Sinoboom GTZZ18J Maintenance Manual

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Part No.504022110002

Rev: A

Oct. 2022

Maintenance

Manual

产品说明书

PRODU

C T MAN U AL

GTZZ18J/AB18J/AB600J

0608E (2132E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

Table of Contents

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Summary of Contents for Sinoboom GTZZ18J

Page 1 Maintenance Part No.504022110002 Rev: A Manual Oct. 2022 产品说明书 PRODU C T MAN U AL GTZZ18J/AB18J/AB600J 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 Models Serial No. Imperial Metric From 0402200100 to present GTZZ18J AB18J AB600J 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 GTZZ18J Maintenance Manual © Oct. 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.. GTZZ18J Maintenance Manual © Oct. 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) © Oct. 2022 GTZZ18J Maintenance Manual...
Page 17 • When the machine travels on the machine. uneven ground or surfaces with gravel, or near holes and steep GTZZ18J Maintenance Manual © Oct. 2022...
Page 18: Work Environment Hazards
3. Lower the main boom. • The drive speed should not exceed 1.1km/h (0.68mph) when the platform is raised. • If the machine can be used outdoors, never operate it in strong or gusty wind. Do not raise © Oct. 2022 GTZZ18J Maintenance Manual...
Page 19 • Do not use any device that may any special workplace or by any special work method increase the wind load on the other than those specified by Hunan Sinoboom machine. 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. © Oct. 2022 GTZZ18J 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. GTZZ18J Maintenance Manual © Oct. 2022...
Page 22: Crush Hazards
• Limit the speed of travel according to ground conditions, crowding, gradients, the presence and location of personnel and any © Oct. 2022 GTZZ18J 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. GTZZ18J Maintenance Manual © Oct. 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. © Oct. 2022 1-10 GTZZ18J 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. GTZZ18J Maintenance Manual 1-11 © Oct. 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. © Oct. 2022 1-12 GTZZ18J Maintenance Manual...
Page 27: Specifications
SPECIFICATIONS PERFORMANCE PARAMETERS Table 2-1 GTZZ18J specifications AB18J (Metric) AB600J (Imperial) MEASURE DIMENSION PARAMETERS Max platform height 18.3 m 60 ft Max working height 20.3 m 66 ft 7 in Max horizontal reach 12.2 m 40 ft Max up-and-over height 7.8 m...
Page 28 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. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 29: Engine Specifications
SPECIFICATIONS GTZZ18J Chart of working envelope 360° GTZZ18J（5°） ENGINE SPECIFICATIONS 100mm (3.9 in) Stroke 2.8L Total Table 2-2 Cummins QFS2.8t3NA60 0.62 gal (UK) Displacement 0.74 gal (US) Type Water-cooled Compression 16.7:1 Ratio Number of Cylinders Firing Order 1-2-4-3 94mm (3.7 in)
Page 30: Function Speed
Jib up 30～38s Set the machine to high drive speed mode, and push the handle to the maximum stroke to drive forward and Jib down 25～32s backward for a distance of 30m twice, respectively. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 31: Weight Of Major Components
Main boom telescoping cylinder Main boom luffing cylinder 87.5 Articulated boom luffing cylinder Articulated boom telescoping cylinder Articulated boom leveling cylinder 284.4 Upper leveling cylinder 77.2 Lower leveling cylinder 92.6 Jib boom cylinder 28.5 62.8 GTZZ18J Maintenance Manual © Oct. 2022...
Page 32: Hydraulic System Specifications
16 cc/r Maximum operating pressure 22 MPa (3191psi) Drive Motor Type Plunger motor Displacement 38 cc/r Function Manifold Boom function valve pressure 22 MPa (3191psi) Return Filter Return filter bypass pressure 0.02 MPa (2.9psi) © Oct. 2022 GTZZ18J Maintenance Manual...
Page 33: Hydraulic Hose And Fitting
ED, O-RING + CIRCLIP ED, O-RING + CIRCLIP O-RING L (LIGHT-DUTY) 18 ± 1 Nm(13 ± 1 ft-lb ) 20 ± 2 Nm (15 ± 2 ft-lb) 18 ± 1 Nm (13 ± 1 ft-lb) M10×1 GTZZ18J Maintenance Manual © Oct. 2022...
