To troubleshoot the Sinoboom GTZZ25J when the Towerboom does not go down, follow these steps:

1. Check Limit Switches: Verify if the down limit switch is triggered. The boom may not lower if the system detects it is already at the minimum angle.

2. Inspect Boom Angle: Ensure that the Towerboom (main boom) is not positioned above the set angle value that prevents downward movement.

3. Confirm Enabled Controls: Make sure the footswitch is pressed and controls are active. The system only allows function within 7 seconds of footswitch activation unless a function is continuously used.

4. Verify Control Signals: Check for any faults or disconnections in the platform or ground controller cables.

5. Power Supply: Ensure the battery and external power supply are correctly connected and functioning.

6. Hydraulic System: Inspect hydraulic lines and components for blockages or leaks that may prevent boom movement.

If all checks are normal and the boom still does not lower, further diagnostic or repair by qualified personnel may be required.

This answer is automatically generated

Summary of Contents for Sinoboom GTZZ25J

Page 1 Maintenance Part No.504019110002 Rev: B Manual Nov. 2022 产品说明书 PRODU C T MAN U AL GTZZ25J/AB25J/AB810J 0608E (2132E) G T JZ 0808E (2732E) G T JZ 0808E (2732E) G T JZ G T JZ 0808E (2732E)
Page 3 Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your...
Page 4 : No.128, East Jinzhou Avenue, Ningxiang High-tech Industrial Park, Changsha, Hunan, China Zip Code : 410600 Copyright © Hunan Sinoboom Intelligent Equipment Co., Ltd. All Rights Reserved The final interpretation right of this manual belongs to Hunan Sinoboom Intelligent Equipment Co., Ltd.
Page 5 (See Decals/Nameplates Inspection of the Operation Manual for details.) Trade Identification Model Serial No. Imperial Metric From 0401900410 to present GTZZ25J AB25J AB810J NOTE: • Product model is applied in product nameplate for distinction of products of different main parameters.
Page 6 This Page Intentionally Left Blank...
Page 7 This manual covers the basic parts information of one or more products. Therefore, please use this manual according to your needs. If you find problems in the manual or have suggestions for improve- ment, feel free to share your feedback with Sinoboom, and we will address these issues as soon as possible.
Page 8 This Page Intentionally Left Blank...
Page 9: Table Of Contents
Hydraulic System ..... 3-1 Pins and composite bearing... 4-5 GTZZ25J Maintenance Manual © Nov. 2022...
Page 11 Appendix 3: Major Modification Acid Battery (requires and Repair Record ..... A-7 maintenance) ..... .6-23 GTZZ25J Maintenance Manual © Nov. 2022...
Page 13: Introduction
The owner or administrator of the machine shall also provide the manufacturer’s maintenance information to the person responsible for maintaining the machine. If you have any questions, contact Hunan Sinoboom In- telligent Equipment Co., Ltd.. GTZZ25J Maintenance Manual © Nov. 2022...
Page 15: Safety
In case of any accident involving the machinery of Also, people who have alcohol or drugs in their Hunan Sinoboom Intelligent Equipment Co., Ltd., notify system, or experience excessive fatigue or Hunan Sinoboom Intelligent Equipment Co., Ltd.
Page 16: Electrocution Hazards
Table 1-1 Minimum Safe Distance Voltage Minimum Safe Distance (Phase to Phase, kV) (m/ft) 0-50 3.05 (10) 50-200 4.60 (15) 200-350 6.10 (20) 350 -500 7.62 (25) 500 -750 10.67 (35) 750 -1000 13.725 (45) © Nov. 2022 GTZZ25J Maintenance Manual...
Page 17 • When the machine is driven on uneven ground, gravel or other uneven surfaces, or near holes GTZZ25J Maintenance Manual © Nov. 2022...
Page 18: Work Environment Hazards
1. Retract the telescopic boom; 2. Lower the articulated boom; 3. Lower the main boom. • The drive speed should not exceed 1.1 km/h (0.68 mph) when the platform is raised. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 19 If the machine is to be used in increase the wind load on the any special workplace or by any special work method machine. other than those specified by Hunan Sinoboom Intelligent Equipment Co., Ltd., the manufacturer’s • Do not drive or lift the machine on approval and guidance should be obtained first.
Page 20: Unsafe Operation Hazards
The battery not only provides power, but also serves as a counterweight and is vital to maintaining the stability of the machine. • Do not place or attach any suspended load onto any part of the machine. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 21: Fall Hazards
Maintenance Manual in addition to following more machine as stated in the operation manual and in the stringent industry regulations and workplace rules. maintenance manual in addition to following more stringent industry regulations and workplace rules. GTZZ25J Maintenance Manual © Nov. 2022...
Page 22: Crush Hazards
• Limit the speed of travel according to ground conditions, crowding, gradients, the presence and location of personnel and any © Nov. 2022 GTZZ25J Maintenance Manual...
Page 23: Explosion And Fire Hazards
When entering or exiting the machine, face towards the machine and always keep three- point contact with the machine using two feet and one hand or two hands and one foot. GTZZ25J Maintenance Manual © Nov. 2022...
Page 24: Battery Hazards
Daily check the battery cable for damage, and replace any damaged parts before operating CHEMICAL BURN HAZARD the machine. Avoid battery acid from spilling or contacting with unprotected skin. Seek medical attention immediately if battery acid contacts skin. © Nov. 2022 1-10 GTZZ25J Maintenance Manual...
