Zoomlion ZT20J Service And Maintenance Manual Download Page 2

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Foreword

erious injury.

Warning indicates a potential hazardous situation. If not avoided, will result in death or serious

injury.

Caution indicates a potential hazardous situation. If not avoided, will result in minor or moderate

injury.

Notice indicates information of property and device damage, or wrong operations. If not avoided,

could result in property loss, damage to machine parts or reduced mechanical properties.

Used to indicate or add additional information to individual information.

Indicates that this operation does not comply with safety regulations and is prohibited or prone to

casualties.

Summary of Contents for ZT20J

Page 1: ...sequence for wrong maintenance The highest criterion users must keep in mind that Safety first Pay special attention to the safety control device for regular inspection Do not operate the machine when the safety device fails or working abnormally Do not modify the structure or add additional parts for more functions Otherwise you will be responsible for any personal injury or damage caused by the ...

Page 2: ...l 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 Used to indicate or add additional information to individual information Indicates that this operation does not comply with safety regulations and is prohibited or prone to casualtie...

Page 3: ... and Performance 2 1 2 3 Capacity 2 2 2 4 Components Specification 2 2 2 4 1 Engine 2 2 2 4 2 Battery 2 3 2 5 Tire 2 3 2 6 Functional Speed 2 4 2 6 1 Operating procedure when testing speed 2 4 2 6 2 Test Cautions 2 4 2 7 Torque Requirements 2 5 2 8 Lubrication 2 5 2 8 1 Hydraulic oil 2 5 2 9 Pressure Setting 2 6 SECTION 3 GENERAL INTRODUCTION 3 1 Machine Preparation Inspection and Maintenance 3 1 ...

Page 4: ...Lubrication and Information 3 5 3 3 1 Hydraulic system 3 5 3 3 2 Hydraulic oil 3 5 3 3 3 Hydraulic oil replacement 3 7 3 3 4 Lubrication specification 3 7 3 4 Cylinder Drift Test 3 7 3 4 1 Platform drift 3 7 3 4 2 Cylinder drift 3 8 3 5 Pin and Bearing Inspection Instructions 3 9 3 5 1 Fiber bearing 3 9 3 6 Welding on the Device 3 9 3 6 1 Please perform the following operations when welding on the...

Page 5: ...tion 4 8 4 8 Traveling Motor 4 8 4 8 1 Disassembly 4 8 4 8 2 Installation 4 8 4 9 Rotary Motor 4 9 4 10 Rotary Reducer 4 9 4 10 1 Check and maintenance 4 9 4 10 2 Gear oil replacement 4 10 4 11 Slewing Bearing 4 11 4 11 1 Slew bearing lubrication 4 11 4 11 2 Check and maintenance 4 11 4 11 3 Disassembly 4 12 4 12 Gear clearance adjustment of slewing mechanism 4 12 SECTION 5 BOOM AND PLATFORM 5 1 P...

Page 6: ...c Filter Maintenance 6 1 6 1 1 High pressure filter 6 1 6 1 2 Oil filling filter 6 1 6 1 3 Return oil filter 6 2 6 2 Pressure Setting 6 2 6 3 Starting Procedure 6 3 6 3 1 Drive pump oiling 6 3 6 3 2 Exhaust air in the pump inlet pipe 6 3 6 4 Fault code 6 4 6 5 Common Faults and Methods 6 10 SECTION 7 ELECTRICAL INFORMATION AND SCHEMATIC 7 1 General Introduction 7 1 7 2 Multimeter Basic Operation 7...

Page 7: ... 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 7 5 7 3 4 HD30 HDP20 Series Connector Removal 7 6 7 5 Hydraulic Schematics 7 16 ...

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Page 10: ...ngineers c Familiar with the aerial work platforms maintenance and the potential danger d Received appropriate education and training including courses related to the use of special equipment e Familiar with the relevant maintenance procedures and safety precautions of aerial work platforms 1 Only the trained and qualified personnel who have obtained the qualification certificate can repair the ae...

Page 11: ... Precautions a Ventilation Ventilation is required when starting the engine in a space constrained site Connect a hose to the exhaust pipe to discharge the smoke to the outside Open the doors and windows to keep air flowing b Clean up the work site Implementing the inspecting or maintaining works in a messy place may result in personal injury or a fall accident All obstacles should be removed befo...

Page 12: ...nector otherwise it will cause an electrical short circuit It is strictly forbidden to align water or water jets with electrical components Otherwise there is danger of electric shock Figure 1 2 Mind Electric Shock 1 2 2 Precautions in maintenance a Prevent fire 1 Use non flammable cleaning fluids for parts and components cleaning 2 Store fuel and grease items away from flames or sparks 3 No smoki...

