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Sinoboom GTZZ15J Maintenance Manual

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Part No.504021110002
Rev: B
Nov. 2022
Maintenance
Manual
产品说明书
PRODU
C T MAN U AL
GTZZ15J/AB15J/AB480J
0608E (2132E)
G T JZ
0808E (2732E)
G T JZ
0808E (2732E)
G T JZ
G T JZ
0808E (2732E)

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  • Page 1 Maintenance Part No.504021110002 Rev: B Manual Nov. 2022 产品说明书 PRODU C T MAN U AL GTZZ15J/AB15J/AB480J 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/Nameplate Inspection of the Operation Manual for details) Trade Identification Model Serial No. Imperial Metric From 0402100841 to present GTZZ15J AB15J AB480J 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 GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 10 Oil........5-34 © Nov. 2022 GTZZ15J Maintenance Manual...
  • Page 11 (maintenance-free) ....6-39 Electrical Symbols ....6-40 GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 12 © Nov. 2022 GTZZ15J Maintenance Manual...

  • 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.. GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 14 This Page Intentionally Left Blank © Nov. 2022 GTZZ15J Maintenance Manual...

  • 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 GTZZ15J Maintenance Manual...
  • Page 17 When the machine is driven on • Do not use the platform or boom uneven ground with gravel or assembly to push other machines other uneven surfaces, or near or objects. holes and steep slopes, maintain GTZZ15J 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 GTZZ15J 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 GTZZ15J 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. GTZZ15J 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 GTZZ15J Maintenance Manual...

  • Page 23: Explosion And Fire Hazards

    NOTICE To avoid machine damage, follow all operation and Always follow all operation and maintenance maintenance requirements in the Operation Manual requirements in the Operation Manual and the and the Maintenance Manual. Maintenance Manual. GTZZ15J Maintenance Manual © Nov. 2022...

  • Page 24: Battery Hazards

    Keep any device that may cause sparks or flames (including cigarettes/smoking materials) away from the battery to prevent explosion. • Do not touch the battery terminals or cable clips with tools that may cause sparks. © Nov. 2022 1-10 GTZZ15J Maintenance Manual...
  • Page 25 • Never store the battery in water or humid atmosphere. • Daily check the battery cable for damage, and replace any damaged parts before operating the machine. GTZZ15J Maintenance Manual 1-11 © Nov. 2022...

  • Page 26: Hydraulic Hazards

    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 GTZZ15J Maintenance Manual...
  • Page 27 SAFETY NOTICE After using the machine, the main power switch must be disconnected. GTZZ15J Maintenance Manual 1-13 © Nov. 2022...
  • Page 28 SAFETY This Page Intentionally Left Blank © Nov. 2022 1-14 GTZZ15J Maintenance Manual...

  • Page 29: Specifications

    SPECIFICATIONS PERFORMANCE PARAMETERS Table 2-1 GTZZ15J specifications AB15J (Metric) AB480J (Imperial) Items DIMENSION PARAMETERS Max platform height 14.7m 48ft 3in Max working height 16.7 m 54ft 9in Max horizontal reach 8.5 m 27ft 11in Max horizontal working envelope 9.1 m...
  • Page 30 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 GTZZ15J Maintenance Manual...
  • Page 31 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. GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 32 SPECIFICATIONS GTZZ15J Chart of working envelope 355° GTZZ15J（5°） © Nov. 2022 GTZZ15J Maintenance Manual...

  • Page 33: Engine Specifications

    0.58 gal (US) Ratio Compression 19.1：1 Firing Order 1-3-4-2 Ratio Output 35.3kW@3000rpm Firing Order 1-3-4-2 3210rpm Low RPM Output 35.5kW@3000rpm High RPM 1000rpm 3150rpm Low RPM Generator 12V-55A High RPM 800rpm capacity Generator 12V-55A capacity GTZZ15J Maintenance Manual © Nov. 2022...

  • Page 34: Function Speed

    Test requirements: Table 2-7 Component Metric (kg) Imperial (lb) Chassis assembly (without 2162 4766 oscillating configuration) Chassis assembly (with oscillating 2208 4868 configuration) Turntable assembly 3056 6737 © Nov. 2022 GTZZ15J Maintenance Manual...
  • Page 35 Drive reducer 110.2 Drive motor 15.4 Yanmar engine 4TNV88C-DFLT 226.6 499.6 Yanmar engine 4TNV88-BDFLTC 418.9 Deutz engine D2011L03I 243.7 537.3 Yanmar engine 4TNV88-ZCDCSI 403.4 Note: The weight of components may vary with different configurations selected. GTZZ15J Maintenance Manual © Nov. 2022...