Page 34 G3/8A 50 ± 3 Nm (37 ± 2 ft-lb) 75 ± 5 Nm (55 ± 2 ft-lb) G1/2A 75 ± 5 Nm (55 ± 2 ft-lb) 95 ± 6 Nm (70 ± 4 ft-lb) © Oct. 2022 GTZZ18J Maintenance Manual...
Page 35 3/4-16 50 ± 3 Nm (37 ± 2 ft-lb) 80 ± 6 Nm (59 ± 4 ft-lb) 7/8-14 75 ± 5 Nm(55 ± 4 ft-lb ) 125 ± 10 Nm (92 ± 7 ft-lb) GTZZ18J Maintenance Manual © Oct. 2022...
Page 36: Hydraulic Hose And Fitting Tight
230 Nm (170 ft-lb) 300 Nm (221 ft-lb) 360 Nm (266 ft-lb) 250 Nm (184 ft-lb) 320 Nm (236 ft-lb) 380 Nm (280 ft-lb) 320 Nm (236 ft-lb) 420 Nm (310 ft-lb) 500 Nm (369 ft-lb) © Oct. 2022 2-10 GTZZ18J Maintenance Manual...
Page 37 16 Nm (11 ft-lb) 1/4-28 7/16" 23 Nm (17 ft-lb) 32 Nm (24 ft-lb) 5/16-24 1/2" 41 Nm (30 ft-lb) 58 Nm (43 ft-lb) 3/8-24 9/16" 65 Nm (48 ft-lb) 92 Nm (68 ft-lb) 7/16-20 5/8" GTZZ18J Maintenance Manual 2-11 © Oct. 2022...
Page 38 200 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 © Oct. 2022 2-12 GTZZ18J Maintenance Manual...
Page 39: System Descriptions
The batteries are charged by the DC generator of the engine. Power- off switches are used to protect the control system. GTZZ18J Maintenance Manual © Oct. 2022...
Page 41: 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 42: 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 annual machine inspection, notify Hunan Sinoboom Intelligent Equipment Co., Ltd. of the current machine ownership information.
Page 43: 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. GTZZ18J Maintenance Manual © Oct. 2022...
Page 44: Cleanliness
• The static and dynamic load tests of the machine suggest a compliance with the relevant standard. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 45: 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. GTZZ18J Maintenance Manual © Oct. 2022...
Page 46: 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. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 47: 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. GTZZ18J Maintenance Manual © Oct. 2022...
Page 48: Following Amaintenance Schedule
Every half a year or every 500 completed, the machine shall be re-inspected and A+B+C hours the box marked “REPAIRED” shall be checked. Select the appropriate inspection procedure based Every year or every 1000 hours A+B+C+D on the inspection type. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 49 A-17 Check Connector Tilting Checklist B Procedures YES/Machine is REPAIRED/ NO/Machine Has Problem in Good Condition Machine Has Items Damage or Description Been Repaired Malfunction B-1 Inspect and Replace Hydraulic Oil Tank Return Filter Element GTZZ18J Maintenance Manual © Oct. 2022...
Page 50 Counterbalance Valve Locking B-18 Inspect Electrical Wiring B-19 Inspect Battery B-20 Test Oscillate Outriggers and Oscillate Multi-way Valve Lever B-21 Test Drive Speed B-22 Inspect Emergency Lowering B-23 Inspect Tilt Protection B-24 Test Braking Distance © Oct. 2022 GTZZ18J Maintenance Manual...
Page 51: 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. GTZZ18J Maintenance Manual © Oct. 2022...
Page 52: 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 53: Inspect All Decals
Note: If the decals on the machine need to be replaced, oil pump will have entrained air and hydraulic please contact Hunan Sinoboom Intelligent Equipment components will be damaged. Performing daily Co., Ltd..
Page 54: Inspect Hydraulic Leakage
The inspection must be performed with the engine stopped. Keeping the diesel fuel at an appropriate level is vital to maintaining the engine performance and extending service life. The diesel fuel in the tank at an © Oct. 2022 GTZZ18J Maintenance Manual...
Page 55: Inspect Fuel Leakage
Inspecting fuel leakage is vital to safe and normal 2. Pull out the emergency stop button at ground machine operation. If a fuel leak is not discovered and controller to ON position. GTZZ18J Maintenance Manual © Oct. 2022...
Page 56: Inspect Coolant Level
3. The coolant level should be at the fill inlet of the coolant box. 4. Add coolant as needed. Do not overfill the tank. It is recommended to choose the -18℃ ready-mix © Oct. 2022 5-10 GTZZ18J Maintenance Manual...