Page 13: ...omponents might cause burn hazard as the temperature of components goes high when the machine is running These components include engines mufflers engine cooling water radiators hydraulic oil reducers hydraulic kits and hydraulic accessories These components or parts should be allowed to cool down before starting inspection or maintenance Figure 1 4 Caution Hot b Pay attention to the installed pos...

Page 14: ...ohibited b Pay attention to high pressure oil High pressure fuel or hydraulic oil can cause serious damage to the skin or eyes To avoid this danger the following instructions should be followed 1 The pressure inside the pipe must be released before disassembling the pipe 2 Wear goggles and protective gloves when checking for leaks Leakage of high pressure oil may not be visible use cardboard or wo...

Page 15: ...ention promptly Figure 1 6 Mind battery liquid d Use the specified greased items Use the recommended grade or the same grade of oil and grease when replenishing or replacing The combination of different grades of grease will result in a chemical reaction that changes the properties of the grease and adversely affects the mechanical properties When using a grease that is different from the grade us...

Page 16: ...include mandatory confirmation of normal mechanical movement 1 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 2 It is forbidden to dump waste liquid at the sewage pipe ground surface river etc at will The waste liquid should be discharged into a suita...

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Page 19: ... km h 3 73mph Max Hydraulic System Pressure 21Mpa 21Mpa Max Wind Speed 12 5m s force 6 wind 28mph force 6 wind Max Working Force 400N 90lb Electrical System Pressure 12V DC 12V DC Gross Weight 12200kg 26896lb In stowed position 2 2 Specification and Performance Table 2 2 Specification and Performance Turntable Swing 360 360 Tail Swing 1 45m 4ft9in Platform Dimension 2 44 0 91 m 8 3ft Width 2 49m 8...

Page 20: ...Engine Oil Capacity 8L 2 1 us gal Rotate Speed 1200 idle speed 2000 low speed 2600 high speed 1200 idle speed 2000 low speed 2600 high speed Current Output of Generator 14V 95A 14V 95A Horsepower 49 49 Coolant Cold water 11L Cold water 2 9 us gal Table 2 5 D447L4 Deutz Engine Specification Type Electric Control Electric Control Fuel No 0 National IV No 0 National IV Engine Oil Capacity 15L 4 us ga...

Page 21: ...0 high speed Current Output of Generator 12V 65A 12V 65A Horsepower 61 61 Coolant Cold water 11L Cold water 2 9 us gal 2 4 2 Battery Table 2 7 Battery Specification Rated Voltage 12 V 20 hour rate capacity 90 Ah Cold Start Current 750 A 0º F 18 Storage Capacity 160 Min 80º F 27 2 5 Tire Table 2 8 Tire Size Size Type Ply Rating Max Capacity Weight tire and wheel 8km h 5mph 0km h 0mph 355 55D 625 Fo...

Page 22: ...tively e 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 f Drive raised choose a smooth ground with the main boom less than 7 and the extension length less than 1m Adjust the speed switch to high speed Record the time...

Page 23: ...Nm 154 2ftlb 294 Nm 217ftlb M18 288 Nm 212 4ftlb 405 Nm 298 7ftlb M20 408 Nm 301ftlb 538 Nm 396 8ftlb M22 555 Nm 409 4ftlb 780 Nm 575 3ftlb M24 705 Nm 520ftlb 992 Nm 731 7ftlb M27 1032 Nm 761 2ftlb 1450 Nm 1069 5ftlb M30 1400 Nm 1032 6ftlb 1970 Nm 1453ftlb Note when maintenance is required or the fasteners are loose follow the torque gauge to determine the appropriate torque value 2 8 Lubrication ...

Page 24: ... 9 Pressure Setting Table 2 12 Pressure Setting Main boom lifting 21MPa Boom telescoping 21MPa Turntable swing 21MPa Chassis diversion 21MPa Jib lifting 21MPa Platform rotation 21MPa Platform leveling 21MPa ...

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Page 27: ...by a qualified equipment engineer 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 repair and maintain the products described in this manual Pre delivery and daily inspections are performed in the same way but at different times Pre del...

Page 28: ...ironment or with a high frequency of operation Table 3 1 Inspection and maintenance Type Frequency Main responsibility Maintenance certification Reference Pre start Before daily use of each shift User or operator User or operator Operation and Safety Manual Pre delivery Ex factory after sold rented or leased Owner dealer or user Qualified engineer Maintenance Manual and the applicable checklist Da...