  • Page 36: Hydraulic System Specifications

    Return Filter Return filter bypass pressure 0.02 MPa (2.9psi) High-pressure Filter High-pressure filter bypass pressure 0.2 MPa (2.9psi) HYDRAULIC HOSE AND FITTING SPECIFICATIONS HYDRAULIC HOSE TORQUE Hydraulic hoses must be torqued to the following specifications. © Nov. 2022 GTZZ15J Maintenance Manual...

  • Page 37: Hydraulic Fitting Torque

    210 ± 13 Nm (155 ± 10 ft-lb) M42×2 280 ± 20 Nm (207 ± 15 ft-lb) 540 ± 30 Nm (398 ± 22 ft-lb) 260 ± 15 Nm (192 ± 11 ft-lb) M48×2 GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 38 G3/4A 120 ± 8 Nm (89 ± 6 ft-lb) 185 ± 12 Nm (136 ± 9 ft-lb) 180 ± 10 Nm (133 ± 7 ft-lb) 320 ± 20 Nm (236 ± 15 ft-lb) © Nov. 2022 2-10 GTZZ15J Maintenance Manual...

  • Page 39: Hydraulic Hose And Fitting Tight

    The seal cannot be confirm there are no leaks. reused if the fitting or hose end has been tightened beyond specifications. GTZZ15J Maintenance Manual 2-11 © Nov. 2022...

  • Page 40: Fastener Torque Specifications

    2000 Nm (1475 ft-lb) 2400 Nm (1770 ft-lb) Unless special torque requirements are listed in this manual or other instructions, torque Unified Thread Standard bolts (label: UNC) to the values listed in the table below. © Nov. 2022 2-12 GTZZ15J Maintenance Manual...
  • Page 41 200 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 GTZZ15J Maintenance Manual 2-13 © Nov. 2022...
  • Page 42 SPECIFICATIONS This Page Intentionally Left Blank © Nov. 2022 2-14 GTZZ15J Maintenance Manual...

  • Page 43: System Descriptions

    The batteries are charged by the DC generator of the engine. Power- off switches are used to protect the control system. GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 44 SYSTEM DESCRIPTIONS This Page Intentionally Left Blank © Nov. 2022 GTZZ15J Maintenance Manual...

  • Page 45: Service And Guidelines

    Referen to the Inspection A qualified Sinoboom equipment mechanic is a person Procedures in appropriate areas of this manual to recognized by Sinoboom as one who, by possession of perform the inspection and maintenance procedures. a recognized degree, certificate and training, has...

  • Page 46: Preventive Maintenance

    Intelligent Equipment Co., Ltd. of the current machine ownership information. PREVENTIVE MAINTENANCE The preventive maintenance must be performed by a qualified Sinoboom equipment mechanic. Reference the Repair & Inspection Report and Maintenance Schedule in this manual for the inspection items and intervals. Reference the Inspection Procedures in appropriate areas of this manual to perform the inspection and maintenance procedures.

  • Page 47: Storage

    Never attempt to move heavy parts without the aid of a 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. GTZZ15J Maintenance Manual © Nov. 2022...

  • Page 48: Cleanliness

    • The static and dynamic load tests of the machine suggest a compliance with the relevant standard. © Nov. 2022 GTZZ15J Maintenance Manual...

  • Page 49: 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. GTZZ15J Maintenance Manual © Nov. 2022...

  • Page 50: 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 GTZZ15J Maintenance Manual...

  • Page 51: Maintenance

    & counterbalance valve on the cylinder. inspection report. • Immediately remove a damaged or malfunctioning machine from service, mark and stop using it. GTZZ15J Maintenance Manual © Nov. 2022...

  • Page 52: Conducting A Pre-Delivery Inspection

    Every half a year or every 500 involved. Use the table to help you adhere to a routine A+B+C hours maintenance schedule. Every year or every 1000 hours A+B+C+D © Nov. 2022 GTZZ15J Maintenance Manual...

  • Page 53: Completing A Repair & Inspection

    A-9 Inspect Coolant Level (water-cooled engine) A-10 Inspect Engine Belt A-11 Inspect Fuel Strainer (fuel-water separator) A-12 Inspect Cooling Fan A-13 Inspect Engine Intake System A-14 Functional Tests A-15 Perform Maintenance after 30 Days GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 54 B-12 Inspect worm gear end B-13 Inspect Slewing Bearing Bolts B-14 Lubricate Slewing Bearing B-15 Inspect Platform Rotate Cylinder Fasteners B-16 Test Cylinder Drift B-17 Inspect Oscillate Cylinder Exhausting and Counterbalance Valve Locking B-18 Inspect Electrical Wiring © Nov. 2022 GTZZ15J Maintenance Manual...
  • Page 55 Gear Oil D-2 Replace Hydraulic Oil D-3 Inspect Boom Wear Pads D-4 Replace Hydraulic Tank Suction Filter D-5 Replace Coolant and Coolant Hoses (water-cooled engine) D-6 Replace Fuel Hoses User Inspector Signature Inspection Date GTZZ15J Maintenance Manual © Nov. 2022...

