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Zoomlion ZT58J-V Service And Maintenance Manual

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Service and Maintenance
Service and Maintenance Manual
ZT58J
Service and Maintenance Manual
Aug 2022 Version A

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Summary of Contents for Zoomlion ZT58J-V

  • Page 1 Service and Maintenance Service and Maintenance Manual ZT58J Service and Maintenance Manual Aug 2022 Version A...

  • Page 3: Foreword

    Foreword This Service and Maintenance Manual applies to the ZT58J-V 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 5 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 7: Table Of Contents

    Contents Foreword………….…………….………………………….……………………………...….……I Content………….…………….………………………….…………………………..………..…II SECTION 1 MAINTENANCE SAFETY INSTRUCTION............1-1 1.1 Maintenance Personnel Duties, Requirements and Safety Equipment........1-1 1.1.1 Duties..........................1-1 1.1.2 Basic requirements......................1-1 1.1.3 Personnel safety equipment................... 1-1 1.2 Maintenance Precautions......................1-2 1.2.1 Precautions........................1-2 1.2.2 Precautions in maintenance....................1-3 SECTION 2 TECHNICAL PARAMETERS................2-1 2.1 Performance..........................

  • Page 8: Content

    Contents 3.1.4 Machine annual inspection.....................3-1 3.1.5 Preventive maintenance....................3-2 3.2 Maintenance and Instruction..................... 3-2 3.2.1 General Description....................... 3-2 3.2.2 Safety and operating standards..................3-3 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......................3-3 3.2.7 Bearings..........................3-3 3.2.8 Washer..........................3-4 3.2.9 Bolt and torque applications..................
  • Page 9 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......................4-3 4.4 Outrigger extension system....................... 4-4 4.5 Traveling Drive System......................4-4 4.6 Travel Reducer...........................4-5 4.6.1 Disassembly........................
  • Page 10 Contents 4.16.1 Engine main components................... 4-14 4.16.2 Fuel system.........................4-15 4.16.3 Cooling system......................4-18 4.16.4 Lubrication system..................... 4-19 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..........................5-2 5.1.3 Rotary actuator....................... 5-3 5.1.4 Jib lifting cylinder......................
  • Page 11 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.....................7-2 7.2.7 Resistance measurement....................7-2 7.2.8 Conduction test.......................7-3 7.2.9 Current measurement.....................
  • Page 13 用户00737755 用户00737755...
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  • Page 15: 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 16: 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. Inspect safety equipment regularly, replace damaged parts if necessary.

  • Page 17: Precautions In Maintenance

    down at any time if necessary, and others can conduct inspection or maintenance. Personnel should keep close contact to work safely. Clean the aerial work platform before inspection or maintenance. The dust or debris on the aerial work platform not only makes the faulty components or parts difficult to find, but also can be mixed into the components or parts during operation.
  • Page 18 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 19 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 20 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 21 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 22 用户00737755 用户00737755...
  • Page 23 用户00737755...

  • Page 24: Section 2 Technical Parameters

    SECTION 2 TECHNICAL PARAMETERS 2.1 Performance Table 2-1 Performance Platform Capacity 300/ 454kg 45% (platform uphill) Max Travel Speed (on slope) 45% (platform downhill) Max Travel Speed (on side slope) Platform Height 56.8m Horizontal Outreach 25.5m 8.43/6.39m (outside) Turning Radius 6.79/2.57m (inside) Max Travel Speed 4.5km/h...

  • Page 25: Capacity

    2.3 Capacity Table 2-3 Capacity Fuel Tank 200 L Hydraulic tank 400 L Engine Oil Capacity 12 L 2.4 Components Specification 2.4.1 Engine Table 2-4 Cummins QSF2.8 Engine Specification Type High pressure common rail Fuel 0# IV standard diesel Engine Oil Capacity 1200r/min (idle speed) Rotate Speed 1600r/min (low speed)

  • Page 26: Battery

    2.4.2 Battery Table 2-5 Battery Specification Rated Voltage 12 V 20 hour rate capacity 100 Ah Cold Start Current 810 A @ 0ºF（-18℃） Storage Capacity 160 Min @ 80ºF（27℃） 2.5 Tire Table 2-6 Tire Size Max Capacity Weight (tire and Size Type Ply Rating...

