Zoomlion Scissor lift ZS4555HD, ZS4045HD, ZS3246HD, ZS2632HD, ZS2032HD, ZS1930HD, ZS1530DC. Service and Maintenance Manual

b) Apply a thin layer of dry film lubrication to the area of the chassis where the scissor wear pads make

contact.

2.6.6 Maintenance every 24 months

Good quality hydraulic oil is essential to good machine performance and service life. Dirty hydraulic oil

and suction filters can affect machine performance, and continuous use can damage components. This

operation should be performed more frequently in harsh working conditions.

If the hydraulic oil has not been replaced for two years, it should be tested once every quarter, and the

hydraulic oil should be replaced if the test fails.

This procedure should be conducted once every quarter. The hydraulic oil should be replaced if the test

fails.

We suggest that changing time of the hydraulic oil is as follows:

a) First changing: operating for 500 hrs after commissioning.

b) Second and subsequent changing: run for 2000 hours or once every two years.

The above recommended intervals are suitable for most applications. Higher temperatures, pressures and

adverse working conditions will accelerate oil failure, so hydraulic oil should be replaced earlier. For

small load work, the oil change time can be extended.

For hydraulic oil types and models, please refer to Table 2-6 Hydraulic oil technical parameters (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.

DO NOT mix oils of different brands or types, as they contain different additives which may cause

negative effects. If mixing of hydraulic oils is unavoidable, permission must be obtained from the

hydraulic oil manufacturer. After-sales service of ZOOMLION does not cover machine malfunction

caused by hydraulic oil mixing.

2-25

Table 2-6 Technical parameters of hydraulic oil

Kinematic

Technical

ISO

Pour

Flash

viscosity

Viscosity

Parameters

Viscosity

Point

cSt(40℃

index

Brand & Type

Grade

℃/℉

/104℉)

Great Wall 4632 grease non-

flammable hydraulic oil N32

-20/-4

270/518

28.8-35.2

180

(Eco-Friendly)

Great Wall Ground 10

10.53(50℃

—

-55/-67

107/225

120

aviation hydraulic fluid

/122℉)

Great Wall ZhuoLi L-HS 15

-57/-71

164/327

15.35

172

Ultra-low temperature hydraulic

Great Wall ZhuoLi L-HS 32

-48/-54

224/435

31.35

166

Ultra-low temperature hydraulic

Great Wall ZhuoLi L-HS 46

-43/-45

238/460

45.81

170

Ultra-low temperature hydraulic

Great Wall ZhuoLi L-HV 15

-45/-49

173/343

15.51

140

Low temperature hydraulic oil

Great Wall ZhuoLi L-HV 32

-39/-38

231/448

33.4

150

Low temperature hydraulic oil

Great Wall ZhuoLi L-HV 46

-37/-35

240/464

48.7

150

Low temperature hydraulic oil

Great Wall ZhuoLi L-HV 68

-35/-31

238/460

70.47

150

Low temperature hydraulic

Great Wall ZhuoLi L-HM 46

Anti-wear hydraulic oil

-15/5

240/464

45.8

(high pressure)

Great Wall ZhuoLi L-HM 68

Anti-wear hydraulic oil (high

-13/9

245/473

67.4

pressure)

Mobil SHC Aware H 32

-30/-22

185/365

140

(Eco-Friendly)

2-26

Table 2-6 Technical parameters of hydraulic oil

Technical

ISO

Pour

Flash

Kinematic

Viscosity

Parameters

Viscosity

Point

viscosity

index

Brand & Type

Grade

℃

cSt(40℃)

Clarity Synthetic EA

-44/-47

221/430

180

Hydraulic Oil

Mobil DTE 10 Ultra 22

-54/-65

224/435

22.4

164

Mobil DTE 10 Ultra 32

-54/-65

250/482

32.7

164

Mobil DTE 10 Ultra 46

-45/-49

232/450

45.6

164

CaltexRando

-60/-76

150/302

15.7

144

Rando HDZ 15

CaltexRando

-49/-56

204/399

150

Rando HDZ 32

CaltexRando

-47/-53

216/421

46.7

153

Rando HDZ 46

CaltexRando

-42/-44

154/309

15.8

155

Rando MV 15

CaltexRando

-36/-33

210/410

33.5

154

Rando MV 32

CaltexRando

-33/-27

214/417

154

Rando MV 46

Proper use of hydraulic oil: please note the corresponding oil viscosity and temperature limit. Under

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.

Add the corresponding type of hydraulic oil according to the customer's requirements before ex-factory.