  • Page 56: Major Modification And Repair Record

    “Good” condition before company. continuing to use the machine. Table 5-4 Major Modification and Repair Record Model Serial No. Machine Repair- Repairman’s Status Problem Description Modification/Repair Item Date Company and Signature Position ter Change © Nov. 2022 GTZZ15J Maintenance Manual...

  • Page 57: Checklist Aprocedures

    • Platform (including rails, floor plate, safety lock, Note: If the manuals need to be replaced, please brackets and entry door) contact Hunan Sinoboom Intelligent Equipment Co., Ltd.. • Structure and welding cracks • Nuts, bolts and other fasteners A-2 Inspect All Decals •...

  • Page 58: Inspect Hydraulic Leakage

    -25°C to 25°C (-13°F to 77° L-HV32 ground control display will show the diesel fuel percentage. High temperature region L-HM68 greater than 40°C (104°F) Extremely low temperature Special programmes region need to be identified. less than -30°C (-22°F) © Nov. 2022 GTZZ15J Maintenance Manual...

  • Page 59: Inspect Fuel Leakage

    A-7 Inspect Fuel Leakage Lowest temperature –29℃ or higher -35# Inspecting fuel leakage is vital to safe and normal Lowest temperature -44℃ or higher -50# machine operation. If a fuel leak is not discovered and GTZZ15J Maintenance Manual © Nov. 2022...

  • Page 60: Inspect Engine Oil Level

    1. Turn the ground/platform select switch to ground control position. 2. Pull out the emergency stop button at ground controller to ON position. © Nov. 2022 5-10 GTZZ15J Maintenance Manual...

  • Page 61: Inspect Coolant Level

    3. The coolant level should be at the fill inlet of the • Wear or misalignment coolant box. • Peeling-off 4. Add coolant as needed. Do not overfill the tank. It is • Glazing or hardening recommended to choose the -18℃ ready-mix GTZZ15J Maintenance Manual 5-11 © Nov. 2022...

  • Page 62: Inspect Fuel Strainer

    • Ensure that a conforming fire extinguisher is readily accessible when performing this inspection procedure. 1. Open the right turntable cover. 2. Locate the fuel strainer. © Nov. 2022 5-12 GTZZ15J Maintenance Manual...

  • Page 63: Inspect Cooling Fan

    Pre-operation Function Test section in Operation Manual. Before performing the function test, 1. Open the cover on the left side of engine. ensure that the safety rules in the operation manual are fully read and understood. GTZZ15J Maintenance Manual 5-13 © Nov. 2022...
  • Page 64 21. OFF position 5. Enable switch 6. Main boom luffing switch 14. Jib boom up/down switch 7. Articulated boom luffing switch 15. Main boom telescoping switch 16. Emergency stop button 8. Turntable rotation switch © Nov. 2022 5-14 GTZZ15J Maintenance Manual...
  • Page 65 9. Platform info 33. Overload limit 10. Alarm message 34. Drive limit (operating position) 22. Overload alarm 35. Drive and boom functions 11. Fault alarm 23. Not used allowed 12. Glow plug 24. Not used GTZZ15J Maintenance Manual 5-15 © Nov. 2022...
  • Page 66 35. Main boom luffing proportional 11. Chassis tilt indicator light 23. Jib boom up/down switch control direction 36. Turntable rotation proportion 12. Overload indicator light 24. Platform leveling switch control direction © Nov. 2022 5-16 GTZZ15J Maintenance Manual...

  • Page 67: Perform Maintenance After

    Replace the return filter more frequently 4. Loosen the filter end cap and remove the filter in harsh environments. element. 5. Apply a thin coat of oil film over the new gasket of return filter. GTZZ15J Maintenance Manual 5-17 © Nov. 2022...

  • Page 68: Fasteners

    A dirty or blocked strainer may cause the machine to work improperly, and © Nov. 2022 5-18 GTZZ15J Maintenance Manual...
  • Page 69 1. Open the right side cover of turntable. 2. Locate the fuel strainer (fuel-water separator). Figure 5-17 Yanmar 4TNV88C-DFLT fuel- water separator Figure 5-15 Deutz D2011L03I fuel strainer Figure 5-18 Yanmar 4TNV88-ZCDCSI fuel- water separator GTZZ15J Maintenance Manual 5-19 © Nov. 2022...