Page 57: Inspect Engine Belt
Shut off the engine before inspection. procedure. Inspect the engine belt for： 1. Open the right turntable cover. • Crack or breakage 2. Locate the fuel strainer. • Wear or misalignment • Peeling-off • Glazing or hardening GTZZ18J Maintenance Manual 5-11 © Oct. 2022...
Page 58: Water Separator
Operation Manual. Before performing the function test, ensure that the safety rules in the operation manual are 2. Locate the cooling fan in the radiator of engine. fully read and understood. 3. Inspect the cooling fan for: • Cracks © Oct. 2022 5-12 GTZZ18J Maintenance Manual...
Page 59 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 GTZZ18J Maintenance Manual 5-13 © Oct. 2022...
Page 60 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 © Oct. 2022 5-14 GTZZ18J Maintenance Manual...
Page 61 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 GTZZ18J Maintenance Manual 5-15 © Oct. 2022...
Page 62: Perform Maintenance After
Before the first use of the new machine, the oscillate cylinder must be exhausted. This procedure must also Figure 5-10 Connector perpendicular to the turntable The connector may be tilted in two directions: backward tilt and forward tilt. Connector tilted backward © Oct. 2022 5-16 GTZZ18J Maintenance Manual...
Page 63 Backward tilt is a common tilt condition for the 6. Pull out the manual release valve knob next to the connector. In case of backward tilt, contact Sinoboom hydraulic tank and hold it while lowering the or a service technician approved by Sinoboom articulated boom.
Page 64: Checklist Bprocedures
In 3. Use a wrench to remove the return filter. case of forward tilt, contact Sinoboom or a service technician approved by Sinoboom immediately to reposition the machine.
Page 65: Fasteners
The machine may be unable to operate properly if the hydraulic oil becomes dirty, and the hydraulic parts may be damaged by contaminated oil. Replace the hydraulic oil frequently, especially when the service environment is very dirty. GTZZ18J Maintenance Manual 5-19 © Oct. 2022...
Page 66: Replace Fuel Strainer (Fuel-Water Separator) Element
4. Loosen the valve plug over the fuel strainer (fuel- water separator). 4. If the air has difficulty in passing through the air filter, observe the following steps to clean the air filter. © Oct. 2022 5-20 GTZZ18J Maintenance Manual...
Page 67: Replace High-Pressure Filter
3. Loosen the clip at the end cap of air filter, and remove the end cap. 4. Remove the air filter element. 5. Use a wet cloth to scrub the inside of filter housing and end cap. GTZZ18J Maintenance Manual 5-21 © Oct. 2022...
Page 68: Inspect Travel Switch
#δ of the worm gear is found to exceed 0.255mm/ damaged or crushed flat. 0.01in during inspection, reduce the end gap #δ to below 0.125mm/0.005in. 2. Inspect whether the exhaust pipe is tightly connected. © Oct. 2022 5-22 GTZZ18J Maintenance Manual...
Page 69: Bolts
The slewing chassis and slewing bearing bearing bolts should be checked after the first 50 hours of operation and every 600 hours thereafter. If the bolts GTZZ18J Maintenance Manual 5-23 © Oct. 2022...
Page 70 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. Inspecting the connecting bolts between turntable and slewing bearing © Oct. 2022 5-24 GTZZ18J Maintenance Manual...
Page 71: Lubricate Slewing Bearing
7. Ensure the feeler gauge won’t go through the outside of bolt head to the bolt shank. Figure 5-27 1. Place the machine in stowed position. 2. Locate the platform oscillating motor. GTZZ18J Maintenance Manual 5-25 © Oct. 2022...
Page 72: Test Cylinder Drift
1℃. 6. Inspect the oscillate cylinder, ensure the oscillate cylinder on the side with load applied is without any evidence of retracting, and then retract the boom. © Oct. 2022 5-26 GTZZ18J Maintenance Manual...
Page 73: Inspect Electrical Wiring
2. Inspect each flexible joint to be free of loosening, and each sensor wiring free of damage. Lithium battery and lead-acid maintenance-free batteryare maintenance-free batteries. INSPECT THE LEAD-ACID BATTERIES • Wear protective clothing and goggles properly. GTZZ18J Maintenance Manual 5-27 © Oct. 2022...