When the working environment temperature changes beyond the working range of the hydraulic oil,

please replace other suitable types of hydraulic oil according to the actual situation. Considering the safety

of the components and the efficiency of the work, it is recommended that the starting temperature of the

equipment is higher than the selected hydraulic oil pour point temperature of 25℃/77℉ or more.

Cleanliness of the hydraulic oil upon delivery is NAS9 (ISO4406 18/15), and for normal operation, the

cleanliness should not be lower than NAS10 (ISO4406 19/16). We suggest that the hydraulic oil should

be checked every 6 months, and the oil should be sampled at least once upon the time for oil changing.

2-27

The oil sample can be sent to the hydraulic oil manufacturer or qualified third-party testing agency for

analysis and to determine whether it is still usable.

This procedure should be conducted once every quarter. The hydraulic oil should be replaced if the test

fails.

a) Disconnect the battery pack from the machine.

Operation in a live circuit can result in serious injury or death. Remove rings, watches and other

jewelry.

a) Open the hydraulic tray.

b) Mark and disconnect the oil return tube from hydraulic filter to the hydraulic tank and remove the

line from the tank. Cover the pipe joint to protect it from dust.

c) Loosen the hydraulic tank fastener and remove the hydraulic tank.

d) Remove the drain plug from the bottom of the hydraulic tank.

e) Put the oil in a suitable container.

The jetted hydraulic oil can burn the skin. Slowly loosen the hydraulic joint to allow the oil pressure

to gradually weaken. Do not let the oil spray out.

a) Clean up and properly dispose any oil that may have spilled.

b) Clean the hydraulic tank with a mild solvent and thoroughly air dry.

c) Tighten the drain plug.

d) Replace the hydraulic tank and install the fasteners that tighten the hydraulic tank.

e) Oil the hydraulic pump and connect it to the tank.

Connect the hydraulic pump tubing to the return filter.

g) Start the oil pump and fill the entire hydraulic system with hydraulic oil to remove the air from the

hydraulic system.

Operation without oil may result in damage to the hydraulic pump. When filling the hydraulic

system, carefully evacuate the tank. Do not expose the hydraulic pump to cavitation.

2-28

SECTION 3 ELECTRICAL SYSTEM MAINTENANCE

3.1 Electrical System Trouble shooting

If the platform controls LED or ground controls LCD diagnostic readout displays following codes, the

fault condition must repaired or removed before resuming machine operation.

3.1.1 Fault code

Table 3-1 Fault code list

Code

Condition

Machine Reaction

System initialization Fault

Disable All Motion

System communication Fault

Disable All Motion

Invalid option setting Fault

Disable All Motion

Calibration Fault

Disable All Motion

GPS communication Fault

Disable All Motion

CAN communication Fault

Disable All Motion

Chassis Up or Down Switch ON

Disable Chassis Control

Pothole Guard Fault

Disable Lifting and Driving

BMS Comm Fault

Disable Lifting and Driving

Disch Temp Fault I

Warning Only

Disch Current High Fault I

Warning Only

Disable Lifting, and Driving Lift

Total Voltage Low Fault I

Slow to Drive Speed

3-1

Table 3-1 Fault code list

Condition

Machine Reaction

Code

Disable Lifting, and Driving Lift

Cell Voltage Low Fault I

Slow to Drive Speed

Cell Voltage Low Fault II

Disables All Motion

Sharp Diff in Voltage

Disable All Motion

Sharp Diff in Temp

Disable All Motion

Disch Current High Fault II

Disable All Motion

Disch Temp Fault II

Disable All Motion

Pressure Sensor Fault

Disable All Motion

Angle Sensor Fault

Disable All Motion

Pressure Sensor 2 Fault

Disables All Motion

Battery Drain Alarm

Lift Slow to Drive Speed

Battery Drain Shutdown

Disable All Motion

SPI communication Fault

Disable All Motion

Platform Left Button ON

Diagnostic Message Only

Platform Right Button ON

Diagnostic Message Only

Platform Enable Button ON

Disable Platform Control

Joystick Not In Neutral

Lift Slow to Drive Speed

3-2

Table 3-1 Fault code list

Condition

Machine Reaction

Code

Horn Coil Fault

Disable All Motion

Forward Coil Fault

Disable Lifting and Driving

Reverse Coil Fault

Disable Lifting and Driving

Lift Up Coil Fault

Disable Lifting and Driving

Lift Down1 Coil fault

Disable Lifting and Driving

Right Turn Coil Fault

Disable Lifting and Driving

Left Turn Coil Fault

Disable Lifting and Driving

General Brake Coil Fault

Disable Lifting and Driving

Parallel Coil Fault

Disable Lifting and Driving

Motor Controller Fault

Disable All Motion

Motor Controller Current Sensor Fault

Disable All Motion

Motor Controller Hardware Failsafe Fault

Disable All Motion

Motor Controller Motor Short Fault

Disable All Motion

Motor Controller SRO Fault

Disable All Motion

Motor Controller Throttle Fault

Disable All Motion

Motor Controller Emergency Reverse Fault

Disable All Motion

Motor Controller HPD Fault

Disable All Motion

3-3

Table 3-1 Fault code list

Condition

Machine Reaction

Code

Total Voltage Low Fault II

Disable All Motion

High Neutral Current Fault (Zapi Only)

