1. Manuals
  2. Brands
  3. Zoomlion Manuals
  4. Lifting Systems
  5. ZT215J
  6. Service and maintenance manual

Zoomlion ZT215J Service And Maintenance Manual

Hide thumbs Also See for ZT215J:
Table of Contents

Advertisement

Quick Links

Download this manual
Service and Maintenance
Service and Maintenance Manual
ZT215J
Service and Maintenance Manual
Apr 2024 Version A

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ZT215J and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Zoomlion ZT215J

Summary of Contents for Zoomlion ZT215J

  • Page 1 Service and Maintenance Service and Maintenance Manual ZT215J Service and Maintenance Manual Apr 2024 Version A...

  • Page 3: Foreword

    Foreword This Service and Maintenance Manual applies to the ZT215J boom lift (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………….…………….………………………….…………………………..…………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 ........................1-2 1.2.2 Precautions in maintenance ..................
  • Page 6 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 ..................3-3 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 Chassis Angle Sensor System ....................4-3 4.3 Auxiliary Power System ......................
  • Page 8 Contents 4.16.1 Engine main components ..................4-14 4.16.2 Fuel system ......................4-16 4.16.3 Cooling system ......................4-19 4.16.4 Lubrication system....................4-20 4.16.5 Control system ......................4-21 SECTION 5 BOOM AND PLATFORM ................... 5-1 5.1 Platform and Jib ........................5-1 5.1.1 Load cell ........................5-1 5.1.2 Jib chain ........................
  • Page 9 Contents SECTION 7 ELECTRICAL INFORMATION AND SCHEMATIC ........7-1 7.1 General Introduction ....................... 7-1 7.2 Multimeter basic operation ..................... 7-1 7.2.1 Grounding ........................7-1 7.2.2 Backside detection ....................... 7-1 7.2.3 Minimum value/maximum value ................. 7-1 7.2.4 Polarity......................... 7-1 7.2.5 Range ........................... 7-2 7.2.6 Voltage measurement ....................

  • 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

    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 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. The components that affect the stability, strength and performance of the platform could be modified only after obtaining the approval of the manufacturer, such as structural parts, carriers, electrical components, and hydraulic components.
  • 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 660lbs/1000lbs 40% (platform uphill) Max Travel Speed (on slope) 40% (platform downhill) Max Travel Speed (on side slope) Platform Height 214 ft 11 in 65.5 m Horizontal Outreach 101 ft 8 in 31 m 8.43/6.39m (outside)

  • Page 24: Capacity

    2.3 Capacity Table 2-3 Capacity Fuel Tank 200 L 52.8 us gal Hydraulic tank 400 L us gal 158.4 Engine Oil Capacity 12 L 3.17 us gal 2.4 Components Specification 2.4.1 Engine Table 2-4 Cummins F3.8 Engine Specification Type High pressure common rail Fuel 0# IV standard diesel Engine Oil Capacity...

  • Page 25: Battery

    445/50 D710 Foam-filled 12000 kg 16500 kg 480±5 kg 26455 lbs 36376 lbs 1058±11 lbs 2.6 Functional Speed Table 2-7 Functional speed Function ZT215J Boom Lifting 220-300 Boom Descending 200-280 Turntable Swing (a round) 180-220 Boom Extending 300-350 Boom Retracting 300-350...

  • Page 26: Test Cautions

    and descending time respectively. 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 12 ° and the extension length less than 1.5m.

  • Page 27: Lubrication

    the appropriate torque value. Table 2-9 Special toque Requirements Torque value Instruction: Time intervals (N.m) 50 hours after the first run, every 150 hours or 3 Hub fastening bolt M22 540/398.3ftlbs months thereafter 100 hours after the first run, every 500 hours Slew bearing bolt M20 520/383.5 ftlbs thereafter...

  • 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

    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. 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: Safety And Operating Standards

    3.2.2 Safety and operating standards Safety is paramount when performing equipment maintenance. Always pay attention to weight. Never attempt to move heavy parts without mechanical assistance. Do not park heavy objects in unstable locations. Ensure that adequate support is provided when lifting. 3.2.3 Cleaning Prevent dirt or impurities from entering critical parts of the machine for longer service life.

  • Page 34: Washer

    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: Lubrication And Maintenance

    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 Hydraulic system Contaminants are the primary factor in invading the hydraulic system. Contaminants can invade in various ways, such as improper use of hydraulic oil, or the moisture, grease, metal shavings, sealing elements, sand, etc.
  • Page 36 For special environments or users with special requirements, please contact ZOOMLION or hydraulic oil manufacturers. Note: DO NOT mix oils of different brands or types, as they contain different additives which may cause negative effects. If mixing of hydraulic oils is unavoidable, permission must be obtained from the hydraulic oil manufacturer.

  • Page 37: Hydraulic Oil Replacement

    and other rubber components, and 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 38: Cylinder Drift Test

    in Section 2. 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 39: Welding On The Device

    Fiber bearings should be replaced in one of the following situations: Wear or separate fibers on the surface of the liner. Broken or damaged bearing bushing. The bearing has moved or rotated into the bearing housing. Debris is embedded in the surface of the bushing. The pin should be replaced when one of the following conditions is found (the pin should be properly cleaned before inspection): Wear is found in the bearing area.