Page 25: Hydraulic Hazards
Adding terminal protection and anti-corrosion always ensure you read and understand all operation sealants will help reduce corrosion of the battery and maintenance requirements in the Operation terminals and cables. Manual and the Maintenance Manual. GTZZ25J Maintenance Manual 1-11 © Nov. 2022...
Page 26: After Using The Machine
OFF position. 7. Turn the key switch at the ground controls to OFF position and remove the key to avoid unauthorized operation of the machine. 8. Turn off the main power switch. © Nov. 2022 1-12 GTZZ25J Maintenance Manual...
Page 27: Specifications
SPECIFICATIONS PERFORMANCE PARAMETERS Table 2-1 GTZZ25J specifications AB25J (Metric) AB810J (Imperial) Items DIMENSION PARAMETERS Max platform height 24.6 m 80ft 9in Max working height 26.6 m 87ft 3in Max horizontal reach 16.1 m 52ft 10in Max working envelope 16.7 m 54ft 9.5in...
Page 28 Max allowable RH Stored at -20℃ to 50℃ (-4℉ to 122℉) in a well-ventilated environment with Storage environment 90% relative humidity (20℃ [68℉]), and away from rain, sun, corrosive gases, inflammables and explosives. WEIGHT © Nov. 2022 GTZZ25J Maintenance Manual...
Page 29 The loads of persons, accessories, tools and materials are factored into the rated platform capacity. f) The total vibration value of the platform does not exceed 2.5m/s², and the maximum root-mean-square value of the weighted acceleration of the entire machine does not exceed 0.5m/s². GTZZ25J Chart of working envelope 360° 16m 18m GTZZ25J（5°)
Page 30: Engine Specifications
0.74 gal (US) Number of Cylinders Compression 16.7:1 Ratio 96mm (3.78 in) Bore Firing Order 1-2-4-3 103mm (4.06 in) Stroke Output 54kw@2200rpm 2.982L Total 0.66 gal (UK) Torque 270Nm (199 ft-lb)@1800rpm Displacement 0.79 gal (US) © Nov. 2022 GTZZ25J Maintenance Manual...
Page 31: Function Speed
Set the machine to high drive speed mode, and push Platform level up 50～60s the handle to the maximum stroke to drive forward and backward for a distance of 30m twice, respectively. Platform level down 40～50s Jib up 30～38s Jib down 25～32s GTZZ25J Maintenance Manual © Nov. 2022...
Page 32: Weight Of Major Components
Slewing mechanism 367.5 810.2 Turntable cover assembly 162.7 358.7 Turntable cover assembly (with 163.2 359.8 Deutz engine) Main boom telescoping cylinder 255.6 563.5 Main boom luffing cylinder 268.8 592.6 Articulated boom luffing cylinder 359.3 792.1 © Nov. 2022 GTZZ25J Maintenance Manual...
Page 33: Hydraulic System Specifications
High temperature region (＞40℃ [104℉]) L-HM68 Extremely low temperature region Special program to be determined (＜-30℃ [-22℉]) Hydraulic Pump Closed-circuit Variable Pump Displacement 46 cc/r Maximum drive pressure 30MPa (4351.2psi) Throttle-blipping pressure 2MPa (290psi) Open-circuit Variable Pump GTZZ25J Maintenance Manual © Nov. 2022...
Page 34: Hydraulic Hose And Fitting
260 ± 16 Nm (192 ± 12 ft-lb) M42 × 2 240 ± 15 Nm (177 ± 11 ft-lb) M45 × 2 250 ± 16 Nm (184 ± 12 ft-lb) 280 ± 18 Nm(207 ± 13 ft-lb ) M52 × 2 © Nov. 2022 GTZZ25J Maintenance Manual...
Page 35: Hydraulic Fitting Torque
280 ± 20 Nm (207 ± 15 ft-lb) 540 ± 30 Nm (398 ± 22 ft-lb) 420 ± 25 Nm (310 ± 18 ft-lb) M48×2 Hydraulic fittings with British Standard Pipe (BSP) thread) must be torqued to the following specifications. GTZZ25J Maintenance Manual © Nov. 2022...
Page 36 110 ± 8 Nm (81 ± 6 ft-lb) 140 ± 10 Nm (103 ± 7 ft-lb) 1-5/16-12 160 ± 10 Nm (118 ± 7 ft-lb) 210 ± 15 Nm (155 ± 11 ft-lb) © Nov. 2022 2-10 GTZZ25J Maintenance Manual...
Page 37: Hydraulic Hose And Fitting Tight
80 Nm (59 ft-lb) 92 Nm (68 ft-lb) 95 Nm (70 ft-lb) 125 Nm (92 ft-lb) 150 Nm (111 ft-lb) 1.75 100 Nm (74 ft-lb) 130 Nm (96 ft-lb) 155 Nm (114 ft-lb) GTZZ25J Maintenance Manual 2-11 © Nov. 2022...
Page 38 509 Nm (375 ft-lb) 715 Nm (527 ft-lb) 7/8-9 Unless special torque requirements are listed in this manual or other instructions, torque Unified Thread Standard bolts (label: UNF) to the values listed in the table below. © Nov. 2022 2-12 GTZZ25J Maintenance Manual...
