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Zoomlion ZA24J 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
ZA24J
Service and Maintenance Manual

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Summary of Contents for Zoomlion ZA24J

  • 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 ZA24J Service and Maintenance Manual Comply with ANSI SAIA_A92.20-2018 and CSA-B354.6-2017 Standard 2020.11 A...
  • Page 5 Foreword This Service and Maintenance Manual applies to the ZA24J aerial work platform (hereinafter referred to as the AWP). 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 ..................3-3 3.2.3 Cleaning ......................... 3-3 3.2.4 Component disassembly and installation ............... 3-3 3.2.5 Component disassembly and reinstallation ..............3-3 3.2.6 Pressure-fit parts ......................
  • Page 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 5.2.1 Leveling cylinder ......................5-4 5.2.2 Upper boom ........................5-5 5.2.3 Upper boom lifting cylinder ................... 5-6 5.2.4 Upper boom cable ......................5-7 5.2.5 Upper boom telescopic cylinder ..................5-9 5.2.6 Tower boom and its cylinder disassembly ..............5-10 5.2.7 Tower boom cable ......................
  • Page 11 履带起重机操作手册 第一章 安全操作说明...
  • Page 13 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 14 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 15 One of them must be in front of the turntable or platform control panel so that the engine can be maintenance. shut 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 16 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 17 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 18 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 19 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 23 SECTION 2 TECHNICAL PARAMETERS 2.1 Performance Table 2-1 Performance Platform capacity 250kg 45% (platform uphill) Max travel speed (on slope) 45% (platform downhill) Max travel speed (side slope) Platform height 24.5m Horizontal outreach 18.9m (outside) 6.48 m Turning radius (inside) 3.35 m Max travel speed 5.0 km/h Max hydraulic system pressure...
  • Page 24 2.3 Capacity Table 2-3 Capacity Fuel tank 150 L Hydraulic oil tank 170 L Engine oil capacity 2.4 Components Specification 2.4.1 Engine Table 2-4 CumminsQSF2.8 Engine parameters Type High pressure common rail Fuel No. 0 National IV Engine oil capacity About 8 L Rotate speed 1,200 (idling)
  • Page 25 2.6 Functional Speed Table 2-7 Functional speed (Unit: s) Function ZA24J Upper boom lifting 70~80 s Upper boom lowering 80~90s Turntable swing (a round) 110~130 s/200~240 s Upper boom extending 50~60 s Upper boom retracting 35~45 s Platform rotation (left an right)
  • Page 26 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 27 2.8 Lubrication 2.8.1 Hydraulic oil Table 2-9 Hydraulic oil specification ISO viscosity grade Pour point ℃ Flash point ℃ Motion viscosity cSt（40℃ ） 33.4 Viscosity index 2.9 Pressure Setting Table 2-10 Pressure setting Upper boom lifting 28MPa Upper boom extending 28MPa Turntable swing 20MPa...
  • Page 29 履带起重机操作手册 第一章 安全操作说明...
  • Page 31 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 Refer to the Machine Annual Inspection Form and the Preventive Maintenance Schedule for this 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.
  • Page 33 maintenance procedures contained in this manual. 3.2.2 Safety and operating standards Safety is paramount when performing equipment maintenance. Always pay attention to weight. Never attempt to move heavy parts without mechanical assistance. Do not park heavy objects in unstable locations. Ensure that adequate support is provided when lifting. 3.2.3 Cleaning Prevent dirt or impurities from entering critical parts of the machine for longer service lift.
  • Page 34 bearings cannot be rotated; If the bearing race and the steel ball (or roller) are sunken, scratched or burnt, scrap the bearing; If the bearing is still serviceable, apply a layer of oil and wrap it in clean paper (or wax paper). Do not open the reusable or new bearing packaging until you are ready to install it;...
  • Page 35 3.2.13 Battery The battery was cleaned with a non-metallic brush and an aqueous solution of sodium bicarbonate. Then rinse with clean water. When the battery is completely dry, apply the battery terminals with an anti-corrosion compound. 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...
  • Page 36 Table 3-3 Hydraulic system maintenance period Replacing Period Maintenance Mounting First Every Every 24 Every 500hrs Every 1,000hrs Items position 50hrs or 2,000hrs or months (not or 2 months or 6 months 30 days 12 months working) Replace return Control oil ★...
  • Page 37 hydraulic oil, accelerating its deterioration.And a large amount of air entering the oil will aggravate the "cavitation" phenomenon that the hydraulic oil compressibility will be increased, and the machine performance will be affected. As such, the following instructions should be noted for air invasion preventing: Eliminate air after maintenance or oil replacement;...
  • Page 38 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 39 Hydraulic oil tank air filter Maintenance point- replaceable filter element. Time interval- first 50 hrs after usage, every 6 months or 1,000 hrs thereafter. Low pressure filter Maintenance point- replaceable filter element. Time interval- first 50 hrs after usage, every 6 months or 1000 hrs thereafter. High pressure filter Maintenance point- replaceable filter element.