  • Page 40: Use Insulating Grease In Electrical Connection Locations

    the grounded location and the weld zone. Violation of the above requirements may result in damage to components (Such as electronic module, rotating bearing, collector ring, etc.). 3.7 Use insulating grease in electrical connection locations Insulating silicone grease should be used for all electrical connections for the following reasons: Preventing the mechanical joint between the male and female pins from being oxidized.
  • Page 41 connections and repair if necessary. Check all harness connectors to ensure they are fully seated and locked. Check the ignition coil and spark plug cable for hardening, cracking, wear, separation, cracking of the dust cover, and proper meshing. Replace the spark plug at the time intervals specified in the engine manufacturer's manual. Check and confirm that all electrical components are securely connected.
  • Page 42 Table 3-4 Inspection and preventive maintenance schedule Time intervals Pre- Items delivery or Every 2 Pre-start Weekly Monthly Annually daily years Boom assembly Boom weldment 1,2,4 1,2,4 Oil pipe/wire rope bracket 1,2,9,12 1,2,9,12 device Shaft pin and pin bolt limiting stopper Pulley and pulley pins Bearings Wear pad...
  • Page 43 Table3-4 Inspection and preventive maintenance schedule (continuous) Time intervals Items Pre-delivery or Every 2 Pre-start Weekly Monthly Annually daily years Capacity indicator Drive brake Swing brake Boom synchronization/sequencing system Manual descent/auxiliary power Power system Engine idle, throttle and Engine fluid (engine oil, 9,11 engine coolant, diesel oil) Air/diesel filter...
  • Page 44 All system functional test 21, 22 Paint and appearance Imprint check date on the frame Notifying Zoomlion machine ownership Footnote: 1. Before daily use or each shift 2. Before each sale, rental or delivery 3. Use 3 months or 150 hours, or idle for more than 3 months, or buy as a used machine 4.

  • Page 47: 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 48: 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 49: Chassis Angle Sensor System

    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 75Nm/55.4ft·lbs...

  • Page 50: Outrigger Extension System

    horizontal position when the boom is lowering. However, the auxiliary power system does not support drive function. 4.4 Outrigger extending system Locate the boom between two rear wheels when extending the outrigger. Start engine, then control the machine traveling and extend the outrigger at the same time to ensure outrigger can be extended and retracted synchronously.

  • Page 51: Travel Reducer

    or not in the transport state). Figure 4-4 Travel system disassembly diagram 4.6 Travel Reducer 4.6.1 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 110 kg/242lb).

  • Page 52: Traveling Motor

    Use a suitable lifting device to support the travel reducer (the travel reducer weighs approximately 110 kg/242lb). 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//295ftlb. Connect the hydraulic line that was previously disassembled to the travel motor.

  • Page 53: Steering Control System

    the traveling motor output shaft and its surroundings. Damage to the seal can cause oil leakage. Make sure that the traveling motor output shaft is properly aligned with the mounting ring gear on the reducer. Tighten the two bolts used to connect the travel motor to the steering knuckle. The tightening torque reaches 95 Nm/70ftlb.

  • Page 54: Rotary Motor

    direction arrow. 4.11 Rotary motor This type of rotary motor is a cycloid motor, which is the actuator of the rotary system. Maintenance motor disassembly method: Remove the hydraulic hose connected to the motor, mark it properly and plug it properly, and plug the motor oil port.

  • Page 55: Gear Oil Replacement

    damaged. Insufficient braking torque: brake torque is reduced or the friction pad is deformed cause by severe friction, the friction pad should be replaced. 4.12.2 Gear oil replacement Determine the correct position of the oil ports on the reducer and brake. Brake oil port Fill port Drain port...

  • Page 56: Check And Maintenance

    temperature irregularities or sandy or humid areas. Use a grease gun to inject Mobilux EP 2, Shell Alvania EP (LF) 2 grease, etc. into the slewing ring from the grease fitting at the slewing ring until the grease leaks from the seal and fills the ring. Lubricate the slewing bearing, generally add grease once every 150 hours of work.

  • Page 57: Slewing Gear Clearance Adjustment

    The bolt of slewing bearing is important to the unit. Do not use the removed bolt, the new bolt should be used. Figure 4-8 Upper part disassembly 4.14 Slewing Gear Clearance Adjustment The gear clearance of slewing mechanism refers to the meshing gap between small gear on the rotary reducer and slewing bearing (large gear).

  • Page 58: Generator

    Loose the mounting bolt without completely unscrewing it. Adjust the adjusting bolt and measure the backlash between the slewing gear and the slewing bearing with a plug gauge. Repeatedly adjust and measure the clearance to 0.3-0.6mm/0.012-0.024in. Tighten the mounting bolt with a tightening torque of 540Nm to 550Nm. Hold the adjustment bolt and tighten the locking bolt.

  • Page 59: Carbon Brush And Slip Ring Maintenance

    Figure 4-12 Overload protection. When checking or maintaining the circuit breaker, stop the engine operation. The circuit breaker provides overload protection for the generator windings. If the circuit breaker is open, the generator will stop outputting. If the circuit breaker remains open, check the equipment connected to the platform socket for any malfunction.

  • Page 60: Engine System

    Use 220 emery paper to clean the ring. Be as careful as possible when removing debris. If the depression of the ring is deep and cannot be cleaned, contact the generator manufacturer's service personnel. Reinstall the belt, brush holder assembly and terminal switchboard. 4.16 Engine System The engine system consists of fuel system, cooling system, control system, mounting system and urea system, as shown in Figure 4-1.

