance Manual ZOOMLION ZS1930E Series ZS1530E Series Service and Maintenance Manual Oct 2023 Version A...
Page 3: Foreword
This manual should be considered a permanent part of your machine and should remain the machine at all times. Do not repair the parts marked with professional maintenance. Zoomlion AWP Machinery Company does not take the consequence for wrong maintenance.
Page 4 Service and Maintenance Manual 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.
Page 5: Table Of Contents
Service and Maintenance Manual Contents Foreword ................................I Content ................................III SECTION 1 MAINTENANCE SAFETY INSTRUCTION ..............1-1 1.1 Maintenance Cycle Instruction ......................... 1-1 1.2 User Responsibility ..........................1-1 1.3 Service Center Obligation ........................1-1 1.4 Disclaimer ..............................1-2 SECTION 2 MAINTENANCE REQUIREMENTS .................. 2-1 2.1 General ..............................
Page 6: Content
Service and Maintenance Manual Contents 2.6.3.7 Test the horn...................... 2-16 2.6.3.8 Test the drive brakes ..................2-16 2.6.3.9 Test the top drive speed-stowed position ............2-18 2.6.3.10 Test the drive speed-raised position ..............2-18 2.6.3.11 Test slow drive speed-stowed position ............2-19 2.6.3.12 Hydraulic oil analysis ..................
Page 9: Section 1 Maintenance Safety Instruction
Your proper maintenance is an important prerequisite for the use of the aerial work platform. Read and understand this manual before attempting to any maintenance procedure. Conduct daily and regular maintenance in accordance with the contents and requirements of this manual. Zoomlion's marketing network throughout the world will provide you with professional consulting, maintenance and repair services.
Page 10: Disclaimer
Service and Maintenance Manual 1.4 Disclaimer Zoomlion does not assume any responsibility for direct or indirect losses caused by the following actions: Wrong operations or applications. Unauthorized modification and parameter adjustment of the machine. Do not use Zoomlion's original accessories and dedicated oils.
Page 13: Section 2 Maintenance Requirements
If you find any items that require immediate repair and adjustment, perform maintenance immediately. Contact local Zoomlion service center for repairing. Please use the accessories and grease specified by our company for good performance. Timely replacement of consumables, such as filter element to prevent failures due to delays.
Page 14: Safety Precautions
Service and Maintenance Manual 2.2.2 Safety precautions Perform all locks, turn the power switch to off position and remove the switch keys during machine inspection and maintenance. If not comply with the rules, could result in serious injury or death. Set the warning sign during maintenance.
Page 15 Service and Maintenance Manual Figure 2-3 DO NOT spray water at the joint 1. Do not spray water on electrical components and connectors while cleaning the machine. 2. Lubricate the steering knuckles after cleaning. 3. Clean the control panel with warm water containing detergent only. DO NOT use corrosive cleaning agent.
Page 16: Pre-Delivery Inspection
The Gregorian time (day, month, year) at which the machine is working and stored. Maintenance intervals of Zoomlion Scissor Lifts are generally determined by the certain running time of functional components, and the special content needs to be determined in the latter way.
Page 17: Maintenance Schedule
Service and Maintenance Manual Table 2-1 Maintenance intervals Maintenance Intervals Maintenance Intervals Running Time (hours) Instruction Daily (D) Before and after operation Monthly (M1) About 100 Once a month Quarterly (M3) About 250 Once every three months Every 6 months (M6) About 500 Once every six months Annually (M12)
Page 18 Service and Maintenance Manual Table 2-2 Maintenance schedule Maintenance Every Quarter Every 6 Annuall Items Work Description Daily Monthly months years Lubricating steering ★ 2.6.2.2 knuckles ★ 2.6.3.1 Battery maintenance Li-ion battery ★ 2.6.3.2 maintenance Inspect electrical ★ 2.6.3.3 wire Inspect the tires and ★...