Page 39 200 Nm (148 ft-lb) 9/16-18 13/16" 200 Nm (148 ft-lb) 280 Nm (207 ft-lb) 5/8-18 15/16" 350 Nm (258 ft-lb) 495 Nm (365 ft-lb) 3/4-16 1-1/8" 560 Nm (413 ft-lb) 780 Nm (575 ft-lb) 7/8-14 GTZZ25J Maintenance Manual 2-13 © Nov. 2022...
Page 41: System Descriptions
The batteries are charged by the DC generator of the engine. Power- off switches are used to protect the control system. GTZZ25J Maintenance Manual © Nov. 2022...
Page 43: Service And Guidelines
Sinoboom product model. A qualified Sinoboom equipment mechanic is a person Reference the Repair & Inspection Report for items recognized by Sinoboom as one who, by possession of requiring inspection. Reference the Inspection a recognized degree, certificate, training, has Procedures in appropriate areas of this manual to successfully demonstrated the ability and proficiency to perform the inspection and maintenance procedures.
Page 44: Preventive Maintenance
SERVICE AND GUIDELINES For the purpose of receiving the safety-related bulletins, it is important that Hunan Sinoboom Intelligent Equipment Co., Ltd. has updated ownership information for each machine. When performing each annual machine inspection, notify Hunan Sinoboom Intelligent Equipment Co., Ltd. of the current machine ownership information.
Page 45: Storage
Never attempt to move heavy parts without the aid of a this manual. mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided. GTZZ25J Maintenance Manual © Nov. 2022...
Page 46: Cleanliness
• The static and dynamic load tests of the machine suggest a compliance with the relevant standard. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 47: Pressure-Fit Parts
2. Unless specific torque requirements are given • Excessive sloppiness in joints. within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in • Noise originating from the joint during operation. GTZZ25J Maintenance Manual © Nov. 2022...
Page 48: Application Of Insulating Silicone Grease To Electrical Connections
1. Prior to the machine assembling, apply silicone grease around the male pins and female pins inside the connectors to prevent oxidization. An injector may be used for the convenience of operation. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 49: Maintenance Procedures
Tag the machine and do not use it. • Keep all machine inspection records for at least 10 years or until the machine is no longer in use or as required by machine owner/company/custodian. GTZZ25J Maintenance Manual © Nov. 2022...
Page 50: Following Amaintenance Schedule
Every half a year or every 500 repair is completed and the box marked "- A+B+C hours REPAIRED" shall be checked. Select the appropriate inspection procedure based on the Every year or every 1000 hours A+B+C+D inspection type. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 51 REPAIRED/ YES/Machine is NO/Machine Has Problem Machine Has Items in Good Damage or Description Been Repaired Condition Malfunction B-1 Inspect and Replace Hydraulic Oil Tank Return Filter Element B-2 Inspect Rim, Tire and Fasteners GTZZ25J Maintenance Manual © Nov. 2022...
Page 52 B-21 Test Drive Speed B-22 Inspect Emergency Lowering B-23 Inspect Tilt Protection B-24 Test Braking Distance Checklist C Procedures REPAIRED/ YES/Machine is NO/Machine Has Problem Machine Has Items in Good Damage or Description Been Repaired Condition Malfunction © Nov. 2022 GTZZ25J Maintenance Manual...
Page 53: Major Modification And Repair Record
1. A major modification/repair is a modification/repair made to all or part of a machine that affects the 3. Major modifications/repairs to the machine must be stability, strength or performance of the machine. performed by a qualified service technician. GTZZ25J Maintenance Manual © Nov. 2022...
Page 54: Checklist Aprocedures
If the Note: If the manuals need to be replaced, please manual is missing or illegible, it will fail to provide the contact Hunan Sinoboom Intelligent Equipment Co., information necessary for safe machine operation. Ltd..
Page 55: Inspect All Decals
Note: If the decals on the machine need to be replaced, components. Performing daily inspection of the please contact Hunan Sinoboom Intelligent Equipment hydraulic oil level will help you determine if a problem Co., Ltd..
Page 56: Inspect Hydraulic Leakage
-10# and pull out the emergency stop button at the ground controller to the ON position, and then turn Lowest temperature -14℃ or higher -20# on the key switch at the ground controller, the © Nov. 2022 GTZZ25J Maintenance Manual...
Page 57: Inspect Fuel Leakage
• Fuel injection system EXPLOSION AND FIRE HAZARD If fuel leakage is discovered, immediately forbid any other personnel from entering the area or operating the machine, and repair the leakage as soon as possible. GTZZ25J Maintenance Manual © Nov. 2022...
Page 58: Inspect Engine Oil Level
HIGH TEMPERATURE AND PRESSURE HAZARDS Before inspecting the coolant level, allow the coolant to cool down to room temperature, and slowly open the cover to release the pressure. NOTICE Turn off the engine before inspection. © Nov. 2022 5-10 GTZZ25J Maintenance Manual...
Page 59: Inspect Engine Belt
13mm [0.5 in.].) 50% ethylene glycol and -32℃～0℃ 50% water mixed coolant 60% ethylene glycol and -54℃～-32℃ 40% water mixed coolant Figure 5-5 Replace the engine belt immediately if the above conditions occur. GTZZ25J Maintenance Manual 5-11 © Nov. 2022...
