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Zoomlion ZA64JERT-Li Service And Maintenance Manual

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ZOOMLION INTELLIGENT ACCESS MACHINERY CO.,LTD.
Add:Tengfei Road 997, Wangcheng District, Changsha, Hunan,PRC
E-mail:awm@zoomlion.com
Open up the WeChat, Scan the QR code above; All rights reserved 2015 © Zoomlion,reserves all rights,Without the written permission of Zoomlion, the contents of any part of this sample may not be copied for any purpose.
Zip Code:410200
Tel:400-800-0157
ZA64JERT-Li
Service and Maintenance Manual
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Summary of Contents for Zoomlion ZA64JERT-Li

  • Page 1 Add:Tengfei Road 997, Wangcheng District, Changsha, Hunan,PRC E-mail:awm@zoomlion.com Tel:400-800-0157 Open up the WeChat, Scan the QR code above; All rights reserved 2015 © Zoomlion,reserves all rights,Without the written permission of Zoomlion, the contents of any part of this sample may not be copied for any purpose.
  • Page 3 Service and Maintenance Manual ZA64JERT-Li Service and Maintenance Manual 2023.12 A...

  • Page 5: Foreword

    Foreword This Service and Maintenance Manual applies to the ZA64JERT-Li mobile elevating work platform (hereinafter referred to as the MEWP). This manual describes proper inspection, servicing and maintenance. Users must fully understand and apply the contents described in this manual to maximize the performance and ensure the long-term safe and efficient use.
  • Page 6 Foreword Symbols and their description: Danger indicates an imminently dangerous situation. If not avoided, will result in death or serious injury. Warning indicates a potential hazardous situation. If not avoided, will result in death or serious injury. Caution indicates a potential hazardous situation. If not avoided, will result in minor or moderate injury.

  • Page 7: 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 .............................

  • Page 8: Content

    Contents 3.2 Maintenance and Instruction ......................3-3 3.2.1 General description ........................3-3 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 Bearing ............................
  • Page 9 Contents 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 Manual Lowering System ......................... 4-3 4.4 Traveling Drive System ........................4-4 4.5 Travel Reducer ..........................4-4 4.5.1 Disassembly ...........................
  • Page 10 Contents 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 ........................7-3 7.3 DEUTSCH Connector ........................7-4 7.3.1 DT/DTP series connector assembly ....................7-4 7.3.2 DT/DTP Series connector disassembly ..................7-5 7.3.3 HD30/HDP20 Series connector assembly ..................

  • Page 13: Section 1 Maintenance Safety Instruction

    SECTION ONE 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. 1.

  • Page 15: Precautions In Maintenance

    of them must be in front of the turntable or platform control panel so that the engine can be shut 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.
  • Page 16 Figure 1-3 Mind explosion The positive and negative wires of the battery must be removed when welding to prevent the positive and negative poles of the welder from forming a loop with the unit body, thereby burning electrical components such as controllers and sensors. The company does not take the consequences for wrong operation.
  • Page 17 It is strictly forbidden to disassemble electronic components. Do not allow tools or parts to fall into the inspection hole; do not allow objects to fall into the holes during work. Falling objects can damage the machine or cause the machine to malfunction. Any tools or objects that fall into the inspection hole must be removed;...
  • Page 18 a short circuit and damage the wiring, electrical components and electronic components of the electrical system. The cable on the negative terminal side (ground side) must be removed before the inspection or maintenance work on the electrical system. Mind battery liquid; Battery fluid contains dilute sulfuric acid.
  • Page 19 Restore or reset the safety device and recalibrate the safety device if necessary; Remove the tools and equipment for maintenance, replace parts and scattered objects, and clean up the site; It should always be borne in mind that all maintenance should include mandatory confirmation of normal mechanical movement.

  • Page 23: Section 2 Technical Parameters

    SECTION 2 TECHNICAL PARAMETERS 2.1 Performance Table 2-1 Performance 250/ 360kg 550/793 lb Platform capacity 45% (platform uphill) Max travel speed (on slope) 45% (platform downhill) Max travel speed (side slope) 19.38m 63ft 7in Platform height 12.10m 39ft 9in Horizontal outreach 5.49 m (outside) 18ft (outside) Turning radius...