  • Page 61: Fuel System

    Table 4-2 Main components of Cummins engine Name Function Store fuel while suppressing pressure fluctuations caused High pressure by high-pressure fuel pumps and injectors to ensure stable fuel rail system pressure. Intake manifold Evenly distribute air to each cylinder High pressure Increased fuel pressure, high pressure injection pump Oil filler...
  • Page 62 Intake Blocking Exhaust pipe alarm Aftertreatment filter pipe Figure 4-17 Intake system Figure 4-18 Exhaust system Urea Cooling Exhaust tank valve pipe Urea pump Figure 4-19 Urea system Table 4-3 Main components and functions of the fuel system Name Function Oil-water separator Separating the water contained in the fuel, filtering the impurities in the fuel...
  • Page 63 Intake line blocked Check the intake line Damaged starter motor Replace the starter motor Battery voltage is too low Restart after the battery is charged Low ambient temperature Start after fully warmed up Contact the engine manufacturer for Engine failure repairs Table 4-5 Engine stall failure Failure...

  • Page 64: Cooling System

    engine operation manual 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 The gap between the piston ring Blue smoke from and the cylinder wall is too large, Contact the engine manufacturer for engine the oil enters the cylinder and...

  • Page 65: Lubrication System

    Table 4-9 Main components of cooling system Name Function Store antifreeze to provide space for antifreeze to Expansion tank expand when heated. Radiator Cool antifreeze, reduce antifreeze temperature Forced air movement Monitors the coolant level in the expansion tank and Liquid level sensor alarms when it falls below the limit Common faults and solutions of cooling system are shown in Table 4-9:...
  • Page 66 Figure 4-21 Lubrication system Table 4-11 Lubrication system Name Function oil pan Stores oil, releases heat from oil Oil suction Suction and filter sump oil filter Provides power for the flow of oil in the oil Oil pump passages Oil cooler Cooling oil in the lubricating oil circuit Filter iron filings and other impurities in the oil to Oil filter...