Page 60: Inspect Fuel Strainer
1. Open the right turntable cover. 2. Locate the fuel strainer. Figure 5-8 WEICHAI WP3.2 fuel strainer Figure 5-6 Cummins QSF2.8t3TC72 fuel- water separator © Nov. 2022 5-12 GTZZ25J Maintenance Manual...
Page 61: Inspect Cooling Fan
4. Please replace it immediately if any of the above Operation Manual. Before performing the function test, conditions occurs. ensure that the safety rules in the operation manual are fully read and understood. GTZZ25J Maintenance Manual 5-13 © Nov. 2022...
Page 62 5. Enable switch 6. Main boom luffing switch 14. Jib luffing switch 22. Articulated boom luffing switch 7. Articulated boom telescoping 15. Main boom telescoping switch switch 16. Emergency stop button 8. Turntable rotation switch © Nov. 2022 5-14 GTZZ25J Maintenance Manual...
Page 63 8. Turntable info 19. Chassis tilt alarm position) 31. Travel and boom movement 9. Platform info 20. Platform tilt alarm allowed 10. Alarm message 21. Heavy load indicator 11. Fault alarm 22. Overload alarm GTZZ25J Maintenance Manual 5-15 © Nov. 2022...
Page 64 35. Main boom luffing proportional 11. Chassis tilt indicator light 23. Jib boom luffing switch control direction 36. Turntable rotation proportional 12. Overload indicator light 24. Platform leveling switch control direction © Nov. 2022 5-16 GTZZ25J Maintenance Manual...
Page 65: Perform Maintenance After
Before the first use of the new machine, the oscillate cylinder must be exhausted. This procedure must also Figure 5-14 Connector perpendicular to the turntable The connector may be tilted in two directions: backward tilt and forward tilt. Connector tilted backward GTZZ25J Maintenance Manual 5-17 © Nov. 2022...
Page 66 Figure 5-15 Connector tilted backward Figure 5-16 Backward tilt is a common tilt condition for the connector. In case of backward tilt, contact Sinoboom 6. Pull out the manual release valve knob next to the or a service technician approved by Sinoboom hydraulic tank and hold it while lowering the immediately to reposition the machine.
Page 67: Checklist Bprocedures
The connector may be tilted forward in a few cases, and repositioning forward-tilting connector is complicated, which is not described in this manual. In case of forward tilt, contact Sinoboom or a service HIGH PRESSURE HAZARD technician approved by Sinoboom immediately to reposition the machine.
Page 68: Inspect Hydraulic Oil
Shut off the engine before inspection. Replace the hydraulic oil if any of the following conditions exist: • The hydraulic oil is milky white and cloudy. • The hydraulic oil is blackened. © Nov. 2022 5-20 GTZZ25J Maintenance Manual...
Page 69: Water Separator) Element
8. Tighten the plug. 9. Clean up the spilled fuel. 10. Start the engine from the ground controller and inspect the fuel strainer (fuel-water separator) for Figure 5-21 DeutzTD2.9L4 fuel strainer leakage. GTZZ25J Maintenance Manual 5-21 © Nov. 2022...
Page 70: Tank
An unclean or blocked filter could components for leakage. cause the machine to work improperly, and continued operation may result in component damage. The high- pressure filter element should be replaced more often in hostile operating environment. © Nov. 2022 5-22 GTZZ25J Maintenance Manual...
Page 71: Replace Air Filter Element Of
Figure 5-27 Cummins QSF2.8t3TC72 air Regularly inspecting the travel switch is vital to safe filter machine operation. If the travel switch can’t function properly, it will pose dangers to machine operation. Inspecting travel switch GTZZ25J Maintenance Manual 5-23 © Nov. 2022...
Page 72: System
B-11 Inspect Drive Reducer Oil Level Inappropriate gear oil level of drive reducers will reduce the machine performance, and continued use could result in component damage. Figure 5-31 © Nov. 2022 5-24 GTZZ25J Maintenance Manual...
Page 73: Bolts
2. Locate the connecting bolts between the chassis and slewing bearing. 4. Ensure the feeler gauge won’t go through the outside of bolt head to the bolt shank. 5. Rotate the turntable to check all bolts. GTZZ25J Maintenance Manual 5-25 © Nov. 2022...
Page 74: Lubricate Slewing Bearing
6. As indicated by the arrow in Fig 5-31 , page 5-25, insert a 0.04mm feeler gauge between the bolt and washer. 7. Ensure the feeler gauge won’t go through the outside of bolt head to the bolt shank. © Nov. 2022 5-26 GTZZ25J Maintenance Manual...
Page 75: Test Cylinder Drift
7. Drive the machine off the wooden block. 100/3.94 0.39/0.015 8. Perform the same procedure to test the exhausting 125/4.92 0.23/0.009 of oscillate cylinder on the right side. 9. Proceed to test the counterbalance valve locking. 160/6.30 0.14/0.006 GTZZ25J Maintenance Manual 5-27 © Nov. 2022...
Page 76: Inspect Electrical Wiring
If battery acid spills, use water mixed with bicarbonate (baking soda) to neutralize the acid. © Nov. 2022 5-28 GTZZ25J Maintenance Manual...
Page 77: Test Oscillate Outriggers
Ensure that the battery is installed properly and the below: cable is connected tightly. • Connect the battery charger cable to the correct post on the battery (red to positive, black to negative). • Connect the charging plug to 220V socket. GTZZ25J Maintenance Manual 5-29 © Nov. 2022...