  • Page 24: Capacity

    5600 kg/12346 lb 7300 kg/16094 lb 130 kg/287 lb D610 filled 2.6 Functional Speed Table 2-6 Functional speed (Unit: s) ZA64JERT-Li Function 55 s~65 s Upper boom lifting 55 s ~65 s Upper boom lowering 162 s ~186 s Turntable swing (a round)

  • Page 25: Operating Procedure When Testing Speed

    2.6.1 Operating procedure when testing speed Upper boom lifting: telescopic boom retracting. Record lifting and descending time respectively; Turntable swing: upper boom lifted to maximum work height, telescopic boom retracted. Record 360°continuous turntable swing left and right respectively; Upper boom extending: upper boom lifted to maximum work height, telescopic boom retracted. Record telescopic boom extending and retracting time respectively;...

  • Page 26: Lubrication

    Table 2-7 Torque requirements (continous) Strength grade and corresponding torque Nm Bolt diameter 8.8 grade 10.9 grade 1032 1450 1400 1970 Note: when maintenance is required or the fasteners are loose, follow the torque gauge to determine the appropriate torque value. 2.8 Lubrication 2.8.1 Hydraulic oil Table 2-8 Hydraulic oil specification...

  • Page 29: 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 30: Preventive Maintenance

    Refer to the Machine Annual Inspection Form and the Preventive Maintenance Schedule for this inspection. Please refer to the relevant contents of this manual for maintenance and service procedures. To ensure that safety reports are obtained, our company needs to update the ownership information of each machine.

  • Page 31: Maintenance And Instruction

    3.2 Maintenance and Instruction 3.2.1 General description 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 32: Bearing

    3.2.7 Bearing 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 33: Battery

    3.2.13 Battery The battery was cleaned with a non-metallic brush and an aqueous solution of sodium bicarbonate. Then rinse with clean water. When the battery is completely dry, apply the battery terminals with an anti-corrosion compound. 3.2.13.1 Battery inspection Check the battery appearance. The battery top and terminal connections should be kept clean, free of dust, corrosion and dryness.

  • Page 34: Lubrication And Maintenance

    Prevent the cleaning solution from entering the inside of batteries. Rinse with water, and use cloth to dry it. Coat the terminals with protecting spray (available through local battery dealer). Keep the surrounding area clean and dry. 3.2.14 Lubrication and maintenance Parts and components that require lubrication and maintenance refer to the Lubrication Table in Section 3.3 Inspection and Maintenance of Hydraulic System 3.3.1 Regular inspection...
  • Page 35 Table 3-3 Hydraulic system maintenance period Replacing Period Maintenan Mounting First Every Every Every Every 24 ce Items position 50hrs or 500hrs or 1,000hrs or 2,000hrs or months (not 30 days 2 months 6 months 12 months working) Replace return oil Control oil ★...

  • Page 36: Hydraulic Tank And Hydraulic Oil

    the bubble breakage will cause “cavitation” generating noise. The air will not only oxidize hydraulic oil, accelerating its deterioration.And a large amount of air entering the oil will aggravate the "cavitation" phenomenon that the hydraulic oil compressibility will be increased, and the machine performance will be affected.

  • Page 37: Replace Filter

    Refer to Table 3-5 Hydraulic oil parameters (not for models with specified hydraulic oil) for hydraulic oil types and models. Select suitable hydraulic oil types according to specific application. For special environments or users with special requirements, please contact ZOOMLION or hydraulic oil manufacturers.
  • Page 38 High pressure filter Maintenance point- replaceable filter. Time interval- first 50 hrs after usage, every 6 months or 1000 hrs thereafter. Breather plug Maintenance point- breather plug of tank Time interval- first 50 hrs after usage, every 6 months or 1,000 hrs thereafter Note- remove and replace the wing nut and outer cover.
  • Page 39 Refer to Table 3-5 Hydraulic oil parameters (not for models with specified hydraulic oil) for hydraulic oil types and models. Select suitable hydraulic oil types according to specific application. For special environments or users with special requirements, please contact ZOOMLION or hydraulic oil manufacturers.
  • Page 40 Table 3-5 Hydraulic oil technical parameter (continuous) Motion Pour viscosity Flash point Viscosity Brands Parameters viscosity point ℃/℉ index ℃/℉ grade (40℃/104 ℉) Great Wall Zhuoli L-HV 15 173/ -45/-49 15.51 Low temperature hydraulic oil 343.4 Great Wall Zhuoli L-HV 32 231/ -39/-38.2 33.4...
  • Page 41 Proper use of hydraulic fluid. Please note the corresponding oil viscosity and temperature limits. Under normal operating conditions, the recommended oil temperature should be controlled between 30℃ /86℉ and 60℃ /140℉ and the maximum is not more than 90 ℃/194℉ (viscosity grade reaches 32). The oil temperature will affect the viscosity of the oil and the thickness of the oil film.