  • Page 67: Control System

    maintenance Blocked oil passage Contact the engine manufacturer for maintenance Excessive oil clearance Contact the engine manufacturer for maintenance Impurities in overflow valve Contact the engine manufacturer for maintenance 4.16.5 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.
  • Page 68 Engine Coolant Temperature 1 Sensor Circuit - Voltage below normal, or shorted to low source Engine Coolant Temperature - Data Valid But Above Normal Operating Range - Moderately Severe Level Accelerator Pedal or Lever Position 1 Sensor Circuit Frequency - Data valid but below normal operating Range Accelerator Pedal or Lever Position Sensor 1 - Data valid but above normal operational range - Most Severe Level...
  • Page 69 source Engine Fuel Temperature - Data Valid But Above Normal Operating Range - Moderately Severe Level Engine Fuel Temperature Sensor 1 Circuit - Voltage above normal, or shorted to high source Engine Fuel Temperature Sensor 1 Circuit - Voltage below normal, or shorted to low source Engine Fuel Temperature - Data valid but above normal operational range - Most Severe Level...
  • Page 70 shorted to high source Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage below normal, or 1267 shorted to low source Engine Control Module Warning Internal Hardware Failure - Bad intelligent device or component Transmission Output Shaft Speed - Data Valid But Above Normal Operating Range - Moderately Severe Level Injector Power Supply - Bad intelligent device or component 3597...
  • Page 71 Transmission Output Shaft Speed - Data Valid But Below Normal Operating Range - Moderately Severe Level Multiple Unit Synchronization Switch - Data erratic, intermittent or incorrect 1377 Sensor Supply 6 Circuit - Voltage above normal, or shorted to high source 3514 Sensor Supply 6 Circuit - Voltage below normal, or shorted to low source 3514...
  • Page 72 Engine ECU Temperature Sensor Circuit - Voltage above normal, or shorted to high 1136 source Engine ECU Temperature Sensor Circuit - Voltage below normal, or shorted to low 1136 source Engine ECU Temperature - Data erratic, intermittent or incorrect 1136 Engine Speed / Position Camshaft and Crankshaft Misalignment - Mechanical system not responding or out of adjustment Turbocharger 1 Compressor Intake Pressure Circuit - Voltage above normal, or...
  • Page 73 Control Module Identification Input State Error - Data erratic, intermittent or 1563 incorrect Accelerator Pedal or Lever Position Sensor 1 Circuit - Voltage above normal, or shorted to high source Accelerator Pedal or Lever Position Sensor 1 Circuit - Voltage below normal, or shorted to low source Overspeed Shutdown Relay Driver Diagnostic has detected an error - Condition 4185...
  • Page 74 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage above 3031 normal, or shorted to high source Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature - Data erratic, intermittent 3031 or incorrect Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Input Lines - Condition Exists 3362 Aftertreatment Diesel Exhaust Fluid Quality Sensor Circuit - Voltage below normal, 3364...
  • Page 75 Aftertreatment Diesel Particulate Filter Differential Pressure - Data Valid But Above 3251 Normal Operating Range Aftertreatment Diesel Particulate Filter Differential Pressure - Data valid but above 3251 normal Operating Range ECU Power Output Supply Voltage 1 - Voltage above normal, or shorted to high 3597 source ECU Power Output Supply Voltage 1 - Voltage below normal, or shorted to low...
  • Page 76 EGR Valve Position Circuit - Voltage below normal, or shorted to low source Exhaust Gas Recirculation Differential Pressure Sensor Circuit - Voltage above normal, or shorted to high source Exhaust Gas Recirculation Differential Pressure Sensor Circuit - Voltage below normal, or shorted to low source Electronic Fuel Injection Control Valve Circuit - Condition Exists Engine Crankshaft Speed/Position - Data erratic, intermittent or incorrect Engine Camshaft Speed / Position Sensor - Data erratic, intermittent or incorrect...
  • Page 77 Auxiliary PWM Driver 1 Circuit - Voltage above normal, or shorted to high source Auxiliary PWM Driver 1 Circuit - Voltage below normal, or shorted to low source Engine Charge Air Cooler Outlet Temperature - Voltage above normal, or shorted to 2630 high source Engine Charge Air Cooler Outlet Temperature - Voltage below normal, or shorted to...
  • Page 78 Moderately Severe Level Aftertreatment Fuel Drain Valve - Mechanical system not responding or out of 4097 adjustment Aftertreatment Fuel Pressure Sensor - Data Valid But Below Normal Operating 3480 Range - Least Severe Level Exhaust Gas Recirculation Temperature - Data Valid But Above Normal Operating Range - Least Severe Level Exhaust Gas Recirculation Temperature - Data Valid But Above Normal Operating Range - Moderately Severe Level...
  • Page 79 Aftertreatment 1 SCR Outlet Temperature Sensor - Data erratic, intermittent or 4363 incorrect Aftertreatment 1 SCR Catalyst System Missing - Condition Exists 4794 Aftertreatment Warm Up Diesel Oxidation Catalyst Intake Temperature Sensor 4809 Circuit - Voltage above normal Aftertreatment Warm Up Diesel Oxidation Catalyst Intake Temperature Sensor 4809 Circuit - Voltage below normal Aftertreatment Warm Up Diesel Oxidation Catalyst Intake Temperature - Data...
  • Page 80 range - Most Severe Level Aftertreatment 1 SCR Intake Temperature - Data Valid But Above Normal Operating 4360 Range - Moderately Severe Level Aftertreatment 1 Intake NOx Sensor - Abnormal update rate 3216 Aftertreatment 1 SCR Outlet Temperature - Data Valid But Above Normal Operating 4363 Range - Moderately Severe Level Aftertreatment 1 Diesel Exhaust Fluid Line Heater 2 Circuit - Voltage above normal,...
  • Page 81 Aftertreatment 1 Diesel Particulate Filter Intake Temperature Sensor Circuit - 3242 Voltage above normal, or shorted to high source Aftertreatment 1 Diesel Particulate Filter Intake Temperature - Data erratic, 3242 intermittent or incorrect Aftertreatment 1 Diesel Particulate Filter Outlet Temperature Sensor Circuit - 3246 Voltage above normal, or shorted to high source Aftertreatment 1 Diesel Particulate Filter Outlet Temperature Sensor Circuit -...
  • Page 82 Intake Manifold 1 Temperature - Data Valid But Below Normal Operating Range - Moderately Severe Level Diesel Particulate Filter 1 Conditions Not Met for Active Regeneration - Condition 3750 Exists Transmission Output Shaft Speed - Received Network Data In Error Sensor Supply 7 Circuit - Voltage above normal, or shorted to high source 5125 Sensor Supply 7 Circuit - Voltage below normal, or shorted to low source...
  • Page 83 circuit Aftertreatment Diesel Exhaust Fluid Dosing Valve - Mechanical system not 5394 responding or out of adjustment Aftertreatment 1 Diesel Exhaust Fluid Pressure Sensor - Voltage above normal, or 4334 shorted to high source Aftertreatment 1 Diesel Exhaust Fluid Pressure Sensor - Voltage below normal, or 4334 shorted to low source Aftertreatment 1 Diesel Exhaust Fluid Pressure Sensor Circuit - Current Below...
  • Page 84 Severe Level Aftertreatment 1 Outlet NOx Sensor - Out of Calibration 3226 Aftertreatment 1 Intake NOx - Out of Calibration 3216 Battery 1 Voltage - Data Valid But Below Normal Operating Range - Least Severe Level Aftertreatment 1 Intake NOx Sensor - Abnormal rate of change 3216 Aftertreatment 1 Intake NOx - Data Valid But Above Normal Operating Range - 3216...
  • Page 85 Aftertreatment 2 Outlet NOx - Abnormal Update Rate 3265 Aftertreatment 1 Outlet Soot Sensor - Voltage Above Normal, or Shorted to High 5835 Source Aftertreatment 1 Outlet Soot Sensor - Voltage below normal, or shorted to low source 5835 Aftertreatment 2 Intake NOx Sensor - Abnormal update rate 3255 Aftertreatment Diesel Particulate Filter Temperature Sensor Module - Abnormal 5742...
  • Page 86 Aftertreatment 1 Diesel Exhaust Fluid Dosing Temperature Sensor - Voltage below 4337 normal, or shorted to low source Anti-Lock Braking (ABS) Active - Condition Exists Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 Sensor Circuit - Voltage above 3515 normal, or shorted to high source Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 Sensor Circuit - Voltage 3515...
  • Page 87 Aftertreatment Diesel Exhaust Fluid Quality - Abnormal Rate of Change 3364 Desired Engine Fueling State - Abnormal Update Rate 5793 Engine Brake Active Lamp - Voltage Above Normal, or Shorted to High Source 5097 Engine Brake Active Lamp - Voltage below normal, or shorted to low source 5097 Aftertreatment 1 Outlet NOx Sensor Closed Loop Operation - Condition Exists 3226...
  • Page 88 Vehicle Identification Number - Condition Exists Vehicle Identification Number - Data erratic, intermittent or incorrect Auxiliary Input/Output 2 Circuit - Current below normal or open circuit Auxiliary Input/Output 2 Circuit - Current above normal or grounded circuit Engine Fuel Leakage - Data Valid But Above Normal Operating Range - Moderately 1239 Severe Level Injector Metering Rail 1 Pressure - Data Valid But Above Normal Operating Range...
  • Page 89 Aftertreatment Diesel Exhaust Fluid Quality - Data Valid But Above Normal 3364 Operating Range - Least Severe Level Aftertreatment Diesel Exhaust Fluid Tank Low Level Indicator 5245 High Pressure Common Rail Fuel Pressure Relief Valve - Condition Exists 5571 Engine Fuel Valve 1 - Root Cause Not Known 7026 Engine Fuel Valve 1 - Out of Calibration 7026...
  • Page 90 Aftertreatment 1 Diesel Particulate Filter Ash Load Percent - Data Valid But Above 3720 Normal Operating Range - Least Severe Level Aftertreatment 1 Diesel Exhaust Fluid Dosing Valve 1 Heater - Data Valid But Below 6326 Normal Operating Range - Moderately Severe Level Engine Air Filter Differential Pressure - Data Valid But Above Normal Operating Range - Least Severe Level Cruise Control System Command State - Mechanical System Not Responding or Out...
  • Page 91 Operating Range - Least Severe Level Aftertreatment 1 Diesel Particulate Filter Conditions Not Met for Active 3750 Regeneration - Special Instructions Machine Constrained Operation- Abnormal Update Rate. No Communication or an invalid data transfer rate has been detected on the J1939 data link between the ECM 520968 and the machine electronic control unit.
  • Page 92 Aftertreatment 1 Outlet NOx Sensor - Data not Rational - Drifted High 3226 Aftertreatment 1 Outlet NOx Sensor - Data not Rational - Drifted High 3226 Fan Speed - Data Valid but Above Normal Operational Range - Most Severe Level 1639 Fan Speed - Data Valid but Below Normal Operational Range - Most Severe Level 1639...
  • Page 93 Range - Moderately Severe Level Maintain ECU Power Lamp - Voltage Above Normal, or Shorted to High Source 6655 Maintain ECU Power Lamp - Voltage Below Normal, or Shorted to Low Source 6655 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Heater - Data Valid But Below 5745 Normal Operating Range Aftertreatment SCR Catalyst Conversion Efficiency - Data Valid But Below Normal...
  • Page 94 Auxiliary Temperature Sensor Input 1 - Special Instructions Auxiliary Pressure Sensor Input 2 - Special Instructions 1388 Engine Speed - Root Cause Not Known Diesel Particulate Filter Active Regeneration Inhibited Due to System Timeout - 3713 Condition Exists Engine Starter Motor Relay Control Circuit - Voltage Above Normal or Shorted to 6385 High Source Engine Starter Motor Relay Control Circuit - Voltage Below Normal or Shorted to...