Page 19 Service and Maintenance Manual Table 2-2 Maintenance schedule Maintenance Every Quarter Every 6 Annuall Items Work Description Daily Monthly months years Test emergency ★ 2.6.3.12 lowering function Test safety arm ★ 2.6.3.13 support limit function Inspect tray latch ★ 2.6.3.14 components Inspect down limit switch, level sensor...
Page 20: Maintenance Inspection
Put it back in the storage box after using the manual. Reminder: if need to replace the manual or label, please contact Zoomlion or Zoomlion dealer. 2.6.1.2 Pre-start inspection It is important to implement pre-start inspection for safety operation. The pre-operation check is done visually before the machine is running.
Page 21: Functional Test
Service and Maintenance Manual Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches or other jewelry. Batteries fluid is highly corrosive. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. Fully charge the battery before performing the following inspections.
Page 22: Maintenenca Every Month
Service and Maintenance Manual 2.6.2 Maintenance every month 2.6.2.1 Maintenance after 30 days 30-day maintenance is a one-time maintenance after the first 30 days or 50 hours of machine operation. Continue the scheduled maintenance after this one-time maintenance. Perform the following maintenance: Tires and hubs.
Page 23 Service and Maintenance Manual Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Check the ambient air temperature and adjust the specific gravity for each as follows: Add 0.004 from the reading of each cell for every 5.5℃/ 42℉ above 26.7℃/ 80℉. Subtract 0.004 from the reading of each cell for every 5.5℃/ 42℉...
Page 24 Service and Maintenance Manual Figure 2-7 ZS1530E Battery connections Figure 2-8 Li-ion Battery connections Table 2-3 Code name Code Name Code Name Battery/Li-ion battery Main Switch Charger Fuse Inspect the battery charger plug and pigtail for damage or excessive insulation wear. Replace as required.
Page 25: Li-Ion Battery Maintenance
Service and Maintenance Manual Consult Zoomlion after-sale service team for more relevant problems. 2.6.3.2 Li-ion battery maintenance The battery system should not be used for a long time. It should be placed in a cool and dry environment (temperature below 30℃/ 86℉ and humidity less than 90%), and it should be charged with a special charger at least every three months.
Page 26: Inspect The Tires And Wheels
Service and Maintenance Manual ECU to platform. All wire harness connectors to platform control box. Lift the platform, replace the safety arm to installation position. Lower the platform. 2.6.3.4 Inspect the tires and wheels This inspection is conducted every 250 hours or quarter, whichever comes first. Maintaining the tires and wheels is essential to safe operation and good performance.
Page 27: Test Key Switch
Service and Maintenance Manual Table 2-4 Ground control panel instruction Name Name Lifting enable button Menu escape button Menu up button LCD diagnostic readout Key switch Emergency stop switch 10A breaker Menu down button Menu enter button Platform up button Platform down button Turn the key switch to Ground Control and pull out the red Emergency Stop button to the on position at both the ground and platform controls,...
Page 28: Test The Horn
Service and Maintenance Manual Result: the machine has no movements. Turn the key switch to off position. Result: the machine has no movements. 2.6.3.7 Test the horn This inspection is conducted every 250 hours or quarter, whichever comes first. Horn is used to alert operators and ground personnel of machine proximity and motion. A malfunctioning horn cannot alert the ground personnel to a dangerous or unsafe condition.
Page 29 Service and Maintenance Manual Figure 2-10 Platform control panel Table 2-5 Platform control panel instruction Name Name Emergency stop switch Horn Button Lift function button Control handle Steering thumb button LED Readout Drive function button Drive speed button 2-17...
Page 30: Test The Top Drive Speed-Stowed Position
Service and Maintenance Manual Choose a point on the machine (i.e., contact patch of a tire) as a visual reference for use when crossing the test line. Bring the machine to top drive speed before reaching the test line. Release the drive joystick when your reference point on the machine crosses the test line.