  • Page 70: Tank

    Shut off the engine before inspection. 1. Remove the air filter of hydraulic tank. 1. Open the right turntable cover, and locate the high- pressure filter. Figure 5-20 High-pressure filter 2. Place a suitable vessel under the filter. © Nov. 2022 5-20 GTZZ15J Maintenance Manual...

  • Page 71: Replace Air Filter Element Of

    1. Open the right side cover of turntable. 2. Locate the engine air filter. Figure 5-23 Yanmar 4TNV88C-DFLT air filter Figure 5-21 Deutz D2011L03I air filter GTZZ15J Maintenance Manual 5-21 © Nov. 2022...

  • Page 72: Inspect Angle Sensor And Travel Switch

    6. The main boom can be fully retracted. 6. Install the bolts back. 7. Clean up the gear oil spills during the inpection. 8. Perform this inspection procedure to all drive reducers of the machine. © Nov. 2022 5-22 GTZZ15J Maintenance Manual...

  • Page 73: Bolts

    After the bolts are replaced and torqued, re-inspect the bolts for tightness. 4. Replace end plate #1, and tighten the bolts to 122 5. Recheck the end gap #δ to make sure it’s within the specified range. GTZZ15J Maintenance Manual 5-23 © Nov. 2022...
  • Page 74 4. Ensure the feeler gauge won’t go through the outside of bolt head to the bolt shank. 5. Rotate the turntable to inspect all the bolts. Inspecting the connecting bolts between turntable and slewing bearing © Nov. 2022 5-24 GTZZ15J Maintenance Manual...

  • Page 75: Lubricate Slewing Bearing

    7. Ensure the feeler gauge won’t go through the outside of bolt head to the bolt shank. B-14 Lubricate Slewing Bearing Regularly remotely lubricating the slewing bearing is vital to proper machine operation. The lubricating GTZZ15J Maintenance Manual 5-25 © Nov. 2022...

  • Page 76: 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 © Nov. 2022 5-26 GTZZ15J Maintenance Manual...

  • Page 77: Inspect Electrical Wiring

    If battery acid spills, use water mixed with bicarbonate (baking soda) to neutralize the acid. GTZZ15J Maintenance Manual 5-27 © Nov. 2022...

  • Page 78: Test Oscillate Outriggers

    Ensure that the battery is installed properly and the 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. © Nov. 2022 5-28 GTZZ15J Maintenance Manual...

  • Page 79: Inspect Emergency Lowering

    3. Turn the key switch on the ground controller to the ON position. 9. Place two wooden blocks under the two wheels on the front or rear of the machine. The wooden block should be 750×250×177mm (2.46×0.82×0.58ft) in GTZZ15J Maintenance Manual 5-29 © Nov. 2022...

  • Page 80: Test Braking Distance

    A dirty 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 is used in hostile environment. © Nov. 2022 5-30 GTZZ15J Maintenance Manual...

  • Page 81: Replace Air Filter Of Hydraulic

    5. Add clean fuel to the new filter element, and lubricate the seal ring with clean fuel and install it to the filter head. 6. Clean up the spilled fuel in performing the procedure. GTZZ15J Maintenance Manual 5-31 © Nov. 2022...

  • Page 82: Replace Engine Oil Filter

    C-4 Replace Engine Oil Filter NOTICE Replace the engine oil filter each time the engine oil is replaced. 1. Open the right turntable cover to locate the engine oil filter, and remove the filter. © Nov. 2022 5-32 GTZZ15J Maintenance Manual...

  • Page 83: Inspect Weighing System

    C-5 Inspect Weighing System engine oil filter Before the test, fully raise and lower the boom and retract and extend the boom at least twice to ensure the pulley and track are adequately lubricated. GTZZ15J Maintenance Manual 5-33 © Nov. 2022...

  • Page 84: Checklist Dprocedures

    1. Drive the machine to rotate the reducer to the position with one bolt at the bottom, as shown in the figure below. © Nov. 2022 5-34 GTZZ15J Maintenance Manual...

  • Page 85: Replace Hydraulic Oil

    3. Remove the drain plug at the bottom of the tank, and completely drain the oil into a suitable vessel. For the capacity of hydraulic tank, please reference Performance Parameters, page 2-1. After the oil is completely drained, re-install the drain plug. GTZZ15J Maintenance Manual 5-35 © Nov. 2022...

  • Page 86: Replace Hydraulic Tank

    3. When the wear extent of the wear pad is greater could result in hydraulic component damage. Extremely than or equal to 3mm (0.118in.), the wear pad harsh condition requires the coolant changes to be assembly should be replaced immediately. performed more frequently. © Nov. 2022 5-36 GTZZ15J Maintenance Manual...