Page 74: Test Oscillate Outriggers
3. Drive the machine to allow the right steer wheel upon the kerb or a block with thickness of 120mm (4.7 in). 4. The other 3 wheels of the machine should come in close contact with the ground. © Oct. 2022 5-28 GTZZ18J Maintenance Manual...
Page 75: Inspect Tilt Protection
10. The tilt alarm will sound with the chassis tilt indicator light flashing, and some functions are restricted, but the boom retracting and lowering, and turntable rotating will be allowed. GTZZ18J Maintenance Manual 5-29 © Oct. 2022...
Page 76: Test Braking Distance
An unclean or blocked air filter of hydraulic tank may cause the hydraulic pump to suction improperly, and continued operation may result in component damage. The air © Oct. 2022 5-30 GTZZ18J Maintenance Manual...
Page 77: Tank
A-8 Inspect Engine Oil Level, Do not come in contact with the hot page 5-9. engine oil when draining to avoid burns. 8. Inspect the engine oil filter element to make sure no leakage occurs. GTZZ18J Maintenance Manual 5-31 © Oct. 2022...
Page 78: Test Weighing System
2. Place a suitable vessel under the bolt as indicated by the arrow in the figure. 3. Remove the bolt as indicated. 4. Fully drain the drive reducer gear oil to the vessel. 5. Mount back the loosened bolt. © Oct. 2022 5-32 GTZZ18J Maintenance Manual...
Page 79: Replace Hydraulic Oil
As friction pair will develop between each wear pad and the telescopic boom surface, improperly shimmed wear pads or continued use of extremely worn wear pads may lead to component damage and unsafe operating conditions. GTZZ18J Maintenance Manual 5-33 © Oct. 2022...
Page 80: Replace Hydraulic Tank
3. When the wear extent of the wear pad is greater than or equal to 3mm (0.118in.), the wear pad assembly should be replaced immediately. © Oct. 2022 5-34 GTZZ18J Maintenance Manual...
Page 81: 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. GTZZ18J Maintenance Manual 5-35 © Oct. 2022...
Page 83: 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 GTZZ18J Maintenance Manual © Oct. 2022...
Page 84: Platform
When installing hoses and fittings, tighten them according to the specified torque. See Hydraulic Hose and Fitting Specifica- tions, page 2-7. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 85: 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 GTZZ18J Maintenance Manual © Oct. 2022...
Page 86: 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. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 87: Telescopic Boom Assembly
1. Extend the telescopic boom to expose the pivot pin #3 for easy removal. Remove the end circlip and gasket at the fixed shaft #3 at the barrel end of the telescopic cylinder, and remove the fixed shaft #3. GTZZ18J Maintenance Manual © Oct. 2022...
Page 88: Articulated Boom Assembly
#6, slider #7 and gasket on the surface of and around the front end of the articulated boom. 12. Using the lifting device, slowly move the telescopic articulated boom away. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 89: Chassis And Turntable Components
Be sure to Replacing tires and rims only use the nuts matching to the cone angle of the wheel. Hunan Sinoboom Intelligent Equipment Co., Ltd. recommends the replacement tires be of the same size, • Tighten the lug nuts to the proper ply rating and brand as the original tires.
Page 90: 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 © Oct. 2022 GTZZ18J Maintenance Manual...
Page 91: 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 92: Engine
A-12 Inspect Cooling Fan The hydraulic generator is optional. Please confirm • A-13 Inspect Engine Intake System whether the hydraulic generator can be installed on the machine before installation. • B-4 Inspect Cooling Syste Installation © Oct. 2022 6-10 GTZZ18J Maintenance Manual...
Page 93 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 94: Hydraulic System
REPAIR PROCEDURES HYDRAULIC SYSTEM Layout of Hydraulic Elements 17 2 14 13 © Oct. 2022 6-12 GTZZ18J Maintenance Manual...