Page 31: Test Slow Drive Speed-Stowed Position
Service and Maintenance Manual over the entire speed range. Select a test area that is firm, level and free of obstructions. Create start and finish lines by marking two lines on the ground 10m/32ft 10in apart. Turn the key switch to Platform Control and pull out the red Emergency Stop button to the on position at both the ground and platform controls.
Page 32: Inspect Tray Latch Components
Service and Maintenance Manual 2.6.3.12 Test emergency lowering function This inspection is conducted every 250 hours or quarter, whichever comes first. The normal emergency descent function of the liner actuator is very important for operator safety and machine performance. In the case of system power failure, operate the emergency descending lever. If the descending speed is abnormally fast, it will affect the operator safety and the machine performance.
Page 33 Service and Maintenance Manual Proper limit switch is essential to good performance and safe operation. A faulty limit switch could cause result in reduced machine performance and a potential unsafe operating condition. Select a test area that is firm, level and free of obstructions. Down limit switch Turn the key switch to ground control.
Page 34: Inspect Up Limit Switch
Service and Maintenance Manual 2.6.3.16 Inspect up limit switch This inspection is conducted every 250 hours or quarter, whichever comes first. Proper limit switch is essential to good performance and safe operation. A faulty limit switch could cause result in reduced machine performance and a potential unsafe operating condition. Select a test area that is firm, level and free of obstructions.
Page 35: Check The Wear Condition Of The Liner Actuator Ball Screw
Service and Maintenance Manual Move the machine to a firm and level ground; Place heavy objects on the platform (264kg for ZS1530); Turn the key switch to ground control. Results: Alarm sound sounded, display OL; Results: The alarm sound did not sound, the display did not display OL, and the platform could continue to rise.
Page 36: Maintenance Every 24 Months
Service and Maintenance Manual space between here Figure 2-11 Inspection of wear pad Measure the distance between the number one inner arm across tube and the chassis deck at the ground control side of the non-steer end of the machine. For ZS1930 Series machines.
Page 37 Service and Maintenance Manual synthetic grease will reduce wear, rust, corrosion and adapt to normal work in high or low temperature environment. Mobil SHC220 grease can achieve very low starting torque and running torque. Its operating temperature range is -40℃~+177℃. The grease filling amount is 50g/ time.
Page 41: Section 3 Electrical System Maintenance
Service and Maintenance Manual SECTION 3 ELECTRICAL SYSTEM MAINTENANCE 3.1 Electrical System Trouble shooting If the platform controls LED or ground controls LCD diagnostic readout displays following codes, the fault condition must repaired or removed before resuming machine operation. 3.1.1 Fault code Table 3-1 Fault code list Code Condition...
Page 42 Service and Maintenance Manual Table 3-1 Fault code list Condition Machine Reaction Code Disable Lifting, and Driving Lift Slow to Total Voltage Low Fault I Drive Speed Disable Lifting, and Driving Lift Slow to Cell Voltage Low Fault I Drive Speed Cell Voltage Low Fault II Disable Lifting, and Driving Sharp Diff in Voltage...
Page 43 Service and Maintenance Manual Table 3-1 Fault code list Condition Machine Reaction Code Load Sending Sensor 3 Fault Disable Lifting and Driving Load Sending Sensor 4 Fault Disable Lifting and Driving Platform Enable Button ON Disable Platform Control Joystick Not in Neutral Lift Slow to Drive Speed General Brake Coil Fault Disable Lifting and Driving...
Page 44: Troubles Shooting Method
Service and Maintenance Manual 3.1.2 Troubles shooting method Table 3-2 Trouble shooting method Code Trouble shooting Method System Initialization Fault: ECU may be malfunctioning, replace it. System Communication Fault: Check communications cable connections and other wiring. If that does not resolve the problem, try replacing the PCU or ECU. Invalid Option setting Fault: Set appropriate option for this lift.