Page 29: ...ion New parts should be stored in containers before use 3 2 4 Component disassembly and installation a Use an adjustable lifting device if needed All spreaders slings chains etc must be parallel to each other and as perpendicular as possible to the top of the hoisted part b The angle between the support structure and the part is less than 90 degrees the load capacity of the eye bolt or similar bra...

Page 30: ...here will not be enough threaded parts to bite the fixed part When replacing bolts only bolts of the same or equivalent size as the original bolts may be used b In addition to the specific torque requirements given in this manual standard torque values shall be applied to heat treated bolts studs and steel nuts in accordance with the recommended factory practice see torque tables in Section 2 3 2 ...

Page 31: ...nance in Section 5 Always check for the presence of metal particles in the filter c Turbidity of the hydraulic fluid indicates that the water content is too high which may promote the growth of organic matter and cause oxidation or corrosion If this happens the system should be drained flushed and refilled with clean hydraulic fluid d Other hydraulic fluids may not contain the specified additives ...

Page 32: ...5 224 435 250 482 232 450 190 374210 410 92 198 231 448240 464270 518 Motion viscosity cSt 40 32 22 4 32 7 45 6 22 5 33 5 10 50 33 4 48 7 28 8 35 2 Viscosity index 140 164 164 164 155 155 150 150 150 180 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 8...

Page 33: ...ded values are suitable for most applications Higher temperatures pressures and adverse working conditions will accelerate oil failure so hydraulic oil should be replaced earlier If the system load is small the oil change time can be extended e Always take the necessary measures to keep the hydraulic oil clean Ensure all the containers used are clean After replacing the hydraulic fluid of the hydr...

Page 34: ...s Millimeter Inch Millimeter Inch 76 2 3 0 66 0 026 89 3 5 0 48 0 019 101 6 4 0 38 0 015 127 5 0 22 0 009 152 4 6 0 15 0 006 177 8 7 0 13 0 005 203 2 8 0 10 0 0038 228 6 9 0 08 0 003 a Use a calibrated dial gauge to measure drift on the cylinder rod The oil in the cylinder must be in a stable ambient temperature b The cylinder must have the normal load applied by the platform c If the cylinder pas...

Page 35: ... pins in the bearing area are rusty d Reassemble the connecting pin with a fiber bearing 1 The dirt and debris on the housing should be blown off There must be no foreign objects on the bearings and housings 2 Bearings and pins should be cleaned with a cleaning agent to remove all grease and lubricant Fiber bearings do not require lubrication 3 During installation and operation the pins should be ...

Page 36: ...ally sealed connectors a The silicone grease should be placed around the male and female pins on the inside of the connector before assembly to prevent oxidation It can be operated with a syringe for convenience Note oxidation for a certain period of time will increase the resistance of the connector and eventually cause a circuit failure b Each wire that exposes the connector housing should be wr...

Page 37: ...ct the wiring harness of the entire engine to confirm the presence of worn severed or damaged connections and repair if necessary e Check all harness connectors to ensure they are fully seated and locked f Check the ignition coil and spark plug cable for hardening cracking wear separation cracking of the dust cover and proper meshing g Replace the spark plug at the time intervals specified in the ...

Page 38: ...r shields 1 2 1 2 Cables or wire 1 2 3 1 2 3 Platform assembly 9 Platform 1 2 1 2 Railing 1 2 1 1 2 Door 5 1 1 5 Floor 1 2 1 1 2 Rotary motor 9 5 15 Lanyard anchorage 2 1 2 10 1 2 10 Turntable assembly 9 Swing bearing or worm gear 1 2 14 1 2 3 13 14 Swivel joint 9 Turntable drive system Turntable pin 1 2 5 1 2 5 Hood hood props and hood latches 5 1 2 5 Chassis assembly 9 Tire 1 16 17 16 17 18 16 1...

Page 39: ...und control 5 5 6 6 Function control locks protective device or brake device 1 5 1 5 5 5 Foot switch 1 5 5 5 Emergency switch Ground and platform 5 5 5 Function limit or cutout switch system 5 5 Capacity indicator 5 Drive brake 5 Swing brake 5 Boom synchronization seque ncing system 5 Manual descent auxiliary power 5 5 Power system 9 Engine idle throttle and RPM 3 3 Engine fluid engine oil engine ...