Page 95: Boom Function Manifold
55–65Nm (41–48ft-lb) Keep fluid flowing in one way 1–1 Check valve 55–65Nm (41–48ft-lb) Keep fluid flowing in one way 1–2 Check valve 55–65Nm (41–48ft-lb) Limit system pressure to prevent overpressure 2–1 Relief valve GTZZ18J Maintenance Manual 6-13 © Oct. 2022...
Page 96 Hydraulic lock 27.1Nm (20ft-lb) To keep the load balanced 40–45Nm (30–33ft-lb) Restrict manual leveling pressure 18–1 Relief valve 40–45Nm (30–33ft-lb) Restrict manual leveling pressure 18–2 Relief valve Damper (φ0.6) 5Nm (3.7ft-lb) Eliminate pressure impact © Oct. 2022 6-14 GTZZ18J Maintenance Manual...
Page 97 Drain fluid from low-pressure end Flush valve 40～45Nm (30～33ft-lb) Control drive pressure Relief valve 12～15Nm (9～11ft-lb) Shuttle valve Oil circuit switch Damper 5Nm (4ft-lb) Damper 5Nm (4ft-lb) 55～65Nm (41～48ft-lb) Keep fluid flowing in one way Check valve GTZZ18J Maintenance Manual 6-15 © Oct. 2022...
Page 98 27.1Nm (20ft-lb) Control braking direction 3–2 Solenoid valve 27.1Nm (20ft-lb) Control 2-speed direction 3–3 Solenoid valve 27.1Nm (20ft-lb) 3–4 Solenoid valve Enable oscillation function Damper 5Nm (9ft-lb) Damper 5Nm (9ft-lb) Damper 5Nm (9ft-lb) © Oct. 2022 6-16 GTZZ18J Maintenance Manual...
Page 99 Figure 6-17 Telescope counterbalance valve (PN.202040003016) Table 6-6 Telescope counterbalance valve (PN.202040003016) NAME TORQUE FUNCTION Counterbalance 45–50Nm (33–37ft-lb) To keep the load balanced valve Counterbalance 45–50Nm (33–37ft-lb) To keep the load balanced valve Choke plug 72–82Nm (51–61ft-lb) GTZZ18J Maintenance Manual 6-17 © Oct. 2022...
Page 100: Hydraulic Symbols
32.0000 28.5682 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 © Oct. 2022 6-18 GTZZ18J Maintenance Manual...
Page 102: 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 © Oct. 2022 6-20 GTZZ18J Maintenance Manual...
Page 103 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 GTZZ18J Maintenance Manual 6-21 © Oct. 2022...
Page 104 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 © Oct. 2022 6-22 GTZZ18J Maintenance Manual...
Page 105 Data valid but higher than normal Electrical circuit #1 of intake manifold temperature sensor (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 GTZZ18J Maintenance Manual 6-23 © Oct. 2022...
Page 106 2963 (lowest-level severity) Data valid but higher than normal Over temperature of intake manifold #1 2964 (lowest-level severity) SAE J1939 accelerator pedal sensor Update error 3326 system Update error 3613 Coolant level sensor © Oct. 2022 6-24 GTZZ18J Maintenance Manual...
Page 107: Use And Maintenance Of Lead-Acid Battery
Discharge tester (if required) • Sodium bicarbonate • Specific gravity hydrometer (for flooded/wet battery) • Terminal post protector (i.e., petroleum jelly and corrosion prevention spray, etc.) • Voltmeter (for flooded/wet battery, colloid and AGM battery) GTZZ18J Maintenance Manual 6-25 © Oct. 2022...
Page 108 Be sure the battery cable connectors are properly caps on the battery. tightened to the battery terminal. Battery cable BATTERY CHARGING connectors that are too tight or loose could damage the terminal or cause a fire. © Oct. 2022 6-26 GTZZ18J Maintenance Manual...
Page 109 Specific Gravity （%） Battery Cell 1.277 2.122 6.37 12.73 1.258 2.103 6.31 12.62 1.238 2.083 6.25 12.50 1.217 2.062 6.19 12.37 1.195 2.040 6.12 12.24 1.172 2.017 6.05 12.10 1.148 1.993 5.98 11.96 GTZZ18J Maintenance Manual 6-27 © Oct. 2022...
Page 110 0.5V; 14V for 12V battery, the • Low-input voltage protection: The battery charger voltage difference between the battery and any will shut down when the input AC voltage is lower © Oct. 2022 6-28 GTZZ18J Maintenance Manual...
Page 111: Use And Care Of Lead-Acid Battery
• Do not rinse or spray the battery pack with a water hose. Lithium battery 17.4787 • Be sure the cable connector is tight on the terminal. 46.7096 46.8000 34.4087 GTZZ18J Maintenance Manual 6-29 © Oct. 2022...
Page 112 28.5682 46.7096 28.5682 Oil temperature θ switch θ 棕兰 Delay relay 黑 θ Fuel level sensor 17.4787 Power-off switch 46.7096 34.4087 Horn 32.0000 Relay 28.5682 16.0000 Key switch Warning lamp Preheating wire © Oct. 2022 6-30 GTZZ18J Maintenance Manual...