  • Page 42: Hydraulic System Exhaust

    3.3.3 Hydraulic system exhaust Normally, the hydraulic system will automatically exhaust. For this reason, the equipment operates at low speed and low pressure. Slowly operate each cylinder to run back and forth until the air is completely exhausted. 3.3.4 Check for damage to hydraulic system piping The hose placed at the bend of the hydraulic tray is prone to friction damage.

  • Page 43: Check Hydraulic Hose

    3.3.6 Check hydraulic hose All hydraulic hoses need to be checked regularly for damage. During these visual inspections, even if only very minor damage is found, all damaged hoses should be replaced immediately. Possible problems with hydraulic hoses: Outer layer damage, such as wear, cuts, cracks, etc .; The outer layer material is aging, forming cracks;...
  • Page 44 Use elbows and other connectors when necessary: ① Avoid too long hose assembly; ② It can ensure tidy installation and convenient maintenance in the future. Incorrect Correct A certain slack compensates for the shrinkage of the hose when it is under pressure; The hose usually has a length change rate of -4% to + 2% when under pressure.

  • Page 45: Cylinder Drift Test

    Arrange the hose: ① Avoid overheated surfaces and sharp edges; ② Avoid friction with components; ③ There must be enough free length for bending activities. Incorrect Correct 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.

  • Page 46: Pin And Bearing Inspection Instructions

    The cylinder must have the normal load applied by the platform. If the cylinder passes this test, it is acceptable. Note: this information is based on a leak of 6 drops of cylinder per minute. 3.5 Pin and Bearing Inspection Instructions 3.5.1 Fiber bearing Disconnect and inspect the connecting pin when one of the following conditions occurs: 1) Joint tilting;...
  • Page 47 c) Ground the platform/support and weld it in any area other than the platform/support; d) Ground a specific boom section and weld it in any area other than the specific boom section; e) Place pins, wear pads, wire ropes, bearings, gears, seals, valves, electrical wiring or tubing between the grounded location and the weld zone.
  • Page 48 Table 3-7 Inspection and preventive maintenance schedule Time intervals Pre-delivery Items Every 2 Pre-start Weekly Monthly Annually or daily years Boom assembly Boom weldment 1,2,4 1,2,4 Oil pipe/wire rope 1,2,9,12 1,2,9,12 Shaft pin and pin Pulley and pulley pins Bearings Wear pad Covers or shields Cables or wire...
  • Page 49 Table 3-7 Inspection and preventive maintenance schedule (continuous) Time intervals Items Pre-delivery or Every 2 Pre-start Weekly Monthly Annually daily years Drive motor Torque hub Function/Control Platform control Ground control Function control locks, protective device or brake device Foot switch Emergency switch (Ground and platform) Function limit or cutout...
  • Page 50 Table 3-7 Inspection and preventive maintenance schedule (continuous) Time intervals Items Pre-delivery or Every 2 Pre-start Weekly Monthly Annually daily years Hydraulic pump 1,2,9 Hydraulic oil tank 1,9,7 1,2,9 1,2,9 Cylinder pinned joints and pins retainer Hydraulic hose and other 1,2,9,12 1,2,9,12 hydraulic fittings...
  • Page 51 All system functional test 21, 22 Painting and appearance Imprint check date on the frame Notifying Zoomlion machine ownership Footnote: 1. Before daily use or each shift 2. Before each sale, rental or delivery 3. Use 3 months or 150 hours, or idle for more than 3 months, or buy as a used machine 4.
  • Page 52 Performance code: 1 －Confirm that the installation is correct and secure 2 －Visually inspect for damage, cracks, deformation or excessive wear 3 －Check if the adjustment is correct 4 －Check for cracked or damaged welds 5 －Correct operation 6 －Return to neutral of OFF position when released 7 －Clean and free of dirt 8 －Interlock function 9 －Check for signs of leaks...

  • Page 55: Section 4 Chassis And Turntable

    4.1.1 Tire inflation In order to endure the safety and normal operation, the air pressure of the pneumatic tire must be the same as the air pressure indicated on the side of the Zoomlion machines or the rim sticker. 4.1.2 Tire damage...

  • Page 56: Tire Replacement

    A smooth, uniform cut with a total length of more than 7.5cm/3 inches in the ply; Cracks (uneven edges) in any direction that exceed 2.5cm/1 inch in the ply; Perforations having a diameter of more than 2.5cm/1 inch; Any damage to the ply of the tire bead. If the tire is damaged but still within the above criteria, the tire must be inspected daily to ensure that the damage does not exceed the permissible standard.

  • Page 57: 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 75 Nm/54.3 ftꞏlb...