  • Page 97: Section 5 Boom And Platform

    SECTION 5 BOOM AND PLATFORM 5.1 Platform and Jib 5.1.1 Load cell 5.1.1.1 Disassembly Platform Assembly Rotary Actuator Transition seat Stop pin Load Cell Tray Stop pin Figure 5-1 Load cell disassembly diagram a） Disconnect the wiring harness at the platform's electrical control box and load cell, disconnect the tubing at the platform valve, collect the hydraulic oil in the pipeline with a suitable container, block the port of the pipeline after the collection, and make a mark.

  • Page 98: Installation

    e） The load cell can be removed by removing the connection bolt 2 between the load cell and the transition seat, then remove the load cell. 5.1.1.2 Inspection Check the line for wear and replace the wiring harness if necessary. Check hydraulic oil leaks and replace the line if necessary.

  • Page 99: Rotary Actuator

    Select suitable lifting equipment, hoist or hold the chain and the chain aluminum tube, and take all feasible safety precautions; Remove the fixing bolts of the connecting seat on the first section of the jib and the second section of the jib; Remove the chain from first jib section.

  • Page 100: Jib Lifting Cylinder

    hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting. Remove the stop pin and connecting pin of the support, main boom, linkage III and linkage IV, and use a suitable lifting device to remove the jib. Remove the bolt 1 connecting the rotary actuator and linkage II and its stop pin, also remove bolt 1 connecting the rotary actuator and upper linkage and its stop pin, and then the rotary actuator can be removed.

  • Page 101: Platform Leveling Cylinder

    5.1.4.3 Installation Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint and balance valve before installation should be cleaned to prevent contaminants from entering the hydraulic system. A hydraulic system pipes joint equipped with a sealing device needs to replace a sealing device before the hydraulic line is connected.

  • Page 102: Jib Telescopic Cylinder

    entering the hydraulic system; If the hydraulic system pipe joints are equipped with sealing devices such as sealing rings, the sealing devices such as sealing rings shall be replaced before connecting the hydraulic pipeline; Threaded fasteners should be tightened in place according to the torque values in Section 2 Specifications.

  • Page 103: Boom Assembly

    5.1.6.3 Installation Please follow the reverse steps of disassembly. Before installation, the pipe joints of the hydraulic pipeline and the interface of the balance valve should be cleaned to prevent contaminants from entering the hydraulic system; If the hydraulic system pipe joints are equipped with sealing devices such as sealing rings, the sealing devices such as sealing rings shall be replaced before connecting the hydraulic pipeline;...

  • Page 104: Jib Leveling Cylinder

    Mark and disconnect the harness of the travel switch from the side of base boom. Mark and disconnect the hydraulic pipeline and harness from the telescopic boom to jib. Collect the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting. Use proper lifting device to hoist or support cable chain and pipe, and take appropriate safety precautions.
  • Page 105 Adjust the posture of the boom and the jib to the level. Five-section boom Limit plate Pin 3 Pin 1 Pin 2 Leveling cylinder Figure 5-4 Jib leveling cylinder disassembly diagram 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 106: Jib Lifting Cylinder

    5.2.3 Jib lifting cylinder 5.2.3.1 Disassembly Cylinder pin 2 Boom assembly 油缸销轴 2 Boom pin 1 臂架销轴 1 臂架总成 转台 Turntable Lifting cylinder 变幅油缸 油缸销轴 3 Cylinder pin 3 Figure 5-8 Boom lifting cylinder disassembly diagram If the lifting cylinder is functioning, adjust the boom to fully retracted posture, and use a proper lifting device to hoist the boom (weight of 13t), and insert a block between the boom and turntable and lifting cylinder and turntable.