Page 40: ...ical system 9 Hydraulic pump 1 9 1 2 9 Hydraulic oil tank 1 9 7 2 1 2 9 1 2 9 Cylinder pinned joints and pins retainer 1 9 1 2 1 2 Hydraulic hose and other hydraulic fittings 1 9 12 1 2 9 12 1 2 9 12 Hydraulic oil tank cap and breather hole 11 1 9 2 1 5 1 5 24 Hydraulic oil filter 1 9 7 7 Hydraulic oil 11 7 11 7 11 Electrical connections 1 20 20 Instruments meter switch light and horn 1 5 23 Gener...

Page 41: ...lidate all relevant security publications 21 21 General structural state and welding 2 4 2 4 All fasteners pins hood and covering 1 2 1 2 Lubricating grease and its specification 22 22 All system functional test 21 21 21 22 Painting and appearance 7 7 Imprint check date on the frame 22 Notifying Zoomlion machine ownership 22 Footnote 1 Before daily use or each shift 2 Before each sale rental or de...

Page 42: ...ee of dirt 8 Interlock function 9 Check for signs of leaks 10 Complete and secure decal 11 Level check 12 Check for wear and correct routes 13 Correct tolerance check 14 Correct lubrication 15 Reverse to appropriate torque specification 16 No boring excessive wear or bare rope 17 Properly inflated and mounted to the rim 18 Appropriately authorized parts 19 Fully charged 20 The joint is not loose c...

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Page 45: ...re 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 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 Also prepare to re...

Page 46: ...commended by our company Due to the dimensional differences between different brands of tire the same brand should be used for the two tires on the same axle 4 1 4 Wheel replacement The rims installed on each model are rigorously designed for stability requirements such as track tire pressure and load capacity Unauthorized changes to the rim width center piece position and diameter size without th...

Page 47: ...ird step 75 Nm 55ftlb 210 Nm 155ftlb 310 Nm 229ftlb d The fastening nut should be tightened for the first time of 50 hours or after each disassembly of the unit Torque should be checked every 3 months or 150 hours of operation 4 2 Swing axle exhaust and locking test 4 2 1 Floating cylinder exhaust a Start engine b The turntable is in a stowed position c Connecting the cleaning tube to the threaded...

Page 48: ...ear position and drive the mechanical device away from the block and ramp f Ensure that the left front wheel is locked on the ground g Drive the telescopic cylinder very carefully to return the boom to the stowed position The floating cylinder should be released and allow the wheel to rely on the ground and it may be necessary to activate the system to release the cylinder h Repeat the above steps...

Page 49: ...p the front axle in its original position and prevent it from swinging The ground controller monitors the boom angle by installing an angle sensor at the end of upper boom The ground controller monitors the boom extension by a wire sensor mounted on the inside of the boom When the ground controller detects that the condition for releasing the front axle lock is satisfied the controller sends a pil...

Page 50: ... of a variable displacement closed pump two variable displacement piston motors two gear reducers and a split flow combining travel control valve The walking speed is changed according to the three factors of driving pump displacement engine speed and motor displacement Traction control is full time full mode Our equipment has three drive modes to choose from at the platform console The drive syst...

Page 51: ...ravel motor on the travel reducer and close the port c Use a suitable lifting device to support the travel reducer the travel reducer weighs approximately 50kg 110lb d Disassemble the six bolts used to connect the travel reducer and the chassis structure e Remove the travel reducer from the equipment and place it in a clean work area Figure 4 7 Travel reducer disassembly diagram ...

Page 52: ...a solid level surface b Remove all hydraulic connections to the traveling motor and mark them c Use a suitable lifting device to support the traveling motor the traveling motor weights approximately 15 4kg 34lb d Disassemble the two mounting bolts used to connect the traveling motor to the steering knuckle e Disassemble the traveling motor from the steering knuckle and place it in a clean work are...

Page 53: ... and plug the motor oil port When disassembling the oil pipe the joint should be slowly disassembled to prevent high pressure hydraulic oil from being splashed and hurting people Remove the connection bolt between the motor and the reducer and remove the motor 1 DO NOT disassemble the hydraulic motor by your own If there is a problem with the hydraulic motor please contact your nearest after sales...

Page 54: ...nism can freely rotate 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 the brake oil seal needs to be replaced if the oil seal is damaged Insufficient braking torque When the braking torque is severely reduced or the friction pad is deformed the friction pad needs to be replaced 4 10 2 Gear oil replacem...