Page 78: Inspect Emergency Lowering
3. Turn the key switch on the ground controller to the ON position. 9. With the machine in operating position, place two wooden blocks under the two wheels on the front or back side of the machine, and then drive the © Nov. 2022 5-30 GTZZ25J Maintenance Manual...
Page 79: Test Braking Distance
An unclean or blocked filter may fail the engine and continued use may result in component damage. The filter element should be replaced more often if the machine operates in hostile environment. GTZZ25J Maintenance Manual 5-31 © Nov. 2022...
Page 80: Replace Air Filter Of Hydraulic
5. Shut off the engine. 6. Open the drain valve to drain the engine oil. Figure 5-41 YUCHAI YCF3050 fuel filter 2. Disconnect and plug the oil tube between the fuel tank and fuel filter. © Nov. 2022 5-32 GTZZ25J Maintenance Manual...
Page 81 Figure 5-45 YUCHAI YCF3050 engine oil drain valve Figure 5-43 Cummins QSF2.8t3TC72 engine oil drain valve BURN HAZARD Do not come in contact with the hot engine oil when draining to avoid burns. GTZZ25J Maintenance Manual 5-33 © Nov. 2022...
Page 82: Replace Engine Oil Filter
1. Open the right turntable cover to find and remove the engine oil filter. Figure 5-48 WEICHAI WP3.2 engine oil filter Figure 5-46 DeutzTD2.9L4 engine oil filter Figure 5-49 YUCHAI YCF3050 engine oil filter 2. Collect the drained oil. © Nov. 2022 5-34 GTZZ25J Maintenance Manual...
Page 83: Test Weighing System
Before conducting any override operation, please make sure the surrounding area and the whole machine are in a safe state, try to avoid operation in a dangerous direction and ensure personal safety. GTZZ25J Maintenance Manual 5-35 © Nov. 2022...
Page 84: Replace Hydraulic Oil
6. Remove the fill plug (for the location, reference 12 Inspect Slewing Reducer Oil Level, page 5- 24), add new gear oil to the fill port until the oil level is even with the bottom of the fill plug. © Nov. 2022 5-36 GTZZ25J Maintenance Manual...
Page 85: Replace Hydraulic Tank
10. Clean up the coolant spills in performing the procedure. 11. Start the engine from the ground controller to Figure 5-52 circulate the coolant in the cooling system. 12. Shut off the engine. GTZZ25J Maintenance Manual 5-37 © Nov. 2022...
Page 86: Replace Fuel Hoses
3mm (0.118in.), the wear pad improperly shimmed wear pads or continued use of assembly should be replaced immediately. extremely worn wear pads may lead to component damage and unsafe operating conditions. © Nov. 2022 5-38 GTZZ25J Maintenance Manual...
Page 87 MAINTENANCE PROCEDURES NOTICE The wear pad disassembled from the boom should never be reused. Make sure to replace it with a new wear pad assembly. GTZZ25J Maintenance Manual 5-39 © Nov. 2022...
Page 89: Repair Procedures
3. Disconnect and tag the cable from the bottom of the use any function and will remain enabled 7 seconds pltaform controller. after the last function has been used. While the controls GTZZ25J Maintenance Manual © Nov. 2022...
Page 90: Platform
When installing hoses and fittings, tighten them according to the specified torque. See Hydraulic Hose and Fitting Specifica- tions, page 2-8. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 91: Platform Level Cylinder
Inspect the inner ring of the bearing at jib boom pin for scratch, deformation, wear or other damages, and replace the bearing if necessary. • Inspect the jib lift cylinder connecting pin for wear, scratch, tapering, ovality or other damages, ensure GTZZ25J Maintenance Manual © Nov. 2022...
Page 92: Cable Track Assembly
4. Remove the bolts as indicated by the arrows in the Wear eye protection when tapping above figure. the brass drift with a wooden hammer. 5. Using the lifting device, slowly move the cable track away from the boom. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 93: Telescopic Boom Assembly
6. Using a brass drift and wooden hammer, tap the pivot pin #1 out. 1. Remove the retaining bolts, gaskets and stopper at the end of fixed shaft #1 of main boom telescopic cylinder and remove the fixed shaft #1. GTZZ25J Maintenance Manual © Nov. 2022...
Page 94: Articulated Boom Assembly
12. Remove the bolt, gasket and nut at the pivot pin #5 connecting the lower articulated boom luffing cylinder with the turntable, and at the pivot pin #7 connecting the articulated boom with the turntable. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 95: Chassis And Turntable Components
The wheel nuts must be installed and maintained at the Replacing tires and rims proper torque to prevent loose Hunan Sinoboom Intelligent Equipment Co., Ltd. wheels, broken studs and recommends the replacement tires be of the same size, possible dangerous separation of ply rating and brand as the original tires.
Page 96: Reducer And Drive Motor
Reducer and Drive Motor motor mounting grooves are aligned with the reducer mounting bolts. 7. Apply the threadlocker Loctite 272 to the bolts and torque the bolts after pre-tightening. 8. Attach the hydraulic hoses. Figure 6-10 © Nov. 2022 GTZZ25J Maintenance Manual...
Page 97: Turntable Slewing Mechanism
Loctite 272 to the bolt, and intall be sure the gear backlash falls within 0.15— the bolts one by one. 0.25mm (0.006–0.01in). 4. Tighten the bolts in the sequence as shown in the figure below. GTZZ25J Maintenance Manual © Nov. 2022...