Page 115: Electrical Schematic Diagram
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 6-23 Electrical schematic diagram of platform (PN.104019060006)-Rising & Cummins engine of EU T3 GTZZ18J Maintenance Manual 6-33 © Oct. 2022...
Page 116 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.104019060014)-Rising & Cummins engine of EU T3 © Oct. 2022 6-34 GTZZ18J Maintenance Manual...
Page 117 PWM_OUT_40 IN_47 OUT_24 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 & Cummins engine of EU T3 GTZZ18J Maintenance Manual 6-35 © Oct. 2022...
Page 118 PWM/OUT_45 XJ1-17/18 XJ1-1/2 Y30a 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 6-26 Electrical schematic diagram of turntable (PN.104019060051)-Rexroth & Cummins engine of EU T3 © Oct. 2022 6-36 GTZZ18J Maintenance Manual...
Page 119: 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 120 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 © Oct. 2022 GTZZ18J Maintenance Manual...
Page 121: 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 GTZZ18J Maintenance Manual © Oct. 2022...
Page 122: 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. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 123: 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). GTZZ18J Maintenance Manual © Oct. 2022...
Page 124: 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. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 125: 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 126: 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. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 127: 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 GTZZ18J Maintenance Manual © Oct. 2022...
Page 128 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. © Oct. 2022 7-10 GTZZ18J Maintenance Manual...
Page 129: 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 GTZZ18J Maintenance Manual 7-11 © Oct. 2022...
Page 130: 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 © Oct. 2022 7-12 GTZZ18J Maintenance Manual...
Page 131: 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. GTZZ18J Maintenance Manual 7-13 © Oct. 2022...
Page 132: 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 © Oct. 2022 7-14 GTZZ18J Maintenance Manual...
Page 133 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. GTZZ18J Maintenance Manual 7-15 © Oct. 2022...
Page 134 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 © Oct. 2022 7-16 GTZZ18J Maintenance Manual...
Page 135: Turntable Panel Information
• The configuration of switches on the turntable panel is subject to the actual machine configuration. GTZZ18J Maintenance Manual 7-17 © Oct. 2022...
Page 136: 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. © Oct. 2022 7-18 GTZZ18J Maintenance Manual...
Page 137 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. GTZZ18J Maintenance Manual 7-19 © Oct. 2022...
Page 139: 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. GTZZ18J Maintenance Manual © Oct. 2022...
Page 141: Appendix 2: Repair & Inspection Report
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 A-16 Perform Oscillate Cylinder Exhausting A-17 Check Connector Tilting Checklist B Procedures GTZZ18J Maintenance Manual © Oct. 2022...
Page 142 Cylinder Fasteners B-16 Test Cylinder Drift B-17 Inspect Oscillate Cylinder Exhausting and Counterbalance Valve Locking B-18 Inspect Electrical Wiring B-19 Inspect Battery B-20 Test Oscillate Outriggers and Oscillate Multi-way Valve Lever B-21 Test Drive Speed © Oct. 2022 GTZZ18J Maintenance Manual...
Page 143 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 GTZZ18J Maintenance Manual © Oct. 2022...
Page 144 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. © Oct. 2022 GTZZ18J Maintenance Manual...
Page 145: 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. GTZZ18J Maintenance Manual © Oct. 2022...
Page 146 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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