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Zoomlion ZA32J Service And Maintenance Manual

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ZOOMLION INTELLIGENT ACCESS MACHINERY CO.,LTD.
Add:Tengfei Road 997, Wangcheng District, Changsha, Hunan,PRC
E-mail:awm@zoomlion.com
Open up the WeChat, Scan the QR code above; All rights reserved 2015 © Zoomlion,reserves all rights,Without the written permission of Zoomlion, the contents of any part of this sample may not be copied for any purpose.
Zip Code:410200
Tel:400-800-0157
ZA32J
Service and Maintenance Manual
EN-SE

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chakib HAMDANI
January 28, 2025

The front left tyre is turned right whitout making any mouvement, and a fault error after opening the axles and the led of the proximity sensor are up zhich is " dtc_axles_fullout_verify_error

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Summary of Contents for Zoomlion ZA32J

  • Page 1 Add:Tengfei Road 997, Wangcheng District, Changsha, Hunan,PRC E-mail:awm@zoomlion.com Tel:400-800-0157 Open up the WeChat, Scan the QR code above; All rights reserved 2015 © Zoomlion,reserves all rights,Without the written permission of Zoomlion, the contents of any part of this sample may not be copied for any purpose.
  • Page 3 Service and Maintenance Manual ZA32J Service and Maintenance Manual 2021.12 A...
  • Page 5 Foreword This Service and Maintenance Manual applies to the ZA32J 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 6 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. Notice indicates information of property and device damage, or wrong operation.
  • Page 7 Contents Foreword ..............................I Content ..............................III SECTION 1 MAINTENANCE SAFETY INSTRUCTION ............1-1 1.1 Maintenance Personnel Duties, Requirements and Safety Equipment ..........1-1 1.1.1 Duties ..........................1-1 1.1.2 Basic requirements ......................1-1 1.1.3 Personnel safety equipment .................... 1-1 1.2 Maintenance Precautions ........................1-2 1.2.1 Precautions ........................
  • Page 8 Contents 3.1.6 Preventive maintenance ....................3-2 3.2 Maintenance and Service Instruction ....................3-2 3.2.1 General instruction ......................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 ..............3-3 3.2.6 Pressure-fit parts ......................
  • Page 9 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 10 Contents SECTION 5 BOOM AND PLATFORM ..................... 5-1 5.1 Platform and Jib ..........................5-1 5.1.1 Load cell disassembly ....................5-1 5.1.2 Rotary actuator disassembly ................... 5-2 5.1.3 Jib lifting cylinder ......................5-2 5.2 Boom Assembly ..........................5-3 5.2.1 Leveling cylinder ......................5-4 5.2.2 Upper boom ........................
  • Page 11 Contents 7.4 Electrical Schematics ........................7-7 7.5 Hydraulic Schematics ........................7-14...
  • Page 13 履带起重机操作手册 第一章 安全操作说明...
  • Page 15 SECTION ONE MAINTENANCE SAFETY INSTRUCTION 1.1 Maintenance Personnel Duties, Requirements and Safety Equipment 1.1.1Duties 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 16 procedures or replacement if necessary; Keep inspection and maintenance records if needed; Certain safety equipment (such as helmets and seat belts) might be damaged after prolonged use and should be inspected and replaced periodically. 1. Inspect safety equipment regularly, replace damaged parts if necessary; 2.
  • Page 17 of them must be in front of the turntable or platform control panel so that the engine can be shut maintenance. down at any time if necessary, and others can conduct inspection or Personnel should keep close contact to work safely; Clean the aerial work platform before inspection or maintenance.
  • Page 18 Figure 1-3 Mind explosion The positive and negative wires of the battery must be removed when welding to prevent the positive and negative poles of the welder from forming a loop with the unit body, thereby burning electrical components such as controllers and sensors. The company does not take the consequences for wrong operation.
  • Page 19 It is strictly forbidden to disassemble electronic components. Do not allow tools or parts to fall into the inspection hole; do not allow objects to fall into the holes during work. Falling objects can damage the machine or cause the machine to malfunction. Any tools or objects that fall into the inspection hole must be removed;...