Page 45 Service and Maintenance Manual Table 3-2 Trouble shooting method Code Trouble shooting Method Disch Current High Fault I: Lower capacity or travel slowly. Total Voltage Low Fault I: Restart the key, charge immediately. Cell Voltage Low Fault I: Restart the key, charge immediately. Cell Voltage Low Fault II: Switch off the key, charge immediately.
Page 46 Right Drive Motor Controller Fault: Check connections to the right motors, drive motor controller and contactor. In case the problem is not solved, contact a Zoomlion technician. Over 80% Load Warning: Platform is getting close to its limit of weight. Consider not adding more load.
Page 47 Service and Maintenance Manual Table 3-2 Trouble shooting method Trouble shooting Method Code Emergency Contactor Fault: Replace the Emergency Contactor. Over 99% Load Warning: Platform has reached its limit of weight. Do not add more load. Overloaded Platform Fault: Remove the excess load immediately. Machine Tilted Beyond Safe Limits Fault: If the machine is tilted, find a way to make it level.
Page 48: Ecu Pin Definition
Service and Maintenance Manual 3.1.3 ECU pin definition Figure 3-1 35 pin interface Table 3-3 ECU 35 pin interface definition Type Function Type Function Support bar contact switch Input Input Outdoor limit switch check check Output Reserve Power Valve-driven power Power Valve-driven power Output...
Page 49 Service and Maintenance Manual Table 3-3 ECU 35 pin interface definition Type Function Type Function Output Reserve Input Pothole switch check Communi Input Up limit switch check PCU communication - cation Power Working power Input Force sensor 3 Output Drive motor speed control Input Driver fault code Output...
Page 50 Service and Maintenance Manual Figure 3-2 14 pin interface Table 3-4 ECU 14 pin interface definition Type Function Output Alarm control Input Reserve Output Reserve Communication GPS Communication CAN-H2 Communication GPS Communication CAN-L2 Input Force sensor 1 Input Force sensor 2 Output Buzzer Output...
Page 51: Electrical Schematic
Service and Maintenance Manual 3.1.4 Electrical schematic Figure 3-3 ZS1530E-Li Electrical schematic 3-11...
Page 52 Service and Maintenance Manual Figure 3-4 ZS1530E-Li CAN Bus 3-12...
Page 53 Service and Maintenance Manual Figure 3-5 ZS1530E Electrical schematic 3-13...
Page 54 Service and Maintenance Manual Figure 3-6 ZS1530E CAN Bus 3-14...
Page 55 Service and Maintenance Manual Figure 3-7 ZS1930E Electrical schematic 3-15...
Page 56 Service and Maintenance Manual Figure 3-8 ZS1930E CAN Bus 3-16...
Page 57 Service and Maintenance Manual Section 4 Common Faults Analysis...
Page 59: Section 4 Common Faults Analysis
Service and Maintenance Manual SECTION 4 COMMON FAULTS ANALYSIS When the work platform is in use, it is necessary to inspect it in time and to repair it when necessary. The purpose of maintenance is as follows: Ensuring the reliability of operations. Maintaining the efficiency of the work platform.
Page 60 Service and Maintenance Manual Table 4-1 Electrical System Fault List Fault Cause Solution phenomenon 1. Check and restore upper limit 1. Loose connection of upper switch connection. limit switch. 2. Recalibration and re-fixing The work platform 2. The position of upper limit installation position of upper limit is elevated to the switch is shifted and cannot...
Page 61 Service and Maintenance Manual Table 4-1 Electrical System Fault List Fault Cause Solution phenomenon 1. 300A main fuse burned 1. Replacement of the 300A main fuse. down. 2. Press 10A circuit breaker to restore 2. 10A breaker tripping. connection. UP and DOWN 3.
Page 63 Add:701 Xulong Nan Lu, Xiangjiang New District, Changsha, Hunan, China 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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Zs1530e series