  • Page 107: Boom

    Inspect all threaded parts for damage such as stretching, thread deformation or distortion and replace if necessary. 5.2.3.3 Installation Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint and balance valve before installation should be cleaned to prevent contaminants from entering the hydraulic system. A hydraulic system pipes joint equipped with a sealing device needs to replace a sealing device before the hydraulic line is connected.
  • Page 108 assembly is installed, if the weights are incorrectly assembled, there will be a risk of instability and tipping of the equipment, causing personal injury and property damage. Risk of personal injury or death. The disassembly of the boom assembly requires personnel with specialized maintenance skills, lifting equipment and a suitable plant.

  • Page 109: Telescopic Cylinder

    Extrusion hazard. When the lifting cylinder piston rod end pin shaft is removed, if the boom support fails, the boom will fall down, causing personal injury and equipment damage. When removing this pin, keep personnel away from the area under the boom. Slowly and carefully remove the boom assembly from the turntable and place it on a suitable support.
  • Page 110 Nut 3 Nut4 First retracting wire rope 第二缩臂钢丝绳 Second retracting wire rope Figure 5-11 Telescopic cylinder disassembly diagram 1 Remove the bolt 3 in the seat 1, loosen the seat. Remove the bolt 4 in the seat 2, loosen the seat. Remove bolt 1 and take out card 1.

  • Page 111: Wire Rope Pulley Disassembly

    rope and drag it out 1m at the same time; Remove the nut 1, remove the mounting seat 1, the threaded end of the wire rope of the first outrigger is free, remove the mounting seat 2, and remove the support block; Both ends of the wire rope of the first outrigger and the telescopic cylinder are pulled out of the inner cavity of one boom at the same time;...
  • Page 112 Telescope Pulley Pin 1 Pulley Fixed Guide pulley Pulley 2 Pulley 3 cylinder cover pulley bracket Pin 3 Pulley Pulley Pulley Pulley Nut 3 Nut 4 Pin 2 2st retracting Nut 5 1st retracting wire rope 3rd extending wire rope wire rope 3st retracting Nut 7...
  • Page 113 Remove pin 4 and pulley 4; Remove the brush and slider of the second boom section front; Drag the threaded end of the wire rope of the third boom section and the second retracting wire rope out of the inner cavity of the second boom section. During this process, pay attention to avoid abnormal scratches with the second boom section when the first retracting wire rope is dragged by the third boom section;...

  • Page 114: Wire Rope And Pulley Check

    Check whether the rope is tangled or misused. Install or operate the wire rope not as required, and make the wire rope rotate around its own axis, which may cause tangling when tension the wire rope. Inspect the extended and retracted wire rope pulley bearings for wear, scratches, or other damage, and for ovality.

  • Page 115: Additional Replacement Criteria

    The boom operation is not smooth or there is abnormal noise. The machine is idle for a long time. The boom is overloaded or holds shock load. The boom is exposed to an arc, and the inside of the wire rope may fuse together. 5.2.7.4 Additional replacement criteria Pulleys and wire ropes must be replaced in sets.
  • Page 116 Figure 5-16 Clamping the rope Install adjusting nuts on the outrigger and retracting arm ropes (if readjusting, remove the nylon sleeve lock nut). Pre-tighten the nut of the extension and retractable wire rope, the torque of the first extension wire rope is 60Nm, the torque of the first retractable wire rope is 80Nm, the torque of the second extension wire rope is 50Nm, the torque of the second retractable wire rope is 60Nm, and the torque of the third extension wire rope is 45Nm, and the torque of the third retractable wire rope is 45Nm;...

  • Page 117: Load Cell Check

    Tighten the four M27 nuts 1 of the first extension wire rope alternately with a torque wrench, with a torque of 60Nm; m) Tighten the three M24 nuts 2 of the second extension wire rope alternately with a torque wrench, with a torque of 50Nm;...

  • Page 118: Platform Leveling Sensor Check

    5.3.2 Platform leveling sensor check a） Keep the working platform unloaded. b） Check the platform angle sensor wires. c） Confirming that the wiring is correct, then power the unit in turntable control box. d） Check that the platform angle sensor working indicator will flash. e）...

  • Page 119: Drive Speed Limit Check

    b） Approach switch indicator will light up if the wire rope is not loose. Approach switch indicator will go out if the wire rope is loose. c） When the wire rope is loose, a loose alarm will be triggered. d） When the steel wire rope is loose and alarmed, the telescopic function of the operation boom is: the boom is forbidden to extend, only the turtle can retract quickly.
  • Page 121 履带起重机操作手册 第一章 安全操作说明...