  • Page 20 Inspection or maintenance of the electrical system without removing the cable of the battery may cause a short circuit and damage the wiring, electrical components and electronic components of the electrical system. The cable on the negative terminal side (ground side) must be removed before the inspection or maintenance work on the electrical system.
  • Page 21 on the mechanically maintained parts; necessary; Restore or reset the safety device and recalibrate the safety device if Remove the tools and equipment for maintenance, replace parts and scattered objects, and clean up the site; It should always be borne in mind that all maintenance should include mandatory confirmation of normal mechanical movement.
  • Page 25 SECTION 2 TECHNICAL PARAMETERS 2.1 Performance Table 2-1 Performance 250kg 551 lb Platform capacity 45% (platform uphill) Max travel speed (on slope) 45% (platform downhill) Max travel speed (side slope) 31.85m 104ft 6in Platform height 21.17 m 69ft 5in Max horizontal outreach (outside) 10.8/8.2m 25ft 4in/10ft 10in Turning radius...
  • Page 26 2.3 Capacity Table 2-3 Capacity 52.8 us gal 200 L Fuel tank 52.8 us gal 200 L Hydraulic oil tank 2.1 us gal Engine oil capacity 2.4 Components Specification 2.4.1 Engine Table 2-4 CumminsQSF2.8 Engine parameters High pressure common rail Type No.
  • Page 27 2.6 Functional Speed Table 2-7 Functional speed (Unit: s) ZA32J Function 150~170 s Upper boom lifting 140~160 s Upper boom lowering 200~220 s / 300~320s Turntable swing (a round) 65~75 s Upper boom extending 55~65 s Upper boom retracting 17~23s...
  • Page 28 position the speed switch to turtle speed. Record the time of forward/reverse through 20m; Drive (raised): select a smooth ground, position the speed switch to low speed. Record the time of forward/reverse through 50m. 2.6.2 Test cautions The stopwatch should be timed from the beginning of the actual action, not when the switch or controller is activated;...
  • Page 29 2.8 Lubrication 2.8.1 Hydraulic oil Table 2-9 Hydraulic oil specification ISO viscosity grade Pour point ℃ Flash point ℃ 33.4 Motion viscosity cSt（40℃ ） Viscosity index 2.9 Pressure Setting Table 2-10 Pressure setting 28MPa Upper boom lifting 28MPa Upper boom extending 20MPa Turntable swing 18MPa...
  • Page 31 履带起重机操作手册 第一章 安全操作说明...
  • Page 33 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 34 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 35 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 lift. This unit has taken preventive measures to protect against such violations.
  • Page 36 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. 3.2.8 Washer Check if holes in the washer are aligned with the opening of the fitting. Hand -made washer should be made of washer material or stock material of the same material and thickness.
  • Page 37 3.2.14 Lubrication and maintenance Parts and components that require lubrication and maintenance refer to the Lubrication Table in Section 3.3 Lubrication and Information 3.3.1 Regular inspection It is necessary to conduct regular maintenance of hydraulic system on time for good performance. The following table shows some routine inspections and maintenance: Table 3-2 Hydraulic system inspection period Inspection Intervals (hrs)
  • Page 38 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. If it is necessary to use alternative oil in a specific circumstance, the performance should be the same as that of the original brand.
  • Page 39 Refer to Table 3-5 Hydraulic oil parameters (not for models with specified hydraulic oil) for hydraulic oil types and models. Select suitable hydraulic oil types according to specific application. For special environments or users with special requirements, please contact ZOOMLION or hydraulic oil manufacturers.
  • Page 40 3.3.2.2 Replace filter Return oil filter Maintenance point- replaceable filter element. Time interval- first 50hrs after usage, every 6 months or 1000hrs thereafter. Hydraulic oil tank air filter Maintenance point- replaceable filter element. Time interval- first 50hrs after usage, every 6 months or 1000hrs thereafter. Low pressure filter Maintenance point- replaceable filter element.