  • Page 27: Test Cautions

    Platform Rotation; Platform leveling. Platform reaches extreme position, rotate the platform to reach the extreme position of another side, record the rotating time; rotate the platform to the original position, record the rotating time. Drive (stowed): choose a smooth ground with the main boom less than 12 ° and the extension length less than 1.5m.

  • Page 28: Lubrication

    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 months thereafter 100 hours after the first run, every 500 hours Slew bearing bolt M20 thereafter Slew reducer connecting 100 hours after the first run, every 500 hours...
  • Page 29 用户00737755 用户00737755...
  • Page 30 用户00737755...

  • 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

    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 33: Safety And Operating Standards

    The following information is provided to assist you in the use and application of the repair and 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.

  • Page 34: Washer

    After removing the bearing, cover it to avoid stains or abrasives. Clean the bearing in a non-flammable cleaning agent and allow it to drip dry. Compressed air can be used, but the 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).

  • Page 35: Battery

    3.2.13 Battery The battery was cleaned with a non-metallic brush and an aqueous solution of sodium bicarbonate. 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 5.
  • Page 36 3-2 is not used to specify the type and parameters of hydraulic oil). Please select the hydraulic oil of the appropriate brand and technical parameters according to the specific use environment of the equipment. For special environments or users with special requirements, please contact ZOOMLION or hydraulic oil manufacturers.

  • Page 37: Hydraulic Oil Replacement

    normal operating conditions, the recommended oil temperature should be controlled between 30 ° C/86 ℉ and 60 ° C/140℉ and the maximum is not more than 90 °C/194℉. The oil temperature affects the oil viscosity and the thickness of the oil film. High temperatures also shorten the service life of oil seals and other rubber components, and the oil also evaporates and oxidizes.

  • Page 38: Cylinder Drift Test

    Special lubricants recommended by the component manufacturer are always the best choice. However, multi-purpose greases typically have characteristics that meet the requirements of various single-function greases. If you have any questions regarding the use of grease in maintenance supplies, please consult your local supplier. Please refer to the description of the lubricant abbreviation in the Lubrication Table in Section 2.

  • Page 39: Welding On The Device

    Disconnect and inspect the connecting pin when one of the following conditions occurs: Joint tilting. Noise is generated at the joint during operation. 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.

  • Page 40: Use Insulating Grease In Electrical Connection Locations

    Ground the platform/support and weld it in any area other than the platform/support. Ground a specific boom section and weld it in any area other than the specific boom section. Place pins, wear pads, wire ropes, bearings, gears, seals, valves, electrical wiring or tubing between the grounded location and the weld zone.
  • Page 41 Inspect the battery case for cracks or damage. Check the positive and negative battery cables for corrosion, abrasion or scratches. Check the connections on the chassis to confirm that the connections are secure. Inspect the wiring harness of the entire engine to confirm the presence of worn, severed or damaged connections and repair if necessary.
  • Page 42 Table 3-4 Inspection and preventive maintenance schedule Time intervals Pre-deliver Items Every 2 Pre-start Weekly Monthly y or daily Annually 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 330Nm...

  • 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

    transport state 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 50 kg/110lb).

  • Page 52: Installation

    4.6.2 Installation Use a suitable lifting device to support the travel reducer (the travel reducer weighs approximately 50 kg/110lb). 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

    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. 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.

  • Page 54: Rotary Motor

    arrow on chassis and platform controller. Push the driving control handle to the direction indicated by the corresponding 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

    the pressure oil enters the brakes, the brakes are opened and the mechanism can rotate freely. When one of the following parts of the brake occurs, its parts should be replaced or the brake is scrapped: There is oil leakage at the input end, and the brake oil seal needs to be replaced if the oil seal is damaged.

  • Page 56: Check And Maintenance

    When the unit is not used for a long time, the slewing bearing should be lubricated, and the lubrication cycle should be shortened when the unit is located in tropical climates affected by temperature irregularities or sandy or humid areas. Use a grease gun to inject Mobilux EP 2, Shell Alvania EP (LF) 2 grease, etc.