  • Page 123: Section 6 Electrical System Maintenance

    SECTION 6 ELECTRICAL SYSTEM MAINTENANCE 6.1 Fault code If the unit fails, please check the fault code indicated on the display of turntable control box. If the following code displays, please remove the fault condition and restart the device before continuing the device operation.
  • Page 124 Table 6-1 Fault Code List (cont.) Item Fault code Description 11154 DTC_INCLINE_SENSOR_OUT_OF_RANGE 11155 DTC_INCLINE_SENSOR_COMM_ERROR 11156 DTC_INCLINE_SENSOR_NOT_STANDARDIZATION 13157 DTC_BOOM_ANGLE_SENSOR_OUT_OF_RANGE 13158 DTC_BOOM_ANGLE_SENSOR_COMM_ERROR 13159 DTC_BOOM_ANGLE_SENSOR_NOT_STANDARDIZATION 13163 DTC_BOOM_ANGLE_SINGAL_REDUNDANCY 13164 DTC_BOOM_LENGTH_SENSOR_NO_RESPOND 13165 DTC_BOOM_LENGTH_SENSOR_ERROR_DETECTION 13167 DTC_BOOM_LENGTH_SENSOR_REDUNDANCY 14166 DTC_LEVELING_SENSOR_COMM_ERROR 13160 DTC_FAULT_LIFT_WIRE_ROPE_SENSOR_LOOSE 22161 DTC_FAULT_SWING_SENSOR 32168 DTC_FAULT_AIR_FILTER_SENSOR 32169 DTC_FAULT_OIL_WATER_SEPARATION_SENSOR 32170 DTC_FAULT_HYDRAULIC_OIL_FILTER_SENSOR 21171...
  • Page 125 Table 6-1 Fault Code List (cont.) Item Fault code Description 12354 DTC_FAULT_UG_TOWER_LIFT_SWITCH_DOUBLE_POWER_ON 12355 DTC_FAULT_UG_JIB_SWITCH_DOUBLE_POWER_ON DTC_FAULT_UG_TELESCOPE_DOUBLE_POWER_ON 12356 DTC_FAULT_UG_ROTATE_SWITCH_DOUBLE_POWER_ON 22357 12358 DTC_FAULT_UG_LEVELING_SWITCH_DOUBLE_POWER_ON DTC_FAULT_UG_SWING_SWITCH_DOUBLE_POWER_ON 22359 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...
  • Page 126 Table 6-1 Fault Code List (cont.) Item Fault code Description 11685 DTC_LEFT_FRONT_STEER_IN_VALVE_SHORT_TO_POWER 21686 DTC_LEFT_FRONT_STEER_IN_VALVE_OPEN_CIRCUIT 21687 DTC_RIGHT_FRONT_STEER_OUT_VALVE_SHORT_TO_GROUND 11688 DTC_RIGHT_FRONT_STEER_OUT_VALVE_SHORT_TO_POWER 21689 DTC_RIGHT_FRONT_STEER_OUT_VALVE_OPEN_CIRCUIT 21690 DTC_RIGHT_FRONT_STEER_IN_VALVE_SHORT_TO_GROUND 11691 DTC_RIGHT_FRONT_STEER_IN_VALVE_SHORT_TO_POWER 21692 DTC_RIGHT_FRONT_STEER_IN_VALVE_OPEN_CIRCUIT 21699 DTC_LEFT_REAR_STEER_OUT_VALVE_SHORT_TO_GROUND 11700 DTC_LEFT_REAR_STEER_OUT_VALVE_SHORT_TO_POWER 21701 DTC_LEFT_REAR_STEER_OUT_VALVE_OPEN_CIRCUIT 21702 DTC_LEFT_REAR_STEER_IN_VALVE_SHORT_TO_GROUND 11703 DTC_LEFT_REAR_STEER_IN_VALVE_SHORT_TO_POWER 21704 DTC_LEFT_REAR_STEER_IN_VALVE_OPEN_CIRCUIT 21705 DTC_RIGHT_REAR_STEER_OUT_VALVE_SHORT_TO_GROUND 11706 DTC_RIGHT_REAR_STEER_OUT_VALVE_SHORT_TO_POWER 21707...
  • Page 127 Table 6-1 Fault Code List (cont.) Item Fault code Description 21693 DTC_FRONT_AXLE_OUT_VALVE_SHORT_TO_GROUND 11694 DTC_FRONT_AXLE_OUT_VALVE_SHORT_TO_POWER 21695 DTC_FRONT_AXLE_OUT_VALVE_OPEN_CIRCUIT 21696 DTC_FRONT_AXLE_IN_VALVE_SHORT_TO_GROUND 11697 DTC_FRONT_AXLE_IN_VALVE_SHORT_TO_POWER 21698 DTC_FRONT_AXLE_IN_VALVE_OPEN_CIRCUIT 21711 DTC_REAR_AXLE_OUT_VALVE_SHORT_TO_GROUND 11712 DTC_REAR_AXLE_OUT_VALVE_SHORT_TO_POWER 21713 DTC_REAR_AXLE_OUT_VALVE_OPEN_CIRCUIT 21714 DTC_REAR_AXLE_IN_VALVE_SHORT_TO_GROUND 11715 DTC_REAR_AXLE_IN_VALVE_SHORT_TO_POWER 21716 DTC_REAR_AXLE_IN_VALVE_OPEN_CIRCUIT 21717 DTC_LEFT_DRIVE_FWD_VALVE_SHORT_TO_GROUND 11718 DTC_LEFT_DRIVE_FWD_VALVE_SHORT_TO_POWER 21719 DTC_LEFT_DRIVE_FWD_VALVE_OPEN_CIRCUIT 21720 DTC_LEFT_DRIVE_REV_VALVE_SHORT_TO_GROUND 11721...
  • Page 128 Table 6-1 Fault Code List (cont.) Item Fault code Description 21750 DTC_REAR_LEG_VALVE_OPEN_CIRCUIT 23654 DTC_MAIN_LIFT_DN_VALVE_SHORT_TO_GROUND 13655 DTC_MAIN_LIFT_DN_VALVE_SHORT_TO_POWER 23656 DTC_MAIN_LIFT_DN_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 22641 DTC_TELESCOPE_IN_VALVE_SHORT_TO_GROUND 12642 DTC_TELESCOPE_IN_VALVE_SHORT_TO_POWER 22643 DTC_TELESCOPE_IN_VALVE_OPEN_CIRCUIT 22644 DTC_TELESCOPE_OUT_VALVE_SHORT_TO_GROUND 12645 DTC_TELESCOPE_OUT_VALVE_SHORT_TO_POWER 22646 DTC_TELESCOPE_OUT_VALVE_OPEN_CIRCUIT 22574 DTC_SWING_LEFT_VALVE_SHORT_TO_GROUND 22575 DTC_SWING_LEFT_VALVE_SHORT_TO_POWER 22576 DTC_SWING_LEFT_VALVE_OPEN_CIRCUIT 22577...
  • Page 129 Table 6-1 Fault Code List (cont.) Item Fault code Description 22798 DTC_ENGINE_START_OPEN_CIRCUIT 32799 DTC_ALARM_SHORT_TO_GROUND 32800 DTC_ALARM_SHORT_TO_POWER 32801 DTC_ALARM_OPEN_CIRCUIT 32802 DTC_LIGHT_SHORT_TO_GROUND 32803 DTC_LIGHT_SHORT_TO_POWER 32804 DTC_LIGHT_OPEN_CIRCUIT 12805 DTC_GROUND_SW_POWER_SHORT_TO_GROUND 12806 DTC_GROUND_SW_POWER_SHORT_TO_POWER 12807 DTC_GROUND_SW_POWER_OPEN_CIRCUIT 12808 DTC_AUX_POWER_SHORT_TO_GROUND 12809 DTC_AUX_POWER_SHORT_TO_POWER 12810 DTC_AUX_POWER_OPEN_CIRCUIT 14814 DTC_PLATFORM_SW_POWER_SHORT_TO_GROUND 14815 DTC_PLATFORM_SW_POWER_SHORT_TO_POWER 14816 DTC_PLATFORM_SW_POWER_OPEN_CIRCUIT 13829...