Disable All Motion

Steer Input Out of Range (Zapi Only)

Disable All Motion

Motor Controller Main Contractor Fault

Disable All Motion

Motor Controller Over Voltage Fault

Disable All Motion

Motor Controller Thermal Cutback Fault

Disable All Motion

Motor Controller Over Heat Fault

Disable All Motion

Motor Controller Pump Motor Fault

Disable All Motion

Motor Controller Left Drive Motor Fault

Disable All Motion

Motor Controller Right Drive Motor Fault

Disable All Motion

MC Pump Motor Short

Disable Lifting and Driving

Left Drive Motor Short Fault

Disable All Motion

Over 80% Load Warning

Diagnostic Message Only

Right Drive Motor Short Fault

Disable All Motion

Left Brake Coil Fault

Disable Lifting and Driving

Right Brake Coil Fault

Disable Lifting and Driving

Motor Post Shorted

Disable Lifting and Driving

Brake Release Switch On

Diagnostic Message Only

3-4

Table 3-1 Fault code list

Condition

Machine Reaction

Code

Brake Release Not Showed

Diagnostic Message Only

Brake Release

Diagnostic Message Only

Motor Field Open

Disable Lifting and Driving

Platform Load is over 90%

Diagnostic Message Only

Left Motor Field Short

Disable Lifting and Driving

Right Motor Field Short

Disable Lifting and Driving

Lift Down2 Coil fault

Disable Lifting and Driving

Over 99% Load Warning

Warning Only

Overloaded Platform Fault

Disable All Motion

Machine Tiled

Disable Lifting and Driving

3-5

3.1.2 Troubles shooting method

Table 3-2 Trouble shooting method

Code

Trouble shooting Method

System Initialization Fault: ECU may be malfunctioning, replace it.

System Communication Fault: Check communications cable connections and

other wiring. If that does not resolve the problem, try replacing the PCU or ECU.

Invalid Option setting Fault: Set appropriate option for this lift.

Calibration Fault: Re-calibration the system, or check the angle and pressure sensor.

GPS communication Fault: Check communications cable connections and other

wiring. If that does not resolve the problem, try replacing the GPS module or ECU.

CAN communication Fault: Check communications cable connections and other

wiring. If that does not resolve the problem, try replacing the CAN application or ECU.

Chassis Up or Down Fault: Check communications cable connections and other

wiring.If that does not resolve the problem, try replacing the ECU.

Pothole Guard Fault: Check that the pothole guards are extended, check the pothole

limit switches. Check wires to the switches, check the down limit switch and

connections.

BMS Communication Fault: Check communications cable connections and other

wiring between ECU and BMS. If that does not resolve the problem, try replacing the

BMS or ECU.

Disch Temp Fault I: Lower capacity or travel slowly.

3-6

Table 3-2 Trouble shooting method

Code

Trouble shooting Method

Disch Current High Fault I: Lower capacity or travel slowly.

Total Voltage Low Fault I: Restart the key, charge immediately.

Cell Voltage Low Fault I: Restart the key, charge immediately.

Cell Voltage Low Fault II: Switch off the key, charge immediately.

Sharp Diff in Voltage: Rest for a while, then power on to see if the fault disappears. If

not, charge timely.

Sharp Diff in Temp: Rest for a while, then power on. If the fault disappears, the device

could proper function.

3-7

Table 3-2 Trouble shooting method

Trouble shooting Method

Code

Disch Current High Fault II: Stop operation, and power on again. If the fault

disappears, lower capacity or travel slowly.

Disch Temp Fault II: Stop operation, and power on again after a period of rest. If the

fault disappears, lower capacity or travel slowly.

Pressure Sensor Fault: Check the wiring to the sensor and then the sensor it self. Also

check to make sure that the correct option is properly selected (or not) for load sensing.

Angle Sensor Fault: Check the wiring to the sensor and then the sensor itself. Also

check to make sure that the correct option is properly selected (or not) for load sensing.