  • Page 57: Slewing Gear Clearance Adjustment

    555Nm. 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 locknut without completely unscrewing it. 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 plug gauge. Repeatedly adjust measure clearance 0.15-0.25mm/0.00591-0.00984in. Tighten the mounting bolt with a tightening torque of 520Nm to 555Nm. 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 Ambient Air Temperature Sensor 1 Circuit - Voltage above normal, or shorted to high source Ambient Air Temperature Sensor 1 Circuit - Voltage below normal, or shorted to low 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...
  • Page 70 Injector Solenoid Driver Cylinder 4 Circuit - Current below normal or open circuit Engine Coolant Temperature - Data erratic, intermittent or incorrect Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage above normal, or 1267 shorted to high source Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage below normal, 1267 or shorted to low source Engine Control Module Warning Internal Hardware Failure - Bad intelligent device...
  • Page 71 shorted to low source Intake Manifold 1 Temperature - Data Valid But Above Normal Operating Range - Moderately Severe Level 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...
  • Page 72 Turbocharger 1 Compressor Intake Temperature Circuit - Voltage below normal, or 1172 shorted to low source Turbocharger 1 Compressor Intake Temperature - Data erratic, intermittent or 1172 incorrect Engine ECU Temperature Sensor Circuit - Voltage above normal, or shorted to 1136 high source Engine ECU Temperature Sensor Circuit - Voltage below normal, or shorted to low...
  • Page 73 shorted to low source Accelerator Pedal or Lever Position Sensor 1 - Data erratic, intermittent or incorrect Control Module Identification Input State Error - Data erratic, intermittent or 1563 incorrect Control Module Identification Input State Error - Data erratic, intermittent or 1563 incorrect Accelerator Pedal or Lever Position Sensor 1 Circuit - Voltage above normal, or...
  • Page 74 normal, or shorted to high source Aftertreatment 1 Diesel Exhaust Fluid Tank Level - Data valid but below normal 1761 operational range -Most Severe Level Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage below 3031 normal, or shorted to low source Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor - Voltage above 3031 normal, or shorted to high source...
  • Page 75 Aftertreatment 1 Outlet NOx Sensor Circuit - Voltage below normal, or shorted to 3226 low source EGR Valve Control Circuit - Abnormal update rate 2791 EGR Valve Controller - Out of Calibration 2791 VGT Actuator Controller - Out of Calibration Aftertreatment Diesel Particulate Filter Differential Pressure - Data Valid But 3251 Above Normal Operating Range...
  • Page 76 Least Severe Level Battery Temperature - Data Valid But Above Normal Operating Range - 1800 Moderately Severe Level Battery Temperature - Data Valid But Below Normal Operating Range - 1800 Moderately Severe Level 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...
  • Page 77 Level Turbocharger Turbine Intake Temperature - Data Valid But Above Normal 2789 Operating Range - Moderately Severe Level Engine Crankshaft Speed/Position - Data Valid But Above Normal Operating Range - Moderately Severe Level Exhaust Gas Pressure 1 - Data erratic, intermittent or incorrect 1209 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...
  • Page 78 Aftertreatment 1 Outlet NOx Sensor - Abnormal update rate 3226 Particulate Trap Active Regeneration Inhibited Due to Inhibit Switch - Condition 3703 Exists Aftertreatment Fuel Rate - Data Valid But Above Normal Operating Range - 3481 Moderately Severe Level Engine Coolant Temperature - Data Valid But Below Normal Operating Range - Moderately Severe Level Aftertreatment Fuel Drain Valve - Mechanical system not responding or out of 4097...
  • Page 79 Aftertreatment 1 SCR Intake Temperature Sensor - Data erratic, intermittent or 4360 incorrect Aftertreatment 1 SCR Outlet Temperature Sensor Circuit - Voltage above normal, 4363 or shorted to high source Aftertreatment 1 SCR Outlet Temperature Sensor Circuit - Voltage below normal, 4363 or shorted to low source Aftertreatment 1 SCR Outlet Temperature Sensor - Data erratic, intermittent or...
  • Page 80 Aftertreatment Purge Air Actuator Circuit - Voltage above normal, or shorted to 3490 high source Aftertreatment Purge Air Actuator - Mechanical system not responding or out of 3490 adjustment Aftertreatment 1 Intake NOx Sensor - Data erratic, intermittent or incorrect 3216 Aftertreatment 1 SCR Intake Temperature - Data valid but above normal 4360...
  • Page 81 Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature Sensor Circuit - 4765 Voltage above normal, or shorted to high source Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature - Data erratic, 4765 intermittent or incorrect Aftertreatment 1 Diesel Particulate Filter Intake Temperature Sensor Circuit - 3242 Voltage below normal, or shorted to low source Aftertreatment 1 Diesel Particulate Filter Intake Temperature Sensor Circuit -...
  • Page 82 Roll Over Protection Brake Control Active - Condition Exists 1818 Aftertreatment Diesel Particulate Filter Regeneration too Frequent - Condition 5397 Exists Aftertreatment Diesel Particulate Filter Incomplete Regeneration - Condition 5319 Exists Engine Crankcase Ventilation Hose Disconnected - Condition Exists 5396 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...