  • Page 87: Replace Fuel Hoses

    D-6 Replace Fuel Hoses Regularly replacing the fuel hoses is vital to safe engine operation and extending service life. Long-time use of old, frayed or broken fuel hoses may pose dangers to machine operation. GTZZ15J Maintenance Manual 5-37 © Nov. 2022...
  • Page 88 MAINTENANCE This Page Intentionally Left Blank © Nov. 2022 5-38 GTZZ15J Maintenance Manual...

  • 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 GTZZ15J 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 GTZZ15J 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 GTZZ15J 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 GTZZ15J Maintenance Manual...

  • Page 93: Telescopic Boom Assembly

    1. Remove the retaining bolts, gaskets and stopper at the fixed shaft #1 of the piston rod end of main boom telescopic cylinder and remove the fixed shaft GTZZ15J Maintenance Manual © Nov. 2022...

  • Page 94: Articulated Boom Assembly

    #5 and #6 connecting the upper articulated boom with the lower connecting frame, and remove the pivot pins #5 and #6. 11. Using the lifting device, slowly move the upper articulated boom away. © Nov. 2022 GTZZ15J Maintenance Manual...

  • Page 95: Chassis And Turntable Components

    Replacing tires and rims torque to prevent wheels from coming loose. Use a torque Hunan Sinoboom Intelligent Equipment Co., Ltd. wrench to tighten the fasteners. If recommends the replacement tires be of the same size, you do not have a torque wrench, 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 GTZZ15J Maintenance Manual...

  • Page 97: Turntable Slewing Mechanism

    NOTICE support or separation for the foldable boom. After disconnecting the hydraulic lines, immediately plug Hunan Sinoboom Intelligent Equipment Co., Ltd. the hydraulic line and fitting to prevent recommends the loosened nuts and bolts be not contaminants entering the hydraulic system.

  • Page 98: Engine

    A-9 Inspect Coolant Level (Water-cooled Engine) whether the hydraulic generator can be installed on the machine before installation. • A-10 Inspect Engine Belt Installation • A-11 Inspect Fuel Strainer (Oil-Water Separator) • A-12 Inspect Cooling Fan © Nov. 2022 6-10 GTZZ15J Maintenance Manual...

  • Page 99: Hydraulic System

    • Debugging must be performed by installation to ensure that the the after-sales personnel of hydraulic generator does not Sinoboom. Do not debug the interfere with other parts of the machine without permission. machine during the whole process. 3. After the hydraulic generator safely enters the...

  • Page 100: Layout Of Hydraulic Elements

    Layout of Hydraulic Elements fails. Figure 6-13 Table 6-2 1. Drive control valve 6. Gear pump 2. Brake/2–speed oscillating control valve 7. Closed-circuit variable displacement pump 3. Boom function manifolds 8. High-pressure filter © Nov. 2022 6-12 GTZZ15J Maintenance Manual...

  • Page 101: Boom Function Manifolds

    Solenoid valve 36.7Nm (27ft-lb) Adjust main boom lifting speed 7–2 Solenoid valve 36.7Nm (27ft-lb) Adjust the turntable rotation speed 7–3 Solenoid valve 26–28Nm Prevent sucking oil from the oil return pipe Check valve (19.2–20.7ft-lb) GTZZ15J Maintenance Manual 6-13 © Nov. 2022...

  • Page 102: Hydraulic Symbols

    日期 16.0000 设 计 标准化 刘晓 图 样 标 记 重 量 比 例 17.4787 101048050002 审 核 银友国 共 页 第 页 工 艺 刘奇志 日 期 2018.10.25 46.7096 34.4087 32.0000 © Nov. 2022 6-14 GTZZ15J Maintenance Manual 16.0000...
  • Page 103 比 例 46.7096 17.4787 101048050002 银友国 34.4087 刘奇志 日 期 2018.10.25 共 页 第 页 2–position 4–way 34.4087 solenoid directional Check valve 46.7096 valve 32.0000 34.4087 32.0000 28.5682 16.0000 28.5682 32.0000 16.0000 16.0000 GTZZ15J Maintenance Manual 6-15 © Nov. 2022...

  • Page 104: Hydraulic Schematic Diagram

    REPAIR PROCEDURES Hydraulic Schematic Diagram © Nov. 2022 6-16 GTZZ15J Maintenance Manual...