Page 98: Engine
2. Tag and disconnect the battery cables. manual introduces part of engine maintenance items, 3. With assitance of a lifting device, remove the please see the following sections for details： battery. • A-6 Inspect Fuel Level © Nov. 2022 6-10 GTZZ25J Maintenance Manual...
Page 99: Hydraulic Generator
Debugging must be performed by interfere with other parts of the the after-sales personnel of machine during the whole Sinoboom. Do not debug the process. machine without permission. 3. After the hydraulic generator safely enters the turntable structure, adjust the direction again to align the mounting hole of hydraulic generator with that of the mounting position.
Page 100: Hydraulic System
1. Oscillate counterbalance valve 6. Articulated boom valve block 11. Power unit 2. Drive control valve 7. Manual control valve 12. Center rotary coupler 3. Brake/2–speed oscillate control 8. Stroke control valve 13. High-pressure filter valve © Nov. 2022 6-12 GTZZ25J Maintenance Manual...
Page 101: Boom Function Manifold
40–45Nm (30–33ft-lb) Check valve Keep fluid flowing in one way Compensator 27.1Nm (20ft-lb) Release power unit pressure valve 27.1Nm (20ft-lb) Flow valve Release LS feedback pressure 40.6Nm (30ft-lb) Solenoid valve Common proportional valve GTZZ25J Maintenance Manual 6-13 © Nov. 2022...
Page 102 Lock the oil of leveling cylinder 40–45Nm (30–33ft-lb) 19–1 Relief valve Restrict the leveling pressure at 180bar 40–45Nm (30–33ft-lb) 19–2 Relief valve Restrict the leveling pressure at 180bar Damper (φ0.6) Eliminate pressure impact © Nov. 2022 6-14 GTZZ25J Maintenance Manual...
Page 103: Hydraulic Symbols
28.5682 32.0000 17.4787 46.7096 Check valve 28.5682 46.7096 Emergency power 28.5682 16.0000 34.4087 46.7096 34.4087 32.0000 Hydraulic motor 棕兰 32.0000 黑 16.0000 28.5682 16.0000 Overflow valve 17.4787 46.7096 34.4087 32.0000 28.5682 16.0000 GTZZ25J Maintenance Manual 6-15 © Nov. 2022...
Page 104: Hydraulic Schematic
REPAIR PROCEDURES Hydraulic Schematic Figure 6-17 Hydraulic schematic (PN.104008050018)-(2WD) © Nov. 2022 6-16 GTZZ25J Maintenance Manual...
Page 105 REPAIR PROCEDURES Figure 6-18 Hydraulic schematic (PN.104008050019)-(4WD) GTZZ25J Maintenance Manual 6-17 © Nov. 2022...
Page 106: Electrical System
7-second limit alarm second limit alarm Check whether the obstacle detection switch Obstacle detection Obstacle detection alarm functions properly alarm Drive controller Drive controller error alarm Check the associated error of drive controller error alarm © Nov. 2022 6-18 GTZZ25J Maintenance Manual...
Page 107 Check the wiring of platform swing right solenoid solenoid valve fault valve fault valve Platform leveling up Platform leveling up solenoid Check the wiring of platform leveling up solenoid solenoid valve fault valve fault valve GTZZ25J Maintenance Manual 6-19 © Nov. 2022...
Page 108 Check whether the main boom relative angle angle sensor sensor comparison error sensor is correctly installed comparison error Main boom relative Main boom relative angle Check the wiring of main boom relative angle angle sensor fault sensor fault sensor © Nov. 2022 6-20 GTZZ25J Maintenance Manual...
Page 109 (highest-level severity) Electrical circuit #1 of coolant level High-voltage short circuit sensor Electrical circuit #1 of coolant level Low-voltage short circuit sensor Data valid but lower than normal Coolant level (medium-level severity) GTZZ25J Maintenance Manual 6-21 © Nov. 2022...
Page 110 SAE J1939 accelerator pedal sensor Update error 3326 system Update error 3613 Coolant level sensor Engine coolant level sensor 3614 Network data error Smart control device or component Engine control calibration module 3697 damaged © Nov. 2022 6-22 GTZZ25J Maintenance Manual...
Page 111: Use And Maintenance Of Lead-Acid Battery
Be sure to charge the battery in a well-ventilated place. • Do not add acid into the battery. Figure 6-20 GTZZ25J Maintenance Manual 6-23 © Nov. 2022...
Page 112 The following figure shows the battery charging and wipe them dry with a cloth. Apply a thin layer of process. petroleum jelly to the terminals or use terminal protector. • Keep the area around the battery clean and dry. © Nov. 2022 6-24 GTZZ25J Maintenance Manual...
Page 113 The self-discharge process will battery in cold temperatures or during cold weather, accelerate in warmer temperatures. If storing the fully charge the battery. This point is very battery in hot temperatures or during hot weathe important. GTZZ25J Maintenance Manual 6-25 © Nov. 2022...
Page 114: Use And Care Of Lead-Acid Battery
24 hours. and negative terminals, etc. 2. Measure the voltage of each individual battery. • Check and confirm the fault description and analyze the cause. © Nov. 2022 6-26 GTZZ25J Maintenance Manual...