  • Page 83 Engine Wait to Start Lamp - Abnormal update rate 1081 Engine Wait to Start Lamp - Received Network Data In Error 1081 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit - Voltage above normal, or 3361 shorted to high source Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit - Voltage below normal, or 3361 shorted to low source Aftertreatment 1 Diesel Exhaust Fluid Dosing Valve 1 Circuit - Voltage Above...
  • Page 84 Engine Turbocharger 1 Boost Pressure - Mechanical system not responding or out 1127 of adjustment Engine Control Module Calibration Memory - Bad intelligent device or component Aftertreatment SCR Operator Inducement - Data valid but above normal 5246 operational range - Most Severe level Engine Protection Torque Derate - Condition Exists 1569 Engine Speed At Idle - Data Valid But Above Normal Operating Range -...
  • Page 85 Engine Turbocharger Lube Oil Pressure - Data Valid But Below Normal Operating Range - Moderately Severe Level Aftertreatment 1 SCR Intermediate NH3 Gas Sensor Power Supply - Data Valid 5851 But Above Normal Operating Range - Moderately Severe Level Aftertreatment 1 SCR Intermediate NH3 Gas Sensor Power Supply - Data Valid 5851 But Below Normal Operating Range - Moderately Severe Level Aftertreatment 1 SCR Intermediate NH3 Sensor - Out of Calibration...
  • Page 86 Aftertreatment Selective Catalytic Reduction Temperature Sensor Module - Data 5743 Valid But Above Normal Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Heater - Voltage Above 5745 Normal, or Shorted to High Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Heater - Voltage below normal, 5745 or shorted to low source Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit 1 Heater - Data Valid But...
  • Page 87 Cause Not Known High Pressure Common Rail Fuel Pressure Relief Valve - Voltage Above Normal, 5571 or Shorted to High Source High Pressure Common Rail Fuel Pressure Relief Valve - Voltage below normal, or 5571 shorted to low source High Pressure Common Rail Fuel Pressure Relief Valve - Root Cause Not Known 5571 Aftertreatment 1 Diesel Exhaust Fluid Pump 1 Motor Speed Circuit - Voltage 4374...
  • Page 88 normal or open circuit Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Sensor Circuit - Current 3031 below normal or open circuit Water in Fuel Indicator 2 Sensor Circuit - Voltage above normal, or shorted to high 6301 source Water in Fuel Indicator 2 Sensor Circuit - Voltage below normal, or shorted to low 6301 source Engine Injector Metering Rail 1 Cranking Pressure - Data Valid But Below Normal...
  • Page 89 Aftertreatment Outlet Oxygen - Data Not Rational - Drifted Low 3227 Aftertreatment 1 Diesel Exhaust Fluid Dosing Valve 1 Heater - Voltage Above 6326 Normal, or Shorted to High Source Aftertreatment 1 Diesel Exhaust Fluid Dosing Valve 1 Heater - Voltage Below 6326 Normal, or Shorted to Low Source Aftertreatment 1 Diesel Exhaust Fluid Property - Root Cause Not Known...
  • Page 90 or Open Circuit Engine Exhaust Back Pressure Regulator Position - Data Erratic, Intermittent or 5625 Incorrect Engine Exhaust Back Pressure Regulator Position Sensor Circuit - Voltage Above 5625 Normal, or Shorted to High Source Engine Exhaust Back Pressure Regulator Position Sensor Circuit - Voltage Below 5625 Normal, or Shorted to Low Source Engine Exhaust Back Pressure Regulator - Out of Calibration...
  • Page 91 Aftertreatment Diesel Exhaust Fluid Dosing Unit Relay Feedback- Voltage Below 520953 Normal or Shorted to Low Source. Aftertreatment 1 SCR Feedback Control Status - Mechanical System Not 4339 Responding or Out of Adjustment Electronic Throttle Control Actuator Driver Circuit - Voltage Above Normal or 3464 Shorted to High Source Electronic Throttle Control Actuator Driver Circuit - Voltage Below Normal or...
  • Page 92 Engine Brake Actuator Driver 1 Circuit - Voltage below normal, or shorted to low 1072 source Engine Brake Actuator Driver Output 2 Circuit - Voltage above normal, or shorted 1073 to high source Engine Brake Actuator Driver Output 2 Circuit - Voltage below normal, or shorted 1073 to low source Engine Fan Clutch 2 Control Circuit - Voltage above normal, or shorted to high...
  • Page 93 Aftertreatment Diesel Exhaust Fluid Line Heater 3 Circuit - Current below normal 4344 or open circuit Electronic Throttle Control Actuator Driver Circuit-Voltage above normal, or 3464 shorted to high source Electronic Throttle Control Actuator Driver Circuit-Voltage above normal, or 3464 shorted to low source Electronic Throttle Control Actuator Driver Circuit-Voltage above normal, or 3464...
  • Page 94 Aftertreatment Diesel Exhaust Fluid Line Heater 3 Circuit - Voltage above normal, 4344 or shorted to high source Aftertreatment Diesel Exhaust Fluid Line Heater 3 Circuit - Voltage below normal, 4344 or shorted to low source Aftertreatment 1 Diesel Exhaust Fluid Line Heater Relay - Mechanical system not 5491 responding or out of adjustment EGR Valve Control Circuit - Mechanical System Not Responding or Out of...
  • Page 95 Least Severe Level Engine Protection Torque Derate - Special Instructions 1569 Engine Start Request - Abnormal Update Rate 7745 Aftertreatment 1 Diesel Particulate Filter Intake Temperature - Data Valid But 3242 Above Normal Operating Range - Least Severe Level Aftertreatment 1 Diesel Particulate Filter Outlet Temperature - Data Valid But 3246 Above Normal Operating Range - Least Severe Level Engine Exhaust Back Pressure Regulator Position - Condition Exists...