  • Page 41 Refer to Table 3-5 Hydraulic oil parameters (not for models with specified hydraulic oil) for hydraulic oil types and models. Select suitable hydraulic oil types according to specific application. For special environments or users with special requirements, please contact ZOOMLION or hydraulic oil manufacturers.
  • Page 42 Table 3-5 Hydraulic oil technical parameter Motion Viscosity Parameters Pour Flash viscosity cSt viscosity index Brands point ℃ point ℃ grade (40℃) Great Wall 4632 grease non- 28.8-35.2 flammable hydraulic oil N32 (environmental friendly) Great Wall Ground No.10 — 10.53(50℃) Aviation hydraulic oil Great Wall Zhuoli L-HS 15 15.35...
  • Page 43 Table 3-5 Hydraulic oil technical parameter (cont.) Motion Viscosity Parameters Pour Flash viscosity cSt viscosity index Brands point ℃ point ℃ grade (40℃) Great Wall Zhuoli L-HV 46 48.7 Low temperature hydraulic oil Great Wall Zhuoli L-HV 68 70.47 Low temperature hydraulic oil Great Wall Zhuoli L-HM 46 45.8 Anti-wear hydraulic oil (high...
  • Page 44 Add the corresponding type of hydraulic oil according to the customer’s requirements before ex-factory. When the working environment temperature changes beyond the working range of the hydraulic oil, please replace other suitable types of hydraulic oil according to the actual situation. Considering the safety of the components and the efficiency of the work, it is recommended that the starting temperature of the equipment is higher than the selected hydraulic oil pour point temperature of 25 ℃...
  • Page 45 transitions so that there is no friction when laying. 3.3.5 check hydraulic cylinder Check the cylinder regularly, the checking items are listed as follows: Check the piston rod for scratches; When performing the corresponding auxiliary action, check whether there is oil leakage at the seal between the piston rod and the cylinder;...
  • Page 46 Failure to comply with installation and positioning requirements (refer to the notes on installing hydraulic lines mentioned below); The fixed equipment on the hose device is damaged; Corrosion, deformation or damage of the hose device; Exceeding storage time or use period. Even if no damage is found, the hose cannot be replaced by more than 6 years (including a maximum of 2 years of storage time) at the latest.
  • Page 47 Incorrect Correct A certain slack compensates for the shrinkage of the hose when it is under pressure; The hose usually has a length change rate of -4% to + 2% when under pressure. Incorrect Correct Use a pipe clamp to ensure the positioning of the hose: Effectively reduce wear between hoses and related components.
  • Page 48 3.4 Cylinder Drift Test Use the following method to determine the maximum acceptable cylinder drift. 3.4.1 Platform drift Measure drift from the platform to the ground. Raise the lower boom slightly (if equipped) and fully extend the upper boom with the platform capacity and power off. The maximum allowable drift in 10 minutes is 2 inches (5 cm).
  • Page 49 cleaned before inspection): Wear is found in the bearing area; 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 50 The silicone grease should be placed around the male and female pins on the inside of the connector before assembly to prevent oxidation. It can be operated with a syringe for convenience. Note: oxidation for a certain period of time will increase the resistance of the connector and eventually cause a circuit failure.
  • Page 51 Table 3-3 Inspection and preventive maintenance schedule Time intervals Items Pre-delivery Every 2 Pre-start Weekly Monthly Annually or daily years Boom assembly 1,2,4 1,2,4 Boom weldment 1,2,9,12 1,2,9,12 Oil pipe/wire rope Shaft pin and pin Pulley and pulley pins Bearings Wear pad Covers or shields 1,2,3...
  • Page 52 Table 3-3 Inspection and preventive maintenance schedule (cont.) Time intervals Items Pre-delivery Every 2 Pre-start Weekly Monthly Annually or daily years Function control locks, protective device or brake device Foot switch Emergency switch (Ground and platform) Function limit or cutout switch system Capacity indicator Drive brake...