Pressure Sensor 2 Fault: Check the wiring to the sensor and then the sensor itself. Also

check to make sure that the correct option is properly selected (or not) for load sensing.

Limp Mode: Battery voltage is low, charge the battery.

Battery Drain Shutdown：Recharge.

SPI Communication Fault： Re-power, then check whether the fault still exists. If it

is, please contact us.

Platform Left Turn Switch ON at power-up Message: Ensure that nothing is holding

the Joystick Toggle Switches down. If OK, consider replacing the Joystick or PCU.

Platform Right Turn Switch ON at power-up Message: Ensure that nothing is holding

the Joystick Toggle Switches down. If OK, consider replacing the Joystick or PCU.

Platform Joystick Enable Switch ON at power-up Fault: Ensure that nothing is holding

the Enable switch closed. Also check the neutral zone parameters. If OK, consider

replacing the Joystick or PCU.

Platform Joystick not in neutral at power-up Message: Make sure that the Joystick is

in the neutral (upright) position. Check the neutral zone parameter setting in the

Labview Programmer. If it’s OK, consider replacing the Joystick or the PCU.

Forward Coil Fault: Check the connections to the Coil’s terminals and make sure they

are tight. If so, check the coil itself to see if it is open or shorted.

3-8

Table 3-2 Trouble shooting method

Trouble shooting Method

Code

Reverse Coil Fault: Check the connections to the Coil’s terminals and make sure they

are tight. If so, check the coil itself to see if it is open or shorted.

Lift Up Coil Fault: Check the connections to the Coil’s terminals and make

sure they are tight. If so, check the coil itself to see if it is open or shorted.

Lift Down1 Coil Fault: Check the connections to the Coil’s terminals and make sure

they are tight. If so, check the coil itself to see if it is open or shorted.

Right Turn Coil Fault: Check the connections to the Coil’s terminals and make sure

they are tight. If so, check the coil itself to see if it is open or shorted.

Left Turn Coil Fault: Check the connections to the Coil’s terminals and make sure

they are tight. If so, check the coil itself to see if it is open or shorted.

General Brake Coil Fault: Check the connections to the Coil’s terminals and make

sure they are tight. If so, check the coil itself to see if it is open or shorted.

Low Speed Coil Fault: Check the connections to the Coil’s terminals and make sure

they are tight. If so, check the coil itself to see if it is open or shorted.

Motor Controller Fault： Check the connections to motor and make sure they are

tight. If so, check there are other detail faults.

Motor Controller Current Sensor Fault: Drive or Lift Motor may be overheating. Let

the lift cool down. If that does not help, cycle power to reset the Motor controller. If

the problem persists, check the wiring and if OK, try replacing the Motor Controller.

Motor Controller Hardware Failsafe Fault: Cycle power. If that does not resolve the

issue check for noise sources. If still needed, try replacing the Motor Controller.

3-9

Table 3-2 Trouble shooting method

Trouble shooting Method

Code

Motor Controller Motor Short Fault: Check wiring first then cycle power. If needed

replace controller.

Motor Controller SRO Fault: Look at motor enable delay with the Scissor

Programmer, it may be too short. Make sure other Motor Controller parameters are

properly selected.

Motor Controller Throttle Fault: Check wiring. Make sure the correct throttle type is

selected in the Motor Controller.

Motor Controller Emergency Reverse Fault: Ensure that the Emergency Reverse

Check parameter is off in the Motor Controller.

Motor Controller HPD Fault: Look at motor enable delay with the Scissor

Programmer, it may be too short. Make sure other Motor Controller parameters are

properly selected.

3-10

Table 3-2 Trouble shooting method

Trouble shooting Method

Code

Total Voltage Low Fault II: Check battery voltage and charge if necessary. Check the

battery connections and tight or clean. Check the voltage to the ECU and PCU.

High Neutral Current: The MC is sensing current in the motors when there should not

be. This could occur anytime the MC thinks the brakes are on and the motors are still

turning. This message sometimes comes just before other faults but should be ignored

in those cases.

Steering Input Out of Range: There is an inappropriate voltage at the steering input of

the ZAPI motor controller. The ZAPI may need to be “trained” for the three steering

voltages (on Differential Steered machines). Or the steering voltage from the ECU was

at some point outside of the range that was recorded during the “training” session. Re-

train the ZAPI and/or check for fluctuating voltages due to lose wires, etc.

Motor Controller Main Contactor Fault: Check the connections to the main contactor.

Replace the contactor if necessary. Replace the Motor Controller if necessary.