  • Page 99: 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 100: Installation

    to remove the tray from the transition seat. 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 101: Rotary Actuator

    container to collect the hydraulic oil in the hydraulic pipeline, and block the port of the pipeline after collecting; 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;...

  • Page 102: Jib Lifting Cylinder

    5.1.3.1 Disassembly Mark and 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. 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.

  • Page 103: Platform Leveling Cylinder

    bearing if necessary. Inspect all threaded parts for damage such as stretching, thread deformation or distortion and replace if necessary. 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 104: Jib Telescopic Cylinder

    5.1.5.3 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 105: Boom Assembly

    Check whether the hydraulic pipeline leaks oil, and it is necessary to replace the pipeline; Inspect all threaded components for damage such as stretching, thread deformation or twisting, and replace if necessary. 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;...

  • Page 106: Jib Leveling Cylinder

    Disconnect the pipeline from the ground control box. Release the pressing plate on the side of base boom. Mark and disconnect the hydraulic pipeline and harness connected to the turntable. Collect the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting.
  • Page 107 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 108: Jib Lifting Cylinder

    Specifications. 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 12t), and insert a block between the boom and turntable and lifting cylinder and turntable.

  • Page 109: Boom

    bearing if necessary. 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 110 Tilt hazard. The counterweight plays a vital role in the stability of the equipment. After the boom 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.