  • Page 58: Traveling Drive System

    4.4 Traveling Drive System The traveling system is mainly composed of wheels, traveling reducer and traveling motor. Specifically, the two-wheel drive system consists of two motor drivers, two travel motors, and two gear reducers. The walking speed is changed according to the change of the motor speed. Our equipment has three drive modes to choose from at the platform console.

  • Page 61: 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 Figure 5-1 Load cell disassembly diagram Retract the tower boom and the upper boom; Disconnect the wiring harness at the platform control box and the load cell, disconnect the pipeline at the platform valve, and mark it at the same time;...

  • Page 62: Rotary Actuator

    should be cleaned to prevent contaminants from entering the hydraulic system; Threaded fasteners should be tightened in place according to the torque values in Section 2 Specifications. 5.1.2 Rotary actuator 5.1.2.1 Disassembly Figure 5-2 Jib lifting cylinder disassembly diagram Disconnect the hydraulic line connecting the rotary actuator balancing valve, collect the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting;...

  • Page 63: Boom Assembly

    Remove the connecting bolts 3 and 5 of the support and the upper and lower links, and remove the pins 4 and 6, so that the jib lifting cylinder can be removed. 5.1.3.2 Inspection a) Check the line for wear and replace the wiring harness if necessary; b) Check hydraulic oil leaks and replace the line if necessary;...

  • Page 64: Cable

    5.2.1 Cable 5.2.1.1 Disassembly Figure 5-3 Cable system disassembly Adjusting the boom to a fully retracted state; Disconnect the pipeline from the ground control box; Mark and disconnect the hydraulic lines from upper boom to the control valve. Collect the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting;...

  • Page 65: Leveling Cylinder

    a) Follow the reverse steps of disassembly. The pipe joints of the hydraulic lines before installation should be cleaned to prevent contaminants from entering the hydraulic system; b) A hydraulic system pipe joint equipped with a sealing device needs to replace a sealing device before the hydraulic line is connected;...

  • Page 66: Lower Leveling Cylinder And Lifting Cylinder

    5.2.2.3 Installation a) 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; b) A hydraulic system pipe joint equipped with a sealing device needs to replace a sealing device before the hydraulic line is connected;...

  • Page 67: Upper Boom

    5.2.3.2 Inspection Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if necessary; Inspect the inner ring of the bearing for scratches, distortion, wear or other damage and replace the bearing if necessary; Inspect all threaded parts for damage such as stretching, thread deformation or distortion and replace if necessary.

  • Page 68: Telescopic Cylinder

    Before disassembling the upper boom, it is necessary to disassemble working platform, jib, cable, and upper leveling cylinder, according to the disassembly steps; Fully retract the upper boom to the horizontal position; Use the appropriate lifting equipment to hang the upper boom (weight about 860kg/1896 lb). The two lifting points should be symmetrically placed on both sides of the center of gravity of the upper boom, as shown in the figure.
  • Page 69 Need to unload the working platform, jib, cable, upper leveling cylinder, counterweight (weight about 1,205kg/2657 lb), hood and upper boom according to the disassembly steps; Disassemble the hood and two stroke switches at the tail of the telescopic cylinder; Mark and disconnect the hydraulic line connecting the two cylinders balancing valve, collect the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting;...

  • Page 70: Tower Boom And Its Cylinder

    5.2.6 Tower boom and its cylinder 5.2.6.1 Disassembly Figure 5-8 Tower boom disassembly diagram Remove the working platform, jib, and upper boom according to the disassembly steps in advance; Mark and disconnect the hydraulic lines and harnesses connected to the components on the turntable, collect the hydraulic oil in the pipeline with a suitable container, and seal the ports of the pipeline after collection;...
  • Page 71 bearing if necessary; Inspect all threaded parts for damage such as stretching, thread deformation or distortion and replace if necessary. 5.2.6.3 Installation a) 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； b) A hydraulic system pipe joint equipped with a sealing device needs to replace a sealing device before the hydraulic line is connected;...