  • Page 105: Electrical System

    Check whether the footswitch or enable switch Footswitch or Enable switch Enable switch 7- function properly 7-second limit alarm second limit alarm Check whether the obstacle detection switch Obstacle detection Obstacle detection alarm functions properly alarm GTZZ15J Maintenance Manual 6-17 © Nov. 2022...
  • Page 106 Check the wiring of platform swing left solenoid solenoid valve fault valve fault valve Platform swing right Platform swing right solenoid Check the wiring of platform swing right solenoid solenoid valve fault valve fault valve © Nov. 2022 6-18 GTZZ15J Maintenance Manual...
  • Page 107 Main boom relative Main boom relative angle Check whether the main boom relative angle angle sensor sensor comparison error sensor is correctly installed comparison error GTZZ15J Maintenance Manual 6-19 © Nov. 2022...
  • Page 108 2. Controller damage. Pre-charging fault of RL 0314 3. If no problem is found in the above motor controller inspections, replace the controller. Pre-charging fault of RR 0414 motor controller © Nov. 2022 6-20 GTZZ15J Maintenance Manual...
  • Page 109 0021 pump motor controller The power generation current limit Activated battery current value sent by the host computer is less attenuation Declined battery current of than the actual value. 0121 FL motor controller GTZZ15J Maintenance Manual 6-21 © Nov. 2022...
  • Page 110 Reduced overvoltage current results in and undervoltage setting. 0224 performance of FR motor voltage increase. controller 4. Check the regenerative brake setup and current limit. Reduced overvoltage 0324 performance of RL motor controller © Nov. 2022 6-22 GTZZ15J Maintenance Manual...
  • Page 111 2. Improper set up motor deceleration value setup; temperature. Reduced overheat 0228 performance of FR motor 3. Monitor the machine operating current to controller determine whether the overheat results GTZZ15J Maintenance Manual 6-23 © Nov. 2022...
  • Page 112 2. Monitor output signal via monitor menu/ outputs menu/Driver 3 PWM to check 2. Stained/damaged/ whether there is output control signal; Open/short-circuited broken wiring. 0133 solenoid brake/coil 3 3. Check the coil of contactor; © Nov. 2022 6-24 GTZZ15J Maintenance Manual...
  • Page 113 2. Damaged encoder; controller signals via monitor/motor menu/motor 3. Improper wiring. speed A/B; Encoder error of RL motor 0336 4. If the checks above fail to discover the controller problem, replace the encoder. GTZZ15J Maintenance Manual 6-25 © Nov. 2022...
  • Page 114 Note: The pins #16 of the 35-pin controller controller output voltage at slider connector is for accelerator slider end input. end of accelerator. High voltage at slider end 0241 of accelerator of FR motor controller © Nov. 2022 6-26 GTZZ15J Maintenance Manual...
  • Page 115 FR motor controller pot2. connector is for pot2 slider end input. Low voltage at slider end of 0344 pot2 of RL motor controller Low voltage at slider end of 0444 pot2 of RR motor controller GTZZ15J Maintenance Manual 6-27 © Nov. 2022...
  • Page 116 Setup change of RR motor 0449 controller VCL run error of pump 0068 motor controller 1. Update the software to the correct version; Software problem VCL run error of FL motor 2. Replace the controller. 0168 controller © Nov. 2022 6-28 GTZZ15J Maintenance Manual...
  • Page 117 2. Encoder fault; can be properly delivered; Motor stalling of FL motor 3. Improper wiring or 0173 controller 2. Ensure the brake is fully disengaged; motor damage GTZZ15J Maintenance Manual 6-29 © Nov. 2022...
  • Page 118 1. Internal voltage failure Power supply fault of FL of controller; 0183 Check the internal controller for fault. motor controller 2. Power supply failure of drive circuit. Power supply fault of FR 0283 motor controller © Nov. 2022 6-30 GTZZ15J Maintenance Manual...
  • Page 119 Motor type error of RL 0389 motor controller Motor type error of RR 0489 motor controller VCL/OS mismatch of pump Controller program error Update the program to the correct version. 0091 motor controller GTZZ15J Maintenance Manual 6-31 © Nov. 2022...
  • Page 120 2. Check the wiring of emergency reverse motor controller which leads to the switch; activation of Emergency reverse emergency reverse 3. Check the programming of emergency 0294 response timeout of FR timeout. reverse. motor controller © Nov. 2022 6-32 GTZZ15J Maintenance Manual...
  • Page 121 Communication timeout 1s communication Check CAN3 signal lines between FL motor 0152 between FL motor controller timeout of FL motor controller and machine main controller. and machine main controller. controller GTZZ15J Maintenance Manual 6-33 © Nov. 2022...
  • Page 122 Total Voltage Overvoltage-Third Charging at High Temperature-First 0x301 0x109 Level Level Total Voltage Undervoltage-First Charging at High Temperature- 0x102 0x209 Level Second Level Total Voltage Undervoltage-Second Charging at High Temperature-Third 0x202 0x309 Level Level © Nov. 2022 6-34 GTZZ15J Maintenance Manual...