Motor Controller Over Voltage Fault. Check battery voltage and make sure the battery

charger is not on. Then cycle power to the lift. If that does not resolve the issue, try

replacing the Motor Controller.

Motor Controller Thermal Cutback Fault: Drive or Lift Motor may be overheating. Let

the lift cool down. If that does not help cycle power to reset the Motor controller. If

that doesn’t resolve the issue, replace the Motor Controller.

Motor Controller Motor Fault: Check connections to the motors. Cycle power to the

lift and if that does not resolve the issue, replace the Motor Controller.

Motor Controller Pump Motor Fault: Check connections to the Pump Motor. Cycle

power to the lift and if that does not resolve the issue, replace the Motor Controller.

Motor Controller Left Drive Motor Fault: Check connections to the motors. Cycle

power to the lift and if that does not resolve the issue, replace the Motor Controller.

Motor Controller Right Drive Motor Fault: Check connections to the motors. Cycle

power to the lift and if that does not resolve the issue, replace the Motor Controller.

Pump Motor Short Fault: Check connections to the pump motor. Cycle power to the

lift and if that does not resolve the issue, replace the Motor Controller.

Left Drive Motor Short Fault: Check the Motor connections and make sure they are

tight. Check the Motor for a short.

3-11

Table 3-2 Trouble shooting method

Trouble shooting Method

Code

Over 80% Load Warning: Platform is getting close to its limit of weight. Consider not

adding more load.

Right Drive Motor Short Fault: Check the Motor connections and make sure they are

tight. Check the Motor for a short.

Left Brake Coil Fault: Check the connections to the Coil’s terminals and make sure

they are tight. If so, check the coil itself to see if it is open or shorted.

Right Brake Coil Fault: Check the connections to the Coil’s terminals and make sure

they are tight. If so, check the coil itself to see if it is open or shorted.

Motor Post shorted: Check the connections of the controller and motor. Make sure the

wiring is not shorted.

Brake Release Switch On: Check the wires to brake release switch or look for a stuck

switch.

Brake Release Not Stowed: Check if the platform is below down limit height. Check

the down limit switch and connections.

Brake Release Need Switch On: Check the wires to brake release switch or look for a

stuck switch. Check the wires to the Toggle Switch or look for a stuck Toggle Switch.

Motor Field Open: The field voltage is different from 1/2 Vbatt. Check connections of

the field wires or leakage to the vehicle frame.

Over 90% Load Warning: Platform is getting close to its limit of weight. Consider not

adding more load.

3-12

Table 3-2 Trouble shooting method

Trouble shooting Method

Code

Left Motor Field Short: Check connections of the field wires or leakage to the vehicle

frame.

Right Motor Field Short: Check connections of the field wires or leakage to the vehicle

frame.

Lift Down Coil 2 Fault: Check the connections to the Coil’s terminals and make sure

they are tight. If so, check the coil itself to see if it is open or shorted.

Over 99% Load Warning: Platform has reached its limit of weight. Do not add more

load.

Overloaded Platform Fault: Remove the excess load immediately.

Machine Tilted Beyond Safe Limits Fault: If the machine is tilted, find a way to make

it level. If the machine is level, check the wiring to the tilt sensor and then the sensor

itself.

3-13

3.1.3 ECU pin definition

Figure 3-1 35 pin interface

Table 3-3 ECU 35 pin interface definition

Type

Function

Type

Function

Chassis elevating

Input

Reserve

control switch

Output

Reserve

Power

Valve-driven power

Power

Valve-driven power

Output

Lifting valve control

Output

Forward control

Output

Pump motor enable

Pump motor speed

Left brake condition

Output

Input

control

check

Chassis lowering

Input

Reserve

Input

control switch

PCU communication

Communication

Input

Chassis key switch

Power

GND

Input

Angle sensor

Lowering valve 1

Input

Brake condition

Output

control

Left turn valve

Output

Horn control

control

3-14

Table 3-3 ECU 35 pin interface definition

Type

Function

Type

Function

Output

Buzzer control

Input

Pothole switch

Input

Up limit switch

Communication

PCU communication -

Power

Working power

Input

Reserve

Drive motor speed

Output

Input

Driver fault code

control

Output

Backward control

Output

Right turn valve control

Parallel valve

Output

control/ Drive motor

Output

Brake valve control

enable

Right brake

Input

Tilt switch

condition check

Input

Down limit switch

Figure 3-2 14 pin interface

3-15

Zoomlion Scissor lift ZS4555HD, ZS4045HD, ZS3246HD, ZS2632HD, ZS2032HD, ZS1930HD, ZS1530DC. Service and Maintenance Manual - page 2