  • Page 75: Section 6 Hydraulic Electrical System Maintenance

    SECTION 6 HYDRAULIC ELECTRICAL SYSTEM MAINTENANCE 6.1 Fault Code When the unit fails, check the fault message indicated by the display on the ground console. If the display on the ground console indicates the following fault code, remove the fault condition and restart the device before continuing operation.
  • Page 76 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 12355 DTC_FAULT_UG_JIB_SWITCH_DOUBLE_POWER_ON 12356 DTC_FAULT_UG_TELESCOPE_DOUBLE_POWER_ON 22357 DTC_FAULT_UG_ROTATE_SWITCH_DOUBLE_POWER_ON 12358 DTC_FAULT_UG_LEVELING_SWITCH_DOUBLE_POWER_ON 22359 DTC_FAULT_UG_SWING_SWITCH_DOUBLE_POWER_ON 22360 DTC_FAULT_UG_ENGINE_SWITCH_DOUBLE_POWER_ON 14361 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_DOUBLE_POWER_ON 14363 DTC_FAULT_PM_JIB_SWITCH_DOUBLE_POWER_ON 14364 DTC_FAULT_PM_TELESCOPE_DOUBLE_POWER_ON 24365 DTC_FAULT_PM_ROTATE_SWITCH_DOUBLE_POWER_ON 14366 DTC_FAULT_PM_LEVELING_SWITCH_DOUBLE_POWER_ON 24367 DTC_FAULT_PM_SWING_JOYSTICK_DOUBLE_POWER_ON 24368 DTC_FAULT_PM_ENGINE_SWITCH_DOUBLE_POWER_ON 14369 DTC_FAULT_PM_DRIVE_JOYSTICK_DOUBLE_POWER_ON 14370 DTC_FAULT_PM_STEER_JOYSTICK_DOUBLE_POWER_ON 14371...
  • Page 77 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list Switch/handle 14393 DTC_FAULT_PM_ENGINE_SWITCH_DOUBLE_POWER_ON 22551 DTC_DRIVE_FORWARD_VALVE_SHORT_TO_GROUND 12552 DTC_DRIVE_FORWARD_VALVE_SHORT_TO_POWER 22553 DTC_DRIVE_FORWARD_VALVE_OPEN_CIRCUIT 22554 DTC_DRIVE_REVERSE_VALVE_SHORT_TO_GROUND 12555 DTC_DRIVE_REVERSE_VALVE_SHORT_TO_POWER 22556 DTC_DRIVE_REVERSE_VALVE_OPEN_CIRCUIT 22557 DTC_DRIVE_FORWARD_VALVE_FEEDBACK_CURRENT_FAULT 22558 DTC_DRIVE_REVERSE_VALVE_FEEDBACK_CURRENT_FAULT 21559 DTC_FLOAT_CONTROL_VALVE_SHORT_TO_GROUND 21560 DTC_FLOAT_CONTROL_VALVE_SHORT_TO_POWER 21561 DTC_FLOAT_CONTROL_VALVE_OPEN_CIRCUIT 21562 DTC_BRAKE_VALVE_SHORT_TO_GROUND 11563 DTC_BRAKE_VALVE_SHORT_TO_POWER 21564 DTC_BRAKE_VALVE_OPEN_CIRCUIT...
  • Page 78 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 22588 DTC_4SELECT_MAIN_CONTROL_RIGHT_VALVE_SHORT_TO_GROUND 22589 DTC_4SELECT_MAIN_CONTROL_RIGHT_VALVE_SHORT_TO_POWER 22590 DTC_4SELECT_MAIN_CONTROL_RIGHT_VALVE_OPEN_CIRCIUT 22593 DTC_MAIN_LIFT_UP_VALVE_SHORT_TO_GROUND 12594 DTC_MAIN_LIFT_UP_VALVE_SHORT_TO_POWER 22595 DTC_MAIN_LIFT_UP_VALVE_OPEN_CIRCUIT 22597 DTC_TOWER_LIFT_UP_VALVE_SHORT_TO_GROUND 12598 DTC_TOWER_LIFT_UP_VALVE_SHORT_TO_POWER 22599 DTC_TOWER_LIFT_UP_VALVE_OPEN_CIRCUIT 23601 DTC_TELESCOPE_VALVE_SHORT_TO_GROUND 13602 DTC_TELESCOPE_VALVE_SHORT_TO_POWER 23603 DTC_TELESCOPE_VALVE_OPEN_CIRCUIT 23604 DTC_HAND_LEVELING_VALVE_SHORT_TO_GROUND 13605 DTC_HAND_LEVELING_VALVE_SHORT_TO_POWER 23606 DTC_HAND_LEVELING_VALVE_OPEN_CIRCUIT 23607...
  • Page 79 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 13779 DTC_MAIN_LIFT_DN_VALVE_SHORT_TO_POWER 23780 DTC_MAIN_LIFT_DN_VALVE_OPEN_CIRCUIT 23781 DTC_TOWER_DN_RIGHT_VALVE_SHORT_TO_GROUND 13782 DTC_TOWER_DN_RIGHT_VALVE_SHORT_TO_POWER 23783 DTC_TOWER_DN_RIGHT_VALVE_OPEN_CIRCUIT 23784 DTC_TOWER_DN_LEFT_VALVE_SHORT_TO_GROUND 13785 DTC_TOWER_DN_LEFT_VALVE_SHORT_TO_POWER 23786 DTC_TOWER_DN_LEFT_VALVE_OPEN_CIRCUIT 22787 DTC_TELEOUT_VALVE_SHORT_TO_GROUND 12788 DTC_TELEOUT_VALVE_SHORT_TO_POWER 22789 DTC_TELEOUT_VALVE_OPEN_CIRCUIT 22790 DTC_TELEIN_VALVE_SHORT_TO_GROUND 12791 DTC_TELEIN_VALVE_SHORT_TO_POWER 22792 DTC_TELEIN_VALVE_OPEN_CIRCUIT 23793 DTC_ROTATE_SELECT_VALVE_SHORT_TO_GROUND 13794...