  • Page 53 Consolidate all relevant security publications General structural state and welding All fasteners, pins, hood Lubricating grease and its and covering specification 21, 22 All system functional test Painting and appearance Imprint check date on the frame Notifying Zoomlion machine ownership 3-21...
  • Page 54 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. Implement inspection annually within 13 months from the date of the last inspection Performance code: 1 －Confirm that the installation is correct and secure 2 －Visually inspect for damage, cracks, deformation or excessive wear...
  • Page 55 履带起重机操作手册 第一章 安全操作说明...
  • Page 57 4.1.1 Tire inflation In order to endure the safety and normal operation, the air pressure of the pneumatic tire must be the same as the air pressure indicated on the side of the Zoomlion machines or the rim sticker. 4.1.2 Tire damage...
  • Page 58 Cracks (uneven edges) in any direction that exceed 2.5cm/1 inch in the ply; Perforations having a diameter of more than 2.5cm/1 inch; Any damage to the ply of the tire bead. If the tire is damaged but still within the above criteria, the tire must be inspected daily to ensure that the damage does not exceed the permissible standard.
  • Page 59 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 330 Nm...
  • Page 60 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 61 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 62 4.6 Traveling Drive System The traveling system is mainly composed of wheels, traveling reducer and traveling motor. Specifically, the four-wheel drive system consists of a variable displacement closed pump, four variable displacement piston motors, four gear reducers, and a split/flow-combining travel control valve. The two-wheel drive system consists of a variable displacement closed pump, two variable displacement piston motors, two gear reducers and a split/flow-combining travel control valve.
  • Page 63 Reducer bolt Steering bolt Reducer Tire bolt Figure 4-6 Travel reducer disassembly diagram 4.7.2 Installation Use a suitable lifting device to support the travel reducer (the travel reducer weighs approximately 110kg; 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 six bolts, and the bolt torque is 400Nm;...
  • Page 64 Steering welds Traveling motor bolts Traveling reducer Traveling motor Tire installation bolt Figure 4-7 Traveling motor disassembly diagram 4.8.2 Installation Use a suitable lifting device to support the traveling motor (the traveling motor weights approximately 15.4kg; Mounting the traveling motor on the machine; Note: if the travel motor output shaft is not aligned, it will cause damage to the bearings and seals of the traveling motor output shaft and its surroundings.
  • Page 65 any switch is not triggered, the control system considers the axle to be retracted. When the operator controls the axle to extend or contract, the outrigger full extension indicator will flash, and when the axle is fully extended, the indicator will continue to light up. When the axle is not fully extended, the range of motion of the main arm is limited to the storage position interval.
  • Page 66 4.12 Traveling/Steering Speed Control The driving/steering speed control system uses the steering sensor of the steering control system to improve the operator's handling and comfort by reducing the effect of turning the chassis on the lateral translation speed. This system changes the driving speed in proportion to the expected turning radius of the chassis in the coordinated and conventional two-wheel steering mode.
  • Page 67 1. It is not recommended that users disassemble the hydraulic motor by themselves. If there is a problem with the hydraulic motor, please contact your nearest after-sales service directly; 2. Be sure to keep in mind the installation position of each interface and part during the disassembly process;...
  • Page 68 4.15.2 Replace the gear oil Insure that the oil ports at the reducer and brake are in place; Remove the oil plug and drain plug, drain the oil inside the reducer and the brake. Figure 4-9 Oil ports in reducer 1.
  • Page 69 If the equipment is not used for a long time, the slewing support shall be lubricated, as the lubrication should be more frequent in windy or humid tropical climates with irregular temperature effects. Use a grease gun to inject Mobilux EP 2, Shell Alvania EP(LF) 2 grease, etc. from the grease nipple at the slewing ring raceway to the slewing ring raceway until the grease leaks from the seal and fills the raceway.
  • Page 70 The bolt of the slewing bearing is a very important connection part of this equipment. The user should not continue to use the removed bolt, but should use new bolts. 4.17 Clearance adjustment of the gear in slewing mechanism The gear gap of the slewing mechanism refers to the meshing gap between the small gear on the slewing reducer and the slewing support (big gear).