Page 55: ... sand or humid areas a Use a grease gun to inject Mobilux EP 2 Shell Alvania EP LF 2 grease from the grease nipple on the slewing ring into the slewing ring until the grease leaks from the seal and fills the ring Lubricate the slewing bearing generally add grease every 150 hours of work if it is used in strict dusty and humid environments shorten it to 50 hours if it is stopped for a long time lub...

Page 56: ... 2 The weight of the car part is about 10T 22046lb To ensure safety please use a crane of more than 15T 33069lb e Remove the connecting bolts between the slewing bearing and the chassis f Install 2 M16 eyebolts lift off the slewing bearing and place it properly g The slewing bearing installation process is the reverse of the above process Bolt installation must use thread locking glue and the bolt...

Page 57: ...letely unscrewing it b Loosen the mounting bolts without completely unscrewing them c Adjust the adjusting bolt and measure the backlash between the slewing gear and the slewing bearing with a plug gauge Adjust and measure repeatedly until the gap is between 0 15mm 0 00591in and 0 25mm 0 00984in d Tighten the mounting bolts with a tightening torque of not less than 520Nm 384ftlb e Hold the adjusti...

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Page 60: ...ve the connecting bolts 1 6 of the bracket and the platform component and use a suitable lifting device to remove the platform component from the bracket c Remove the connecting bolts 4 and 5 of the swing cylinder and the transition base and use appropriate lifting equipment to remove the bracket and the transition base from the swing cylinder d Remove the bolt 3 at the protective hook and remove ...

Page 61: ...ly Figure 5 2 Rotary actuator and jib lifting cylinder disassembly diagram a 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 b Remove the stop pin and connecting pin of the support and the main boom and use a suitable lifting device to remove ...

Page 62: ...ine after collecting b Disassemble the connecting bolt of the support and the lower link 1 the connecting bolt of the support and the upper link 2 the stopper pin and remove the pin to remove the jib lifting cylinder 5 1 3 2 Inspection a Inspect the shaft pin for wear scratches taper ovality or other damage and replace the pin if necessary b Inspect the inner ring of the bearing for scratches dist...

Page 63: ...ulic system a Mark and disconnect the hydraulic lines from base 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 b Mark and disconnect the harness of the travel switch from the side of base boom c Mark and disconnect the hydraulic lines and harness from the telescopic boom to the upper leveling cylinder...

Page 64: ...replace the line if necessary c Inspect all threaded parts for damage such as stretching thread deformation or distortion and replace if necessary d Check the cable structure for bending cracking weld separation or other damage and replace the cable structure if necessary 5 2 1 3 Installation a Follow the reverse steps of disassembly The pipe joints of the hydraulic lines before installation shoul...

Page 65: ...cing valve to prevent dust and other pollutants from entering the oil line 5 2 2 2 Inspection a Inspect the shaft pin for wear scratches taper ovality or other damage and replace the pin if necessary b Inspect the inner ring of the bearing for scratches distortion wear or other damage and replace the bearing if necessary c Inspect all threaded parts for damage such as stretching thread deformation...

Page 66: ...cylinder and the connecting rod f Use a suitable plug to block the connector of the lower leveling cylinder balancing valve to prevent dust and other pollutants from entering the oil line 5 2 3 2 Inspection a Inspect the shaft pin for wear scratches taper ovality or other damage and replace the pin if necessary b Inspect the inner ring of the bearing for scratches distortion wear or other damage a...

Page 67: ...ngle the weight of the boom assembly is supported by the turntable and the connecting rod and the lifting cylinder is under no force b Mark and disconnect the hydraulic pipeline connected to the lifting cylinder collect the hydraulic oil in the pipeline with a suitable container and block the port of the pipeline after the collection c Remove the pin 1 of the base boom connected to the lifting cyl...

Page 68: ...cuit 5 2 4 2 Inspection a Inspect the shaft pin for wear scratches taper ovality or other damage and replace the pin if necessary b Inspect the inner ring of the bearing for scratches distortion wear or other damage and replace the bearing if necessary c Inspect all threaded parts for damage such as stretching thread deformation or distortion and replace if necessary Refer to the Pin and Bearing I...

Page 69: ...oss 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 The disassembly of the boom assembly requires personnel with specialized maintenance skills l...

Page 70: ...he counterweight to the turntable slowly and carefully remove the counterweight from the equipment and place it on the hard ground reliably Figure 5 9 Disassembly of the boom assembly a Mark and disconnect the wiring harness connected to the sensor and the hydraulic pipeline connected to the oil cylinder in the boom collect the hydraulic oil in the pipeline with a suitable container and block the ...