  • Page 80 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 14818 DTC_JIB_LEFT_VALVE_SHORT_TO_POWER 14819 DTC_JIB_LEFT_VALVE_OPEN_CIRCUIT 14820 DTC_JIB_RIGHT_VALVE_SHORT_TO_GROUND 14821 DTC_JIB_RIGHT_VALVE_SHORT_TO_POWER 14822 DTC_JIB_RIGHT_VALVE_OPEN_CIRCUIT 14823 DTC_JIB_TELESCOPE_OUT_VALVE_SHORT_TO_GROUND 14824 DTC_JIB_TELESCOPE_OUT_VALVE_SHORT_TO_POWER 14825 DTC_JIB_TELESCOPE_OUT_VALVE_OPEN_CIRCUIT 14826 DTC_JIB_TELESCOPE_IN_VALVE_SHORT_TO_GROUND 14827 DTC_JIB_TELESCOPE_IN_VALVE_SHORT_TO_POWER 14828 DTC_JIB_TELESCOPE_IN_VALVE_OPEN_CIRCUIT Valve 13829 DTC_LIFT_VALVE_STUCKED_MOVEMENT 13830 DTC_TELESCOPE_VALVE_STUCKED_MOVEMENT 14831 DTC_LEVELING_VALVE_STUCKED_MOVEMENT 12832 DTC_MAIN_LIFT_SAFETY_VALVE_SHORT_TO_GROUND...
  • Page 81 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 32864 DTC_LOW_FUEL_FAULT 14865 DTC_ANTI_CRUSH_ALARM Device status 12866 DTC_SYSTEM_INITIAL_FAULT 12867 DTC_INH_FAULT System 22951 DTC_CONTROL_READ_PARA_ERROR 1018 DTC_CONTROLLER_OVERCURRENT_1 1019 DTC_CURRENT_SENSOR_FAULT_1 1020 DTC_PRECHARGE_FAILED_1 1021 DTC_CONTROLLER_SEVERE_UNDERTEMP_1 1022 DTC_CONTROLLER_SEVERE_OVERTEMP_1 1023 DTC_SEVERE_UNDERVOLTAGE_1 1024 DTC_SEVERE_OVERVOLTAGE_1 1034 DTC_CONTROLLER_OVERTEMP_CUTBACK_1 1035 DTC_UNDERVOLTAGE_CUTBACK_1...
  • Page 82 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 1073 DTC_PARAMETER_CHANGE_FAULT_1 1104 DTC_VCL_RUN_TIME_ERROR_1 1105 DTC_EXTERNAL_SUPPLY_OUT_OF_RANGE_1 1113 DTC_OS_GENERAL_1 1114 DTC_PDO_TIMEOUT_1 1115 DTC_STALL_DETECTED_1 1116 DTC_FAULT_ON_OTHER_TRACTION_CONTROLLER_1 1117 DTC_DUAL_SEVERE_FAULT_1 1119 DTC_SUPERVISOR_FAULT_1 1120 DTC_SUPERVISOR_INCOMPATIBLE_1 1135 DTC_MOTOR_CHARACTERIZATION_FAULT_1 1136 DTC_ENCODER_PULSE_ERROR_1 1137 DTC_MOTOR_TYPE_FAULT_1 1145 DTC_VCL_OS_MISMATCH_1 1146 DTC_EM_BRAKE_FAILED_TO_SET_1 1147...
  • Page 83 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 2051 DTC_COIL3_DRIVER_OPEN_SHORT_2 2052 DTC_COIL4_DRIVER_OPEN_SHORT_2 2053 DTC_PD_OPEN_SHORT_2 2054 DTC_ENCODER_FAULT_2 2055 DTC_MOTOR_OPEN_2 2056 DTC_MAIN_CONTACTOR_WELDED_2 2057 DTC_MAIN_CONTACTOR_DID_NOT_CLOSE_2 2065 DTC_THROTTLE_WIPER_HIGH_2 2066 DTC_THROTTLE_WIPER_LOW_2 2067 DTC_POT2_WIPER_HIGH_2 2068 DTC_POT2_WIPER_LOW_2 2069 DTC_POT_LOW_OVERCURRENT_2 2070 DTC_EEPROM_FAILURE_2 2071 DTC_HPD_SEQUENCING_FAULT_2 2073 DTC_PARAMETER_CHANGE_FAULT_2 2104...
  • Page 84 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 3021 DTC_CONTROLLER_SEVERE_UNDERTEMP_3 3022 DTC_CONTROLLER_SEVERE_OVERTEMP_3 3023 DTC_SEVERE_UNDERVOLTAGE_3 3024 DTC_SEVERE_OVERVOLTAGE_3 3034 DTC_CONTROLLER_OVERTEMP_CUTBACK_3 3035 DTC_UNDERVOLTAGE_CUTBACK_3 3036 DTC_OVERVOLTAGE_CUTBACK_3 3037 DTC_SUPPLY_5V_FAILURE_3 3038 DTC_DO6_OPEN_OR_SHORT_3 3039 DTC_DO7_OPEN_OR_SHORT_3 3040 DTC_MOTOR_TEMP_HOT_CUTBACK_3 3041 DTC_MOTOR_TEMP_SENSOR_FAULT_3 3049 DTC_MAIN_OPEN_SHORT_3 3050 DTC_EMBRAKE_OPEN_SHORT_3 3051 DTC_COIL3_DRIVER_OPEN_SHORT_3 3052...