  • Page 71 4.18Generator 4.18.1 Check and maintain Every 250 hours; Check that the drive belt tension is appropriate 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. Use a hair dryer to blow the inside of the generator every 500 hours of operation.
  • Page 72 4.18.2 Check the carbon brush, replace the carbon brush, clean the slip ring 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 be completely aligned with the slip ring. Check the carbon brush;...
  • Page 75 SECTION 5 BOOM AND PLATFORM 5.1 Platform and Jib 5.1.1 Load cell 5.1.1.1 Disassembly Figure 5-1 Load cell disassembly diagram Retract the tower boom and the upper boom; Disconnect the wiring harness at the platform control box and the load cell, disconnect the pipeline at the platform valve, and mark it at the same time;...
  • Page 76 should be cleaned to prevent contaminants from entering the hydraulic system; Threaded fasteners should be tightened in place according to the torque values in Section 2 Specifications. 5.1.2 Rotary actuator 5.1.2.1 Disassembly Figure 5-2 Jib lifting cylinder disassembly diagram Disconnect the hydraulic line connecting the rotary actuator balancing valve, collect the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting;...
  • Page 77 Remove the stop pin 8 connecting jib cylinder and upper linkage, and remove the lower pin 7; Remove the stop pin 10 of the support and the lower connecting rod, and remove the pin 9 to disassemble the jib lifting cylinder. 5.1.3.2 Inspection Check the line for wear and replace the wiring harness if necessary;...
  • Page 78 5.2.1 Leveling cylinder Figure 5-3 Upper leveling cylinder disassembly diagram 5.2.1.1 Disassembly Stow the upper boom and tower boom and adjust the jib to level; Before disassembling the leveling cylinder, disassemble the jib and working platform according to the operation steps in 5.1.2.1; Mark and disconnect the hydraulic line connecting the leveling cylinder balancing valve, collect the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting;...
  • Page 79 5.2.2 Upper Boom Figure 5-4 Upper boom disassembly diagram Adjust the posture of the tower boom to the stowed state, and adjust the posture of the upper boom to the level of the boom; Before the upper boom is dismantled, the jib, working platform and leveling cylinder shall be dismantled according to the operation steps in 5.1.2.1 and 5.2.1.1;...
  • Page 80 if necessary; Check whether the inner ring of the bearing is scratched, twisted, worn or otherwise damaged, and replace the bearing if necessary; Check all threaded parts for damage such as stretching, thread deformation or twisting, and replace them if necessary. 5.2.2.3 Installation Please follow the reverse steps of disassembly, the pipe joints of the hydraulic pipeline and the balance valve interface should be cleaned before installation to prevent pollutants from entering the...
  • Page 81 Please follow the reverse steps of disassembly, the pipe joints of the hydraulic pipeline and the balance valve interface should be cleaned before installation to prevent pollutants from entering the hydraulic system; If the hydraulic system pipe joints are equipped with sealing devices such as seals, the seals and other seals must be replaced before connecting the hydraulic pipeline;...
  • Page 82 5.2.4.2 Inspection Check whether the wiring is worn or not, and replace the wiring harness if necessary; Check whether the hydraulic pipeline is leaking, and it is necessary to replace the pipeline; Check all threaded parts for damage such as stretching, thread deformation or twisting, and replace if necessary;...
  • Page 83 telescopic cylinder; Operate the lifting equipment, slowly and steadily drag the telescopic cylinder out of base boom, and then hoist it on a suitable support frame; Operate the lifting equipment, tie the rope tightly to the end of the telescopic boom on the right side as shown in the figure, and slowly and steadily drag tower boom out of the upper boom.
  • Page 84 It is necessary to disassemble the jib and working platform, leveling cylinder,upper boom, and upper boom lifting cylinder in advance according to the operation steps of 5.1.2.1, 5.2.1.1, 5.2.2.1, and 5.2.3.1; Pull out the tow chain harness connector of tower boom at the junction of tower boom and No. 1 arm and at the ground electric control box, mark and pull out the wire harness plug of the travel switch from the side of the upper boom;...