Page 71: ... and equipment damage When removing keep personnel away from the area near the boom 5 2 5 2 Inspection a Inspect the shaft pin for wear scratches taper ovality or other damage and replace the pin if necessary b Inspect the inner ring of the bearing for scratches distortion wear or other damage and replace the bearing if necessary c Inspect all threaded parts for damage such as stretching thread de...

Page 72: ...tate c Use a suitable wrench to be clamped on the wrench and remove the nut 2 Figure 5 11 Sensor disassembly diagram d Remove the length sensor and the inclination sensor installed at the end of the boom Note the pipeline at the end of the boom has been removed Figure 5 12 Disassembly of the wire rope sensor assembly 拉绳传感器倾角传感器 Nut 1 boom retracting wire rope Wrench clamp Nut 2 Tilt sensor Length...

Page 73: ...he bolt 5 and remove the pulley cover Figure 5 13 Removal of the retractable rope seat h Remove bolt 6 and remove the retractable wire rope limit cover Move the retracted wire rope to the outside of the boom and place it near the fabrication hole 1 to release the shield of the retracted wire rope head from the fabrication hole 2 i Within the scope of the fabrication hole 2 remove the bolt 7 and re...

Page 74: ...cylinder out towards the tail of the boom o Use lifting equipment to support the two ends of the telescopic oil cylinder and slowly move the telescopic oil cylinder to a suitable support frame Extrusion hazard If the lifting equipment fails to reliably support the telescopic oil cylinder the telescopic oil cylinder may fall when disassembling the telescopic oil cylinder resulting in personal injur...

Page 75: ...e is connected c Threaded fasteners should be tightened in place according to the torque values in Section 2 Specifications 5 2 7 Wire rope pulley disassembly When replacing the wire rope the pulleys need to be replaced simultaneously 5 2 7 1 Disassembly Figure 5 17 Removal of the extending boom wire rope a To remove the telescopic oil cylinder please refer to the telescopic oil cylinder removal s...

Page 76: ...break may be exposed b Check whether the wire rope is corroded c 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 tensioning the wire rope d Inspect the extended and retracted wire rope pulley bearings for wear scratches or other damage and for ovality Replace bearings if ne...

Page 77: ... flashlight to visually inspect the wire rope for rust damage wear misuse and other abnormal phenomena b Pull the wire rope manually to check the tightness of the wire rope The tensioned wire rope has almost no lateral displacement 5 2 8 3 12 years or 7000 hours replacement a After 12 years or 7000 hours of use the wire rope and pulley must be replaced compulsorily b The ropes and pulleys need to ...

Page 78: ...just the boom to the horizontal fully retracted attitude and adjust the initial extension lengths A and B of the boom as required The allowable error of A and B is 5mm 0 197in Figure 5 19 Initial extension of boom b Clamp the rope head to prevent the rope from rotating Do not pinch the threads when tightening otherwise the threads may be damaged When tightening clamp the end of the wire rope near ...

Page 79: ...etractable boom rope M20 and use a torque wrench to tighten the nut of the retractable boom rope to 55 60Nm 40 44ftlb h Enable the boom telescopic function and extend the boom 1 1 5m 3 28 4 92ft i Torque of shortened boom rope M20 nut 1 to 55 60Nm 40 44ftlb j Enable the boom telescopic function make the boom retract about 0 5 0 8m 1 64 2 62ft first do not retract the telescopic cylinder to the ext...

Page 80: ...kg 1000lb to full load f Under the overload condition the overload indicator of the platform and the ground is continuously lit and the alarm is issued g Remove load items from the platform h The load cell adjustment is completed 5 4 Boom Tilt Sensor Check a Keep the working platform unloaded b Retract the boom to the extreme position and raise the boom to a horizontal position c Use an angle test...

Page 81: ...peed check a Start the unit in platform mode and adjust the device to the favorite position b Select ground rabbit speed for engine speed turn the function speed knob to rabbit speed c Operate the travel function At this time the two speed valve will open to enable the high speed travel function d Retracted the boom to the stowed position and the turntable is turned to the stowed position e Raise ...

Page 82: ...5 23 Wear a seat belt when performing a speed limit check Do not lift the boom to an excessively high position for testing and pay attention to driving safety to avoid accidents ...

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Page 85: ... 6 1 1 High pressure filter Time intervals Run for the first time for 50 hours and the filter element should be replaced every 300 hours thereafter 6 1 2 Oil filling filter Time intervals Run for the first time for 50 hours and the filter element should be replaced every 300 hours thereafter ...