  • Page 85 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 3119 DTC_SUPERVISOR_FAULT_3 3120 DTC_SUPERVISOR_INCOMPATIBLE_3 3135 DTC_MOTOR_CHARACTERIZATION_FAULT_3 3136 DTC_ENCODER_PULSE_ERROR_3 3137 DTC_MOTOR_TYPE_FAULT_3 3145 DTC_VCL_OS_MISMATCH_3 3146 DTC_EM_BRAKE_FAILED_TO_SET_3 3147 DTC_ENCODER_LOS_3 3148 DTC_EMR_REV_TIMEOUT_3 3152 DTC_ILLEGAL_MODEL_NUMBER_3 3153 DTC_DUALMOTOR_PARAMETER_MISMATCH_3 4018 DTC_CONTROLLER_OVERCURRENT_4 4019 DTC_CURRENT_SENSOR_FAULT_4 4020 DTC_PRECHARGE_FAILED_4 4021 DTC_CONTROLLER_SEVERE_UNDERTEMP_4 4022...
  • Page 86 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 4066 DTC_THROTTLE_WIPER_LOW_4 4067 DTC_POT2_WIPER_HIGH_4 4068 DTC_POT2_WIPER_LOW_4 4069 DTC_POT_LOW_OVERCURRENT_4 4070 DTC_EEPROM_FAILURE_4 4071 DTC_HPD_SEQUENCING_FAULT_4 4073 DTC_PARAMETER_CHANGE_FAULT_4 4104 DTC_VCL_RUN_TIME_ERROR_4 4105 DTC_EXTERNAL_SUPPLY_OUT_OF_RANGE_4 4113 DTC_OS_GENERAL_4 4114 DTC_PDO_TIMEOUT_4 4115 DTC_STALL_DETECTED_4 4116 DTC_FAULT_ON_OTHER_TRACTION_CONTROLLER_4 4117 DTC_DUAL_SEVERE_FAULT_4 4119 DTC_SUPERVISOR_FAULT_4 4120...
  • Page 87 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 5038 DTC_DO6_OPEN_OR_SHORT_5 5039 DTC_DO7_OPEN_OR_SHORT_5 5040 DTC_MOTOR_TEMP_HOT_CUTBACK_5 5041 DTC_MOTOR_TEMP_SENSOR_FAULT_5 5049 DTC_MAIN_OPEN_SHORT_5 5050 DTC_EMBRAKE_OPEN_SHORT_5 5051 DTC_COIL3_DRIVER_OPEN_SHORT_5 5052 DTC_COIL4_DRIVER_OPEN_SHORT_5 5053 DTC_PD_OPEN_SHORT_5 5054 DTC_ENCODER_FAULT_5 5055 DTC_MOTOR_OPEN_5 5056 DTC_MAIN_CONTACTOR_WELDED_5 5057 DTC_MAIN_CONTACTOR_DID_NOT_CLOSE_5 5065 DTC_THROTTLE_WIPER_HIGH_5 5066 DTC_THROTTLE_WIPER_LOW_5 5067...
  • Page 88 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 5148 DTC_EMR_REV_TIMEOUT_5 Driver 5152 DTC_ILLEGAL_MODEL_NUMBER_5 5153 DTC_DUALMOTOR_PARAMETER_MISMATCH_5 31070 DTC_HIGH_VOLTAGE_LEVEL1 21071 DTC_HIGH_VOLTAGE_LEVEL2 31072 DTC_LOW_VOLTAGE_NORMAL_TEMP_LEVEL1 31073 DTC_LOW_VOLTAGE_LOW_TEMP_LEVEL1 21074 DTC_LOW_VOLTAGE_LOW_TEMP_LEVEL2 21075 DTC_LOW_VOLTAGE_NORMAL_TEMP_LEVEL2 31076 DTC_HIGH_SOC 31077 DTC_LOW_SOC_LEVEL1 21078 DTC_LOW_SOC_LEVEL2 31079 DTC_HIGH_CHARGING_CURRENT_LEVEL1 21080 DTC_HIGH_CHARGING_CURRENT_LEVEL2 31081 DTC_HIGH_DISCHARGING_CURRENT_LEVEL1...
  • Page 89 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 31103 DTC_TEMPERATURE_ACQUISITION_DISCONNECTED 21104 DTC_COMMUNICATION_WITH_ECU_TIME_OUT 21105 DTC_COMMUNICATION_WITH_OBC_TIME_OUT 31106 DTC_LOW_INSULATION_LEVEL1 21107 DTC_LOW_INSULATION_LEVEL2 21108 DTC_MAIN_CONTACTOR_FAULT 21109 DTC_CHARGING_CONTACTOR_FAULT 21110 DTC_HEAT_CONTACTOR_FAULT 21111 DTC_MOS_SHORT_CIRCUIT 21112 DTC_MOS_OPEN_LOAD 21113 DTC_BMS_HARDWARE_FAULT 21114 DTC_MAIN_MOS_OPEN_CIRCUIT 21115 DTC_MAIN_MOS_SHORT_CIRCUIT 21116 DTC_MAIN_MOS_VOLTAGE_FAULT 21117 DTC_ARST_MOS_OPEN_CIRCUIT 21118...
  • Page 90 Table 6-1 Fault code list (continuous) Classification Fault code Fault code list 21138 DTC_FRONT_ARST_MOS_SHORT_CIRCUIT 31139 DTC_FRONT_ARST_HIGH_TEMP 31140 DTC_FRONT_ARST_COMM_FAULT 6-16...