  • Page 85 Before disassembling the tower boom drag chain, follow the steps in 5.1.2.1, 5.2.1.1, 5.2.2.1, 5.2.3.1, 5.2.6.1 to disassemble the jib and working platform, leveling cylinder, upper boom, upper boom lifting cylinder, tower boom; Remove the fixing bolt 32 that fixes the moving tube on the base boom; Remove the bolt 31 that fixes the pallet on base boom;...
  • Page 86 Choose suitable lifting equipment, and fix one end of the rope to the left side of the telescopic cylinder I; Operate the lifting equipment, slowly and steadily drag the telescopic cylinder I out of one arm, then lift it and place it on a suitable support frame; Remove the fastening bolt 35 and the clamping plate 36 connecting the two-section arm and the three-section arm to the telescopic cylinder II;...
  • Page 89 SECTION 6 ELECTRICAL SYSTEM MAINTENANCE 6.1 Fault Code When the unit fails, check the fault message indicated by the display on the ground console. If the display on the ground console indicates the following fault code, remove the fault condition and restart the device before continuing operation.
  • Page 90 Table 6-1 Fault code list (cont.) Classification Fault code Fault code list 12356 DTC_FAULT_UG_TELESCOPE_DOUBLE_POWER_ON 22357 DTC_FAULT_UG_ROTATE_SWITCH_DOUBLE_POWER_ON 12358 DTC_FAULT_UG_LEVELING_SWITCH_DOUBLE_POWER_ON 22359 DTC_FAULT_UG_SWING_SWITCH_DOUBLE_POWER_ON 22360 DTC_FAULT_UG_ENGINE_SWITCH_DOUBLE_POWER_ON 14361 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_DOUBLE_POWER_ON 14363 DTC_FAULT_PM_JIB_SWITCH_DOUBLE_POWER_ON 14364 DTC_FAULT_PM_TELESCOPE_DOUBLE_POWER_ON 24365 DTC_FAULT_PM_ROTATE_SWITCH_DOUBLE_POWER_ON 14366 DTC_FAULT_PM_LEVELING_SWITCH_DOUBLE_POWER_ON 24367 DTC_FAULT_PM_SWING_JOYSTICK_DOUBLE_POWER_ON 24368 DTC_FAULT_PM_ENGINE_SWITCH_DOUBLE_POWER_ON 14369 DTC_FAULT_PM_DRIVE_JOYSTICK_DOUBLE_POWER_ON 14370 DTC_FAULT_PM_STEER_JOYSTICK_DOUBLE_POWER_ON 14371 DTC_FAULT_UG_FOOTSWITCH_CLOSED Switch/handle...
  • Page 91 Table 6-1 Fault code list (cont.) Classification Fault code Fault code list 22556 DTC_DRIVE_REVERSE_VALVE_OPEN_CIRCUIT 22557 DTC_DRIVE_FORWARD_VALVE_FEEDBACK_CURRENT_FAULT 22558 DTC_DRIVE_REVERSE_VALVE_FEEDBACK_CURRENT_FAULT 21559 DTC_FLOAT_CONTROL_VALVE_SHORT_TO_GROUND 21560 DTC_FLOAT_CONTROL_VALVE_SHORT_TO_POWER 21561 DTC_FLOAT_CONTROL_VALVE_OPEN_CIRCUIT 21562 DTC_BRAKE_VALVE_SHORT_TO_GROUND 11563 DTC_BRAKE_VALVE_SHORT_TO_POWER 21564 DTC_BRAKE_VALVE_OPEN_CIRCUIT 21565 DTC_2SPEED_VALVE_SHORT_TO_GROUND 21566 DTC_2SPEED_VALVE_SHORT_TO_POWER 21567 DTC_2SPEED_VALVE_OPEN_CIRCUIT 22568 DTC_STEER_LEFT_VALVE_SHORT_TO_GROUND 12569 DTC_STEER_LEFT_VALVE_SHORT_TO_POWER 22570 DTC_STEER_LEFT_VALVE_OPEN_CIRCUIT 22571...