Page 86: ...to use a calibrated pressure gauge Acceptable only if the pressure reading is within 5 of the specified pressure To ensure that all pressure settings are correct the following operating procedures must be strictly followed a Install a pressure measuring connector on the M port of the main valve group and connect the pressure gauge b Start the boom lowering function the meter reading should be 210 ...

Page 87: ...wo ways to discharge air from the tubing under low pressure conditions a On the main control valve remove the 3 4 inch 19mm tubing from port P1 and then remove the 1 inch 25 4mm tubing from port T Use 12 16 connectors to connect them together Start the machine and let it run for about 10 seconds Shut down remove the 12 16 converter and reconnect the tubing b Remove the 3 4 inch 19mm tubing from po...

Page 88: ...ault code Fault code list Battery 22001 DTC_SYSTEM_LOW_VOLTAGE 22002 DTC_SYSTEM_OVER_VOLTAGE CAN bus 24021 DTC_CANBUS_FAULT_PM2GM 22022 DTC_CANBUS_FAULT_Engine2GM 22023 DTC_CANBUS_FAULT_HMI2GM Engine 22051 DTC_GENERATOR_FAULT 22052 DTC_ENGINE_HIGH_TEMP 22053 DTC_LOW_OIL_PRESSURE 22054 DTC_LOW_FUEL 22055 DTC_FUEL_CUT_OFF 22056 DTC_LOW_COOLANT_LEVEL 22057 DTC_ENGINE_START_FAULT 22058 DTC_THROTTLE_MO...

Page 89: ...C_LEVELING_SENSOR_COMM_ERROR 13167 DTC_BOOM_LENGTH_SENSOR_REDUNDANCY 32168 DTC_FAULT_AIR_FILTER_SENSOR 32169 DTC_FAULT_OIL_WATER_SEPARATION_SENSOR 32170 DTC_FAULT_HYDRAULIC_OIL_FILTER_SENSOR 14175 DTC_FAULT_LOAD_SENSOR_OUT_RANGE Switch handle 22351 DTC_FAULT_UG_FUNCTION_SWITCH_CLOSED 24352 DTC_FAULT_PM_FUNCTION_SWITCH_CLOSED 12353 DTC_FAULT_UG_MAIN_LIFT_SWITCH_DOUBLE_POWER_ ON 12355 DTC_FAULT_UG_J...

Page 90: ...SWING_JOYSTICK_MEDIUM_OFFSET 24378 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_UP_LIMIT 24379 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_DN_LIMIT 24380 DTC_FAULT_PM_MAIN_LIFT_JOYSTICK_MEDIUM_OFFSE T 24381 DTC_FAULT_PM_DRIVE_JOYSTICK_UP_LIMIT 24382 DTC_FAULT_PM_DRIVE_JOYSTICK_DN_LIMIT Switch handle 24383 DTC_FAULT_PM_DRIVE_JOYSTICK_MEDIUM_OFFSET 24384 DTC_FAULT_PM_STEER_JOYSTICK_UP_LIMIT 24385 DTC_FAULT_PM_STEER_JOYSTICK...

Page 91: ...TEER_RIGHT_VALVE_SHORT_TO_POWER 22573 DTC_STEER_RIGHT_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 DTC_SWING_RIGHT_VALVE_SHORT_TO_GROUND 22578 DTC_SWING_RIGHT_VALVE_SHORT_TO_POWER 22579 DTC_SWING_RIGHT_VALVE_OPEN_CIRCUIT 22624 DTC_JIB_FLOW_VALVE_SHORT_TO_GROUND 22625 DTC_JIB_FLOW_VALVE_SHORT_TO...

Page 92: ... DTC_SWING_FLOW_VALVE_FEEDBACK_CURRENT_FA ULT 23651 DTC_MAIN_LIFT_DN_FLOW_VALVE_SHORT_TO_GROU ND 23652 DTC_MAIN_LIFT_DN_FLOW_VALVE_SHORT_TO_POWE R 23653 DTC_MAIN_LIFT_DN_FLOW_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 23657 DTC_MAIN_LIFT_DN_VALVE_FEEDBACK_CURRENT_FA ULT 24658 DTC_JIB_UNLOAD_V...