  • Page 130: Common Faults And Solutions

    Table 6-1 Fault Code List (cont.) Item Fault code Description 12542 DTC_JIB_TELE_OUT_VALVE_SHORT_TO_GROUND Valve/ 12543 DTC_JIB_TELE_OUT_VALVE_SHORT_TO_POWER Output 12544 DTC_JIB_TELE_OUT_VALVE_OPEN_CIRCUIT 12202 DTC_SWING_VALVE_STUCKED_MOVEMENT 33851 DTC_STEEL_WIRE_ROPE_LOOSE 41852 DTC_DRIVE_DIRECTION_REVERSE 24853 DTC_OVER_LOAD 23854 DTC_RESTRICT_OR_UNRESTRICT 24855 DTC_LEVELING_FAULT 23856 DTC_SHORT_ROPE_FAULT 23857 DTC_MAIN_LIFT_CONTROL_SYSTEM_FAULT 41858 DTC_LOWER_SPEED_FAULT 32859 DTC_SYSTEM_FAULT 34860 DTC_SOFT_TOUCH_FAULT 32861 DTC_ALTERNATOR_FAULT Unit...
  • Page 131 Table 6-2 Common faults and solutions (cont.) Fault Cause Solution 6. Engine oil pressure Add engine oil excessive low 7. Low fuel level Add fuel Overload 1. Platform overcapacity 1. Platform unloading alarm 2. Load cell communication Check load cell harness or replace sensor fault 1.
  • Page 132 2. 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 135: General Introduction

    SECTION 7 ELECTRICAL INFORMATION AND SCHEMATIC 7.1 General Introduction This section introduces basic electrical information and schematics for locating and correcting most operational problems that may arise. If problems that are not listed in this section, or problems that cannot be corrected by the listed solutions, occur, you should obtain authoritative technical guidance before performing maintenance.

  • Page 136: Range

    signal is connected, and that the lead of the other port is connected to the positive signal. 7.2.5 Range M = mega = 1,000,000 * (displayed number). k = thousand = 1,000 * (displayed number). m = milli = (displayed number) /1,000. μ= micro = (displayed number) /1,000,000.

  • Page 137: Conduction Test

    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 138: Deutsch Connector

    Set the expected current range of the multimeter. Verify that the multimeter leads and jacket are properly connected within the current range of your choice. If the multimeter cannot automatically adjust the range, set the correct range (refer to the multimeter operation manual).

  • Page 139: Dt/Dtp Series Connector Disassembly

    7.3.2 DT/DTP Series Connector Disassembly Figure 7-6 DT/DTP contact removal When disassembling, use a non-toothed nose pliers or hook line to pull the wedge locker vertically. Use a screwdriver to remove the retaining finger from the contact, release the retaining finger, and gently pull the wire to remove the contact.

  • Page 140: Hd30/Hdp20 Series Connector Removal

    Push the contacts straight into the retaining ring until they are obstructed. Pull gently to confirm that the connector is fully locked. Locking fingers Contact Unlocked position Contact locked in position Figure 7-8 HD/HDP lock contact position Note: for unused wire cavities, a sealing plug should be inserted to achieve complete isolation from the environment.

  • Page 141: Electrical Schematics

    7.4 Electrical Schematics...
  • Page 144 7-10...
  • Page 145 7-11...
  • Page 146 7-12...
  • Page 147 7-13...
  • Page 148 7-14...

  • Page 149: Hydraulic Schematics

    7.5 Hydraulic Schematics Hydraulic Schematics(1/2) 7-15...
  • Page 150 Hydraulic Schematics(2/2) 7-16...
  • Page 151 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.

Table of Contents