  • Page 111: Telescopic Cylinder

    Use suitable lifting equipment (lifting weight of 12t) to support the head and tail of the boom. Remove cylinder pin 2 and boom pin 1. 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.
  • Page 112 Use suitable tools to loosen the nut 1 so that the retracted wire rope is in a relaxed state. Nut 3 Nut4 First retracting wire rope Second retracting wire rope 第二缩臂钢丝绳 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.

  • Page 113: Wire Rope Pulley Disassembly

    of the hoisting equipment, slowly and carefully move the telescopic oil cylinder out 1m in the direction of the boom tail, and the mounting base 1 is connected to the threaded end of the first outrigger wire 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;...
  • Page 114 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 115 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 116: Wire Rope And Pulley Check

    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 117 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. Wire rope is rusted or corroded.
  • Page 118 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...

  • Page 119: Load Cell Check

    Enable the boom telescopic function and retract the boom by 0.5 to 0.8m (not to the limit position); 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 120: Platform Leveling Sensor Check

    g） Remove load items from the platform. h） The load cell adjustment is completed. 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）...

  • Page 121: Check Of Wire Rope Damage Indication System

    5.3.5 Check of Wire Rope Damage Indication System a） Two approach switches are installed at the end of the boom to detect the loose state of the wire rope. 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.
  • Page 122 Do not lift the boom to an excessively high position for testing, and pay attention to driving safety to avoid accidents. 5- 24...
  • Page 123 履带起重机操作手册 第一章 安全操作说明...

  • Page 125: 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 126 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 127 Table 6-1 Fault Code List (cont.) Item Fault code Description 12354 DTC_FAULT_UG_TOWER_LIFT_SWITCH_DOUBLE_POWER_ON DTC_FAULT_UG_JIB_SWITCH_DOUBLE_POWER_ON 12355 DTC_FAULT_UG_TELESCOPE_DOUBLE_POWER_ON 12356 DTC_FAULT_UG_ROTATE_SWITCH_DOUBLE_POWER_ON 22357 DTC_FAULT_UG_LEVELING_SWITCH_DOUBLE_POWER_ON 12358 DTC_FAULT_UG_SWING_SWITCH_DOUBLE_POWER_ON 22359 DTC_FAULT_UG_ENGINE_SWITCH_DOUBLE_POWER_ON 22360 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_DOUBLE_POWER_ON 14361 DTC_FAULT_PM_JIB_SWITCH_DOUBLE_POWER_ON 14363 DTC_FAULT_PM_TELESCOPE_DOUBLE_POWER_ON 14364 DTC_FAULT_PM_ROTATE_SWITCH_DOUBLE_POWER_ON 24365 DTC_FAULT_PM_LEVELING_SWITCH_DOUBLE_POWER_ON 14366 DTC_FAULT_PM_SWING_JOYSTICK_DOUBLE_POWER_ON 24367 DTC_FAULT_PM_ENGINE_SWITCH_DOUBLE_POWER_ON 24368 DTC_FAULT_PM_DRIVE_JOYSTICK_DOUBLE_POWER_ON 14369 DTC_FAULT_PM_STEER_JOYSTICK_DOUBLE_POWER_ON 14370 DTC_FAULT_UG_FOOTSWITCH_CLOSED...
  • Page 128 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 129 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 130 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 131 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 132: Common Faults And Solutions

    Table 6-1 Fault Code List (cont.) Item Fault code Description 12542 DTC_JIB_TELE_OUT_VALVE_SHORT_TO_GROUND 12543 DTC_JIB_TELE_OUT_VALVE_SHORT_TO_POWER Valve/ 12544 DTC_JIB_TELE_OUT_VALVE_OPEN_CIRCUIT Output 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 133 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 134 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.
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  • Page 137: Multimeter Basic Operation

    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 138: Range

    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 139: 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 140: 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 141: 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 142: 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 143: Electrical Schematics

    7.4 Electrical Schematics 7- 7 用户00737755 用户00737755...
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  • Page 151: Hydraulic Schematics

    7.5 Hydraulic Schematics Hydraulic Schematics(1/2) 7- 15 用户00737755 用户00737755...
  • Page 152 Hydraulic Schematics(2/2) 7- 16 用户00737755 用户00737755...
  • Page 153 Add:Tengfei Road 997 , Wangcheng District, Changsha, Hunan,PRC Tel:400-800-0157 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.

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