  • Page 92 Table 6-1 Fault code list (cont.) Classification Fault code Fault code list 22590 DTC_4SELECT_MAIN_CONTROL_RIGHT_VALVE_OPEN_CIRCIUT 22593 DTC_MAIN_LIFT_UP_VALVE_SHORT_TO_GROUND 12594 DTC_MAIN_LIFT_UP_VALVE_SHORT_TO_POWER 22595 DTC_MAIN_LIFT_UP_VALVE_OPEN_CIRCUIT 22597 DTC_TOWER_LIFT_UP_VALVE_SHORT_TO_GROUND 12598 DTC_TOWER_LIFT_UP_VALVE_SHORT_TO_POWE 22599 DTC_TOWER_LIFT_UP_VALVE_OPEN_CIRCUIT 23601 DTC_TELESCOPE_VALVE_SHORT_TO_GROUND 13602 DTC_TELESCOPE_VALVE_SHORT_TO_POWER 23603 DTC_TELESCOPE_VALVE_OPEN_CIRCUI 23604 DTC_HAND_LEVELING_VALVE_SHORT_TO_GROUND 13605 DTC_HAND_LEVELING_VALVE_SHORT_TO_POWER 23606 DTC_HAND_LEVELING_VALVE_OPEN_CIRCUIT 23607 DTC_JIB_VALVE_SHORT_TO_GROUND Valve 13608 DTC_JIB_VALVE_SHORT_TO_POWER...
  • Page 93 Table 6.2 Common faults and solutions Fault Feature Fault Cause Solution Remove the battery or replace it with a 1. Battery exhausted new one. 2. Operation switch or Push the operating switch or handle handle is not returned to back to the neutral position neutral position 3.
  • Page 94 Replace controller 1. If you encounter any equipment failure, contact Zoomlion for timely troubleshooting; 2. If there is no absolute understanding of the fault resolution, please contact Zoomlion or Zoomlion dealers to solve it; 3. It is forbidden to open the electric control cabinet to change the wire.
  • Page 97 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 not be corrected by the listed solutions, occur, you should obtain authoritative technical guidance before performing maintenance.
  • Page 98 connected to the device under test. Also check that the lead of the COM port is grounded or the negative signal is connected, and that the lead of the other port is connected to the positive signal. 7.2.5 Range M = mega = 1,000,000 * (displayed number); k = thousand = 1,000 * (displayed number);...
  • Page 99 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); Make sure the multimeter leads are securely connected. 7.2.8 Conduction test Figure 7-3 Conduction test The multimeter needs to use a separate button to initiate the continuity test of the beep;...
  • Page 100 choice; 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. 7.3 DEUTSCH Connector 7.3.1 DT/DTP series connector assembly Figure 7-5 DT/DTP contact installation Pinch the crimped contact about 25mm (1 in) behind the contact cylinder;...
  • Page 101 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 102 that the connector is fully locked. Figure 7-8 HD/HDP lock contact position Note: for unused wire cavities, a sealing plug should be inserted to achieve complete isolation from the environment. 7.3.4 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;...
  • Page 103 7.4 Electrical Schematics 图 7-11 电气原理图 图 1/7...
  • Page 104 图 7-12 电气原理图 图 2/7...
  • Page 105 图 7-13 电气原理图 图 3/7...
  • Page 106 图 7-14 电气原理图 图 4/7 7-10...
  • Page 107 图 7-15 电气原理图 图 5/7 7-11...
  • Page 108 图 7-16 电气原理图 图 6/7 7-12...
  • Page 109 图 7-17 电气原理图 图 7/7 7-13...
  • Page 110 7.5 Hydraulic Schematics Figure 7-12 Electrical schematics (Figure 1/2) 7-14...
  • Page 111 Figure 7-12 Electrical schematics (Figure 2/2) 7-15...
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