  • Page 40 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 41 Table 3-5 Hydraulic oil technical parameter Parameters ISO viscosity Pour Flash Motion viscosity Viscosity point ℃ point ℃ Brands grade cSt (40℃) index Great Wall 4632 grease non-flammable hydraulic oil 28.8-35.2 N32 (environmental friendly) Great Wall Ground No.10 — 10.53(50℃) Aviation hydraulic oil Great Wall Zhuoli L-HS 15 15.35...
  • Page 42 Table 3-5 Hydraulic oil technical parameter (cont.) Parameters ISO viscosity Pour Flash Motion viscosity Viscosity point ℃ point ℃ Brands grade cSt (40℃) index 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 Anti-wear hydraulic oil (high...
  • Page 43 other rubber components, while the oil also evaporates and oxidizes. 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 44 intact. Replace it if damaged. Make sure that all pipelines and hoses are kept at a sufficient distance at 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;...
  • Page 45 squeezing, twisting, etc .; Leak; 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.
  • Page 46 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 47 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 48 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 49 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. Each wire that exposes the connector housing should be wrapped with silicone grease to prevent short circuits.
  • Page 50 Table 3-3 Inspection and preventive m.aintenance schedule Time intervals Items Pre-delivery Every 2 Pre-start Weekly Monthly Annually or daily years 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 Cables or wire...
  • Page 51 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 52 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 53 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 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 A smooth, uniform cut with a total length of more than 7.5cm/3 inches in the ply; 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 130 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 Figure 4-6 Travel system disassembly diagram 2 4.7 Travel Reducer 4.7.1 Disassembly Place the machine on a solid level surface; Remove all hydraulic lines connected to the travel motor on the travel reducer and close the port; Use a suitable lifting device to support the travel reducer (the travel reducer weighs approximately 50kg/110lb;...
  • Page 64 Figure 4-7 Travel reducer disassembly diagram 4.7.2 Installation Use a suitable lifting device to support the travel reducer (the travel reducer weighs approximately 50kg/110 lb; 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 260Nm/188 ft·...
  • Page 65 4.8 Traveling Motor 4.8.1 Disassembly Place the machine on a solid level surface; Remove all hydraulic connections to the traveling motor and mark them; Use a suitable lifting device to support the traveling motor (the traveling motor weights approximately 15.4kg/34 lb; Disassemble the two mounting bolts used to connect the traveling motor to the steering knuckle;...
  • Page 66 Reinstalling the previously removed hydraulic line connected to the traveling motor; Start the unit and check the function of the traveling motor. 4.9 Rotary motor The rotary motor is the cycloidal motor, and it serves as an executive component of the rotary system. Disassemble and maintain the rotary motor: Remove the hydraulic hose connected to the motor, mark and seal it, then plug the oil feeding port of the motor;...
  • Page 67 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. Clean the interior of the rotary reducer and the brake with cleaning fluid before feeding oil; 2.
  • Page 68 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 69 should not continue to use the removed bolt, but should use new bolts. 4.12 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 70 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 71 4.13.2 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 5.2.3.3 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 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 If you need to disassemble the drag chain separately, disassemble the bolts 18 and 19. 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 Use appropriate lifting equipment to fix one end of the rope to the pin hole on the left side of the 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 Figure 5-9 CG of tower boom 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 other seals must be replaced before connecting the hydraulic pipeline; Thread fasteners should be tightened in place according to the torque requirements in "Section 2 Specifications". 5.2.7 Tower boom cable chain 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;...
  • Page 86 Mark and disconnect the hydraulic pipeline connecting the two cylinder balance valves, collect the hydraulic oil in the pipeline with a suitable container, and block the port of the pipeline after collection; Remove the telescopic balance valve, and use suitable lifting equipment to drag the telescopic arm back about 1.2m until the limit bolt 35 is exposed;...
  • 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 leads are reversed. Check the voltage prediction value, signal position, and whether the lead is properly 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);...
  • Page 99 First test the multimeter and leads by touching the two leads. The result should show a short circuit of resistance (very low resistance); The circuit power must be turned off before testing the resistor; Disconnect each component from the circuit before testing; If the multimeter cannot automatically adjust the range, set the correct range (refer to the multimeter operation manual);...
  • Page 100 Set the expected current range of the multimeter; Verify that the multimeter leads and jacket are properly connected within the current range of your choice; If the multimeter cannot automatically adjust the range, set the correct range (refer to the multimeter operation manual);...
  • Page 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 Figure 7-11 Electrical schematics (Figure 1/6)
  • Page 104 Figure 7-11 Electrical schematics (Figure 2/6)
  • Page 105 Figure 7-11 Electrical schematics (Figure 3/6)
  • Page 106 Figure 7-11 Electrical schematics (Figure 4/6) 7-10...
  • Page 107 Figure 7-11 Electrical schematics (Figure 5/6) 7-11...
  • Page 108 Figure 7-11 Electrical schematics (Figure 6/6) 7-12...
  • Page 109 7.5 Hydraulic Schematics Figure 7-12 Electrical schematics (Figure 1/2) 7-13...
  • Page 110 Figure 7-12 Electrical schematics (Figure 2/2) 7-14...