  • Page 91: Common Faults And Solutions

    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 95: General Introduction

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

  • Page 96: Range

    leads are reversed. Check the voltage prediction value, signal position, and whether the lead is properly connected to the device under test. Also check that the lead of the COM port is grounded or the negative signal is connected, and that the lead of the other port is connected to the positive signal. 7.2.5 Range M = mega = 1,000,000 * (displayed number);...

  • Page 97: 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 98: 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 99: 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 100: Hd30/Hdp20 Series Connector Removal

    Figure 7-8 HD/HDP lock contact position Note: for unused wire cavities, a sealing plug should be inserted to achieve complete isolation from the environment. 7.3.4 HD30/HDP20 Series connector removal Figure 7-9 HD/HDP contact removal With the rear insert facing the side, select the appropriate size of the insertion and removal tool to clamp the wire of the contact to be removed;...

  • Page 101: Electrical Schematics

    7.4 Electrical Schematics Figure 7-11 Electrical schematics (Figure1/10)
  • Page 102 Figure 7-12 Electrical schematics (Figure2/10)
  • Page 103 Figure 7-13 Electrical schematics (Figure 3/10)
  • Page 104 Figure 7-14 Electrical schematics (Figure 4/10) 7-10...
  • Page 105 Figure 7-15 Electrical schematics (Figure 5/10) 7-11...
  • Page 106 Figure 7-16 Electrical schematics (Figure6/10) 7-12...
  • Page 107 Figure 7-17 Electrical schematics (Figure7/10) 7-13...
  • Page 108 Figure 7-18 Electrical schematics (Figure8/10) 7-14...
  • Page 109 Figure 7-19 Electrical schematics (Figure9/10) 7-15...
  • Page 110 Figure 7-20 Electrical schematics (Figure10/10) 7-16...

  • Page 111: Hydraulic Schematics

    7.5 Hydraulic Schematics Figure 7-21 Hydraulic schematics 7-17...

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