Page 115: Electrical Symbols
Toggle switch θ Electrical Symbols Table 6-11 Symbol Description Level switch Buzzer Oil temperature θ switch θ Valve θ θ Delay relay Two lines connected Power-off switch θ GTZZ25J Maintenance Manual 6-27 © Nov. 2022 28.5682 46.7096...
Page 116 Symbol Description Relay Horn Warning lamp Key switch Valve Preheating wire Two lines non- connected 兰棕 Proximity switch/ 黑 Pressure sensor 28.5682 46.7096 28.5682 兰棕黑 Fuel level sensor 46.8000 28.5682 © Nov. 2022 6-28 GTZZ25J Maintenance Manual...
Page 118: Electrical Schematic Diagram
XJ1-13/14 XJ1-3/4 PWM/OUT_45 Y30a XJ1-17/18 XJ1-1/2 XJ1-15/16 OUT_24 XJ1-19/20 IN_48 OUT_23 DT19 XJ1-11/12 2/19 IN_49 OUT_26 XJ1-9/10 XJ1-7/8 IN_50 OUT_25 XJ1-5/6 Figure 6-23 Electrical schematic diagram of turntable (PN.104019060051)-Rexroth & Cummins EU T3 © Nov. 2022 6-30 GTZZ25J Maintenance Manual...
Page 119 XJ1-13/14 XJ1-3/4 PWM/OUT_45 XJ1-17/18 XJ1-1/2 Y30a OUT_24 XJ1-15/16 XJ1-19/20 IN_48 OUT_23 DT19 2/19 XJ1-11/12 IN_49 OUT_26 XJ1-9/10 XJ1-7/8 IN_50 OUT_25 XJ1-5/6 Figure 6-24 Electrical schematic diagram of turntable (PN.104019060036)-Rexroth & Deutz EU T4 GTZZ25J Maintenance Manual 6-31 © Nov. 2022...
Page 120 SQ107 V(C)_IN_59 PWM_OUT_38 V(C)_IN_60 PWM_OUT_39 V(C)_IN_56 PWM_OUT_40 OUT_24 IN_47 H103 L105 L106 IN_48 OUT_23 H104 IN_49 OUT_26 H105 IN_50 OUT_25 H106 H100 HG100 S116 SB100 Figure 6-25 Electrical schematic diagram of platform (PN.104019060050)-Rexroth © Nov. 2022 6-32 GTZZ25J Maintenance Manual...
Page 121 BAT1 DO_06 S100 Y10b PWM_4 Y25a DO_26 DO_27 S102-I S101 DO_08 Y25b D0_24 Y26b D0_25 Y26a D0_02 D0_03 供电电源供电电源供电电源供电电源 Figure 6-26 Electrical schematic diagram of turntable (PN.104019060006)-Rising & Cummins EU GTZZ25J Maintenance Manual 6-33 © Nov. 2022...
Page 122 TX232A TX232A DO_08 DO_06 AI_V_7 DO_12 DI_17 DO_10 S202 DI_14 PWM_1 PWM_3 DI_16 S203 DI_15 H201 S216 － E201 － E202 SB200 Figure 6-27 Electrical schematic diagram of platform (PN.104019060006)-Rising & Cummins EU © Nov. 2022 6-34 GTZZ25J Maintenance Manual...
Page 123: Control System
Therefore, personnel who qualified personnel who have been professionally have not been professionally trained and authorized trained and authorized by Sinoboom, otherwise the by Sinoboom cannot disassemble their housings, consequences will be at your own risk. otherwise moisture and dust will enter the internal mechanism and normal operation will not be guaranteed.
Page 124 Proportional Valve EAT Info Engine Info Engine Fault Diagnoses Turntable Info Turntable Panel Info Platform Panel Info-Input Platform Panel Info-Output Platform Info Alarm Info Alarm Info Fault Info Figure 7-1 Display interface navigation diagram © Nov. 2022 GTZZ25J Maintenance Manual...
Page 125: Main Interface After Booting
Turn the ground/platform select switch on the ground controller to the ground control position, pull out the Figure 7-2 Main interface after booting DESCRIPTION OF ICON FUNCTION Table 7-1 Description Description Icon Icon Configuration Left/Right arrow key Increase key Turntable information GTZZ25J Maintenance Manual © Nov. 2022...
Page 126: Language Setting
/Press to directly return to the previous menu Up/Down arrow key LANGUAGE SETTING Figure 7-3 CONFIGURATION interface 2. Select Language through , and press 1. Press on the main interface to enter to enter LANGUAGE interface. CONFIGURATION interface. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 127: Test-Run Information
3s to complete the calibration (the icon before the selected option is switched from , indicating calibration succeeded, and the corresponding actual value will be changed). GTZZ25J Maintenance Manual © Nov. 2022...
Page 128: Weight Calibration
7. If re-calibration is required, press to return to the TEST-RUN INFO interface, then re-enter the WEIGHT CALIBRATION interface, and repeat the previous step. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 129: Advanced Setting
CONTROL SYSTEM ADVANCED SETTING Personnel who have not been professionally trained and authorized by Sinoboom are not allowed to modify the advanced setting (including sensor configuration, turntable enable, standardization, proportional configuration, parameter restore/save and reserved setting); otherwise they will be responsible for the consequences.
Page 130: Standardization
KCS standard ( ) will be displayed in the upper right corner of the main interface. • In D/B mode, driving function and boom actions can be performed at the same time. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 131: Proportional Configuration
• Minimum current: refers to the starting current of actions, which affects the starting and inching performance of actions. The minimum current should be set to a value that allow the action to just GTZZ25J Maintenance Manual © Nov. 2022...