  • Page 123: Use And Maintenance Of Lead-Acid Battery

    Use and Maintenance of Lead-Acid Battery (requires maintenance) REQUIRED EQUIPMENT Figure 6-15 • Protective goggles and gloves • Wrench with rubber handle • Sodium bicarbonate • Terminal post protector (i.e., petroleum jelly and corrosion prevention spray, etc.) GTZZ15J Maintenance Manual 6-35 © Nov. 2022...
  • Page 124 Battery terminals could become corroded if not kept Figure 6-17 clean and dry. To prevent corrosion, apply a thin layer of petroleum jelly or use a terminal protector. BATTERY INSTALLATION SAFETY PREVENTIVE MAINTENANCE INSTRUCTIONS © Nov. 2022 6-36 GTZZ15J Maintenance Manual...
  • Page 125 The battery will bleed air in the equalization process chargers are automatic and pre-programmed, but some (forming bubbles). chargers allow the user to set the voltage and current values. Details about proper charging are as follows: GTZZ15J Maintenance Manual 6-37 © Nov. 2022...
  • Page 126 Voltage Test When Charging Test of Specific Gravity 1. Disconnect and reconnect the DC plug to restart the 1. Fill and drain the specific gravity hydrometer 2～3 charger. times. Then, obtain a sample from the battery. © Nov. 2022 6-38 GTZZ15J Maintenance Manual...

  • Page 127: Use And Care Of Lead-Acid Battery

    Then, the battery charger will restart after a delay of 10 seconds. • Charging indication: The yellow indicator lamp will illuminate when charging, the green indicator lamp GTZZ15J Maintenance Manual 6-39 © Nov. 2022...

  • Page 128: Electrical Symbols

    Two lines connected 17.4787 46.7096 Power-off switch 棕 兰 46.8000 黑 34.4087 θ Motor 0000 28.5682 16.0000 28.5682 Relay 46.7096 46.8000 Storage battery 28.5682 Warning lamp Lithium battery 46.8000 Valve Toggle switch 28.5682 © Nov. 2022 6-40 GTZZ15J Maintenance Manual...
  • Page 129 REPAIR PROCEDURES Symbol Description Two lines non- connected 棕 兰 Proximity switch/ 黑 Pressure sensor 28.5682 46.7096 28.5682 棕 兰 黑 θ Fuel level sensor 46.8000 Horn 28.5682 Key switch Preheating wire GTZZ15J Maintenance Manual 6-41 © Nov. 2022...
  • Page 130 REPAIR PROCEDURES © Nov. 2022 6-42 GTZZ15J Maintenance Manual...

  • Page 131: Electrical Schematic Diagram

    PWM_5 DO_07 Y10a DO_06 Y10b S100 BAT1 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 6-19 Electrical schematic diagram of turntable (PN.104020060006)-Rising GTZZ15J Maintenance Manual 6-43 © Nov. 2022...
  • Page 132 DO_08 Y25b DO_06 Y25a AI_V_7 DO_12 Y28b DO_10 DI_17 Y28a S202 DI_14 PWM_1 DI_16 PWM_3 S203 DI_15 H201 S216 － E201 － E202 S212 SB200 Figure 6-20 Electrical schematic diagram of platform (PN.104020060009)-Rising © Nov. 2022 6-44 GTZZ15J Maintenance Manual...
  • Page 133 XJ2-6 XJ1-22 PWM_OUT_40 XC2:43 XJ2-5 Y29a PWM_OUT_46 XJ1-13/14 XJ1-3/4 PWM/OUT_45 XJ1-17/18 XJ1-1/2 XJ1-15/16 OUT_24 XJ1-19/20 IN_48 OUT_23 XJ1-11/12 IN_49 OUT_26 XJ1-9/10 XJ1-7/8 IN_50 OUT_25 XJ1-5/6 Figure 6-21 Electrical schematic diagram of turntable (PN.104021063010）-Rexroth GTZZ15J Maintenance Manual 6-45 © Nov. 2022...
  • Page 134 PWM_OUT_43 PWM_OUT_44 PWM_OUT_37 Y29b PWM_OUT_38 Y29a PWM_OUT_39 PWM_OUT_40 PWM_OUT_46 PWM/OUT_45 OUT_24 H103 IN_48 OUT_23 H104 IN_49 OUT_26 H105 IN_50 OUT_25 H106 H106 S116 HG100 SB100 Figure 6-22 Electrical schematic diagram of platform (PN.104021063011)-Rexroth © Nov. 2022 6-46 GTZZ15J Maintenance Manual...
  • Page 135 PWM_OUT_46 XJ1-13/14 XJ1-3/4 PWM/OUT_45 XJ1-17/18 XJ1-1/2 XJ1-15/16 OUT_24 XJ1-19/20 IN_48 OUT_23 2/19 XJ1-11/12 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.104021063053）-Rexroth & Yanmar, China Stage III GTZZ15J Maintenance Manual 6-47 © Nov. 2022...
  • Page 136 DO_06 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 6-24 Electrical schematic diagram of turntable (PN.104021063092)-Rising & Deutz, China Stage III © Nov. 2022 6-48 GTZZ15J Maintenance Manual...
  • Page 137 PWM_OUT_46 XJ1-13/14 XJ1-3/4 PWM/OUT_45 XJ1-17/18 XJ1-1/2 XJ1-15/16 OUT_24 XJ1-19/20 IN_48 OUT_23 2/19 XJ1-11/12 IN_49 OUT_26 XJ1-9/10 XJ1-7/8 IN_50 OUT_25 XJ1-5/6 Figure 6-25 Electrical schematic diagram of turntable (PN.104021063121）-Rexroth & Yanmar, China Stage IV GTZZ15J Maintenance Manual 6-49 © Nov. 2022...
  • Page 138 Y29a PWM_OUT_39 PWM_OUT_40 PWM_OUT_46 PWM/OUT_45 OUT_24 H103 IN_48 OUT_23 H104 IN_49 OUT_26 H105 IN_50 OUT_25 H106 H106 S116 HG100 SB100 Figure 6-26 Electrical schematic diagram of platform (PN.104021063108）-Rexroth & Yanmar, China Stage IV © Nov. 2022 6-50 GTZZ15J Maintenance Manual...