Page 93: ...LVE_SHORT_TO_GROUND 14676 DTC_JIB_UP_VALVE_SHORT_TO_POWER 24677 DTC_JIB_UP_VALVE_OPEN_CIRCUIT 24678 DTC_JIB_DN_VALVE_SHORT_TO_GROUND 14679 DTC_JIB_DN_VALVE_SHORT_TO_POWER 24680 DTC_JIB_DN_VALVE_OPEN_CIRCUIT 22741 DTC_BOOM_UP_VALVE_STUCKED 22742 DTC_BOOM_DN_VALVE_STUCKED 24743 DTC_LEVEL_UP_VALVE_STUCKED 24744 DTC_LEVEL_DN_VALVE_STUCKED 33851 DTC_STEEL_WIRE_ROPE_LOOSE 41852 DTC_DRIVE_DIRECTION_REVER...

Page 94: ...e battery or replace it with a new one 2 Operation switch or handle is not returned to neutral position 2 Return the operation switch or handle to neutral position 3 Emergency stop button is pressed Reset emergency stop button 4 The main power switch is not turned on Turn on the main power switch on the turntable 5 Engine overheat Shutdown and radiating No Fault Feature Fault Cause Solution 1 Engi...

Page 95: ...m fault alarm 1 Leveling valve wiring failure 1 Check the leveling valve wiring for short circuit or open circuit 2 Failure to level solenoid valve 2 Replace the leveling solenoid valve 7 Action cannot be performed normally 1 Whether the authorization switch is pressed 1 First operate the authorization switch then operate the action 2 Motion switch damaged 2 Replace switch 3 Motion handle damaged ...

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Page 98: ...de of the wire ie the rear end of the connector In this way the circuit is turned on to obtain a reading If the connector is sealed backside detection should be conducted carefully to avoid damaging the sealing material around the wire It is best to use probes designed specifically for this technology especially when operating on sealed connectors Insert the detector into the side of the connector...

Page 99: ...nnected 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 For example 1 2 kΩ 1200Ω For example 50 mA 0 05 amps 7 2 6 Voltage measurement Figure 7 1 Voltage measurement direct current If the multimeter cannot automatically adjust the range set the correct range refer to the multime...

Page 100: ...before testing d If the multimeter cannot automatically adjust the range set the correct range refer to the multimeter operation manual e Make sure the multimeter leads are securely connected 7 2 8 Conduction test Figure 7 3 Conduction test a The multimeter needs to use a separate button to initiate the continuity test of the beep b The circuit power must be turned off before testing the conductio...

Page 101: ... range of the multimeter b Verify that the multimeter leads and jacket are properly connected within the current range of your choice c If the multimeter cannot automatically adjust the range set the correct range refer to the multimeter operation manual d Make sure the multimeter leads are securely connected 7 3 DEUTSCH Connector 7 3 1 DT DTP series connector assembly A B C D Figure 7 5 DT DTP co...

Page 102: ...snap into place immediately The rectangular wedge is non directional Can be used in any direction Note the socket is as shown follow the same steps to complete the plug connection 7 3 2 DT DTP Series Connector Disassembly A B c Figure 7 6 DT DTP contact removal a When disassembling use a non toothed nose pliers or hook line to pull the wedge locker vertically b Use a screwdriver to remove the reta...

Page 103: ...ard you c Push the contacts straight into the retaining ring until you hear a slight click Gently pull to confirm that the connector is fully locked Figure 7 8 HD HDP lock contact position Note for unused wire cavities a sealing plug should be inserted to achieve complete isolation from the environment 7 3 4 HD30 HDP20 Series Connector Removal A B Figure 7 9 HD HDP contact removal ...

Page 104: ...and removal tool to clamp the wire of the contact to be removed b Slide the tool into the cavity of the insert until the tool catches the contact and feels stressed c Pull the contact wire assembly out of the connector Figure 7 10 HD HDP Unlocking contact Note do not twist or tilt the insertion tool 7 4 Electrical Schematics ...

Page 105: ...7 8 Figure 7 11 Electrical Schematics Figure 1 6 Perkins engine ...

Page 106: ...7 9 Figure 7 12 Electrical Schematics Figure 1 6 Deutz D447 engine ...

Page 107: ...7 10 Figure 7 13 Electrical Schematics Figure 1 6 Deutz D2 9 engine ...

Page 108: ...7 11 Figure 7 14 Electrical Schematics Figure 2 6 ...

Page 109: ...7 12 Figure 7 14 Electrical Schematics Figure 3 6 ...

Page 110: ...7 13 Figure 7 16 Electrical Schematics Figure 4 6 ...

Page 111: ...7 14 Figure 7 17 Electrical Schematics Figure 5 6 ...

Page 112: ...7 15 Figure 7 18 Electrical Schematics Figure 6 6 ...

Page 113: ...7 16 7 5 Hydraulic Schematics Figure 7 19 Hydraulic Schematics Figure ...

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