Page 132 TB Lift Up Inspect (Up) Condition of fully raising: up limit switch is triggered or the articulated boom is positioned at an angle bigger than the set value. © Nov. 2022 7-10 GTZZ25J Maintenance Manual...
Page 133: Parameter Restore/Save
Notes: All parameters can be adjusted within 0~100. Parameter restore/save 1. On the ADVANCED SETTING interface, select Parameter Restore/Save through , and press to enter PARAMETER RESTORE/SAVE interface. Figure 7-19 PARAMETER RESTORE/SAVE interface GTZZ25J Maintenance Manual 7-11 © Nov. 2022...
Page 134: System Information
• The configuration of sensors is subject to the actual machine configuration. Figure 7-20 SYSTEM INFO interface Figure 7-22 SENSOR INFO 1 © Nov. 2022 7-12 GTZZ25J Maintenance Manual...
Page 135: Digital Input Information
Figure 7-26 OUTPUT INFO 1 interface the machine meets the requirements. • The configuration of switches is subject to the actual machine configuration. GTZZ25J Maintenance Manual 7-13 © Nov. 2022...
Page 136: Proportional Information
EAT INFO interface, and the status indicator light will be on. At this time, it is necessary to contact the engine manufacturer for EAT. Figure 7-29 ENGINE INFO interface © Nov. 2022 7-14 GTZZ25J Maintenance Manual...
Page 137 Standstill regeneration is requested indicator light Standstill regeneration is requested, but Fast since the driver has ignored the request for a flashi- long time, the standstill regeneration can only be completed through the DEUTZ diagnostic tool. GTZZ25J Maintenance Manual 7-15 © Nov. 2022...
Page 138 Regeneration function is being executed NCD is not working NCD indicator light (- Solid Yanmar only) NCD is working Regeneration prohibiting Conditions prohibiting active regeneration do indicator light (Yuchai only) not exist © Nov. 2022 7-16 GTZZ25J Maintenance Manual...
Page 139: Turntable Panel Information
• The configuration of switches on the turntable panel is subject to the actual machine configuration. GTZZ25J Maintenance Manual 7-17 © Nov. 2022...
Page 140: Alarm Information
Figure 7-40 FAULT INFO interface 1 Figure 7-38 JOYSTICK INFO interface 3. Press successively to return to the main interface, and power off the machine as required. © Nov. 2022 7-18 GTZZ25J Maintenance Manual...
Page 141 BMS Fault Code Description for Lithium Battery section in the Maintenance Manual (if the machine is equipped with any lithium battery). 5. Press successively to return to the main interface, and power off the machine as required. GTZZ25J Maintenance Manual 7-19 © Nov. 2022...
Page 143: Appendix 1: Prepare The Work Record Before Delivery
2. Use the table to record the results. After each section is complete, mark the appropriate box. 3. Record the inspection results. If any inspection results are "NO", the machine must be stopped, and re-in- spected after repair is completed and the box marked "inspection" must be checked. GTZZ25J Maintenance Manual © Nov. 2022...
Page 145: Appendix 2: Repair & Inspection Report
A-14 Functional Tests A-15 Perform Maintenance after 30 Days A-16 Perform Oscillate Cylinder Exhausting Checklist B Procedures REPAIRED/ YES/Machine is NO/Machine Has Problem Machine Has Items in Good Damage or Description Been Repaired Condition Malfunction GTZZ25J Maintenance Manual © Nov. 2022...
Page 146 B-16 Test Cylinder Drift B-17 Inspect Counterbalance Valve Locking B-18 Inspect Electrical Wiring B-19 Inspect the Battery B-20 Test Oscillate Outriggers B-21 Test Drive Speed B-22 Inspect Emergency Lowering B-23 Inspect Tilt Protection B-24 Test Braking Distance © Nov. 2022 GTZZ25J Maintenance Manual...
Page 147 D-3 Replace Hydraulic Oil D-4 Replace Hydraulic Tank Suction Filter D-5 Replace Coolant and Coolant Hoses (water-cooled engine) D-6 Replace Fuel Hoses D-7 Inspect Boom Wear Pads User Inspector Signature Inspection Date Inspector Title GTZZ25J Maintenance Manual © Nov. 2022...
Page 148 4. Record the inspection results. If any inspection item is marked as “NO”, the machine must be stopped and re- inspected after repair is completed and the box marked "REPAIRED” shall be checked. Select the appropriate inspection procedure based on the inspection type. © Nov. 2022 GTZZ25J Maintenance Manual...
Page 149: Appendix 3: Major Modification And Repair Record
Modification/Repair” in the form will be “Good” and the machine can be used. If either inspection result is “NO”, the machine must be re-inspected after the repair is completed until the machine is in “Good” condition before continuing to use the machine. GTZZ25J Maintenance Manual © Nov. 2022...
Page 150 Solution s Alw ays For B et t er A ccess Solution s Always for Better Access Solutions AS/N ZS Hunan Sinoboom Intelligent Equipment Co., Ltd. 长沙市宁乡高新技术产业园区金洲大道东 128 号 No.128, East Jinzhou Avenue, Ningxiang High-tech Industrial Park, Changsha, Hunan, China 市宁乡高新技术产业园区金洲大道东...

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