  • Page 139: 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 140 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 GTZZ15J Maintenance Manual...

  • Page 141: 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 GTZZ15J Maintenance Manual © Nov. 2022...

  • Page 142: 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 GTZZ15J Maintenance Manual...

  • Page 143: 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). GTZZ15J Maintenance Manual © Nov. 2022...

  • Page 144: 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 GTZZ15J Maintenance Manual...

  • Page 145: 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 146: 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 GTZZ15J Maintenance Manual...

  • Page 147: 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 GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 148 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 GTZZ15J Maintenance Manual...

  • Page 149: 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 GTZZ15J Maintenance Manual 7-11 © Nov. 2022...

  • Page 150: 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 GTZZ15J Maintenance Manual...

  • Page 151: 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. GTZZ15J Maintenance Manual 7-13 © Nov. 2022...

  • Page 152: 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 GTZZ15J Maintenance Manual...
  • Page 153 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. GTZZ15J Maintenance Manual 7-15 © Nov. 2022...
  • Page 154 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 GTZZ15J Maintenance Manual...

  • Page 155: Turntable Panel Information

    • The configuration of switches on the turntable panel is subject to the actual machine configuration. GTZZ15J Maintenance Manual 7-17 © Nov. 2022...

  • Page 156: 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 GTZZ15J Maintenance Manual...
  • Page 157 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. GTZZ15J Maintenance Manual 7-19 © Nov. 2022...
  • Page 158 CONTROL SYSTEM This Page Intentionally Left Blank © Nov. 2022 7-20 GTZZ15J Maintenance Manual...

  • Page 159: 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. GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 160 CONTROL SYSTEM This Page Intentionally Left Blank © Nov. 2022 GTZZ15J Maintenance Manual...

  • Page 161: 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 YES/Machine is REPAIRED/ NO/Machine Has Problem in Good Condition Machine Has Items Damage or Description Been Repaired Malfunction GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 162 B-17 Inspect Oscillate Cylinder Exhausting and Counterbalance Valve Locking B-18 Inspect Electrical Wiring B-19 Inspect the Battery B-20 Test Oscillate Outriggers and Oscillate Multi-way Valve Lever B-21 Test Drive Speed B-22 Inspect Emergency Lowering © Nov. 2022 GTZZ15J Maintenance Manual...
  • Page 163 D-2 Replace Hydraulic Oil D-3 Inspect Boom Wear Pads D-4 Replace Hydraulic Tank Suction Filter D-5 Replace Coolant and Coolant Hoses (water-cooled engine) D-6 Replace Fuel Hoses User Inspector Signature Inspection Date Inspector Title GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 164 4. If any inspection item is marked as “NO”, the machine must be stopped, and after the repair is completed, the machine shall be re-inspected and the box marked “REPAIRED” shall be checked. Select the appropriate inspection procedure based on the inspection type. © Nov. 2022 GTZZ15J Maintenance Manual...

  • Page 165: 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. GTZZ15J Maintenance Manual © Nov. 2022...
  • Page 166 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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