Sinoboom AB22EJ Plus Maintenance Manual

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Part No.503009110002

Rev: B

Nov. 2022

Maintenance

Manual

产品说明书

PRODU

C T MAN U AL

AB22EJ Plus/AB710EJ Plus

0608E (2132E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

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Summary of Contents for Sinoboom AB22EJ Plus

Page 1 Maintenance Part No.503009110002 Rev: B Manual Nov. 2022 产品说明书 PRODU C T MAN U AL AB22EJ Plus/AB710EJ Plus 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 APPLICABLE RANGE Use the following table to identify the specific serial number for models included in this manual. Check the model of your machine before consulting the manual, and then use the correct manual according to the serial number of the model. See the nameplate on your machine to identify the model and serial number.
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 AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 11 Unit setting......7-8 Appendix 1: Prepare the Work Record before Delivery..A-1 Appendix 2: Repair & Inspection Report ......A-3 Appendix 3: Major Modification and Repair Record ..... A-7 AB22EJ Plus 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.. AB22EJ Plus 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 AB22EJ Plus Maintenance Manual...
Page 17 The machine. battery is vital to maintaining the • When the machine is driven on stability of the machine. uneven ground, gravel or other uneven surfaces, or near holes AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 18: Work Environment Hazards
3. Lower the main boom. • The drive speed should not exceed 1.1 km/h (0.68 mph) when the platform is raised. • If the machine can be used outdoors, never operate it in © Nov. 2022 AB22EJ Plus 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. The battery is vital to maintaining the stability of the machine. © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 21: Fall Hazards
At a minimum, operators must operate and maintain the machine as stated in the operation manual and in the maintenance manual in addition to following more stringent industry regulations and workplace rules. AB22EJ Plus 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 AB22EJ Plus Maintenance Manual...
Page 23: Explosion And Fire Hazards
During operation, keep the left and right doors of the chassis closed and locked. Only trained service personnel can open the left and right doors to repair the machine. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 24: Battery Hazards
Seek medical attention immediately if battery acid contacts skin. • Daily check the battery cable for damage, and replace any damaged parts before operating the machine. © Nov. 2022 1-10 AB22EJ Plus 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. AB22EJ Plus 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 AB22EJ Plus Maintenance Manual...
Page 27: Specifications
SPECIFICATIONS PERFORMANCE PARAMETERS Table 2-1 AB22EJ Plus specifications AB22EJ Plus (Metric) AB710EJ Plus (Imperial) Items DIMENSION PARAMETERS Max platform height 21.6 m 70 ft 10 in Max working height 23.6 m 77 ft 5 in Max horizontal reach (230 kg, 340 13.4 m/11.9m/10.45m...
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 AB22EJ Plus Maintenance Manual...
Page 29 0.5m/s². g) It is recommended not to use lead-acid batteries in environments below 0 °C, otherwise the battery capacity will decay rapidly and the battery life will be affected. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 31: Motor Specifications
30m twice, respectively. 85～105s boom retracted Turntable rotating (360°)- 145～170s boom extended Main boom extending 52～62s Main boom retracting 38～46s Platform rotating (180°) 18～22s Platform leveling up 50～60s Platform leveling down 40～50s AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 32: Weight Of Major Components
Main boom luffing cylinder 146.1 322.2 Articulated boom luffing cylinder 123.5 272.3 Upper leveling cylinder 38.4 84.7 Lower leveling cylinder 36.5 80.5 Jib boom cylinder 30.5 67.3 Hybrid motor 65.5 144.4 Drive reducer 38.3 84.5 © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 33: Hydraulic System Specifications
FITTING SPECIFICATIONS Other hydraulic oil can be added upon delivery as required by customers, but different hydraulic oil cannot be mixed. HYDRAULIC HOSE TORQUE Hydraulic hoses must be torqued to the following specifications. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 34: 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 © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 35 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) AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 36: 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. © Nov. 2022 2-10 AB22EJ Plus Maintenance Manual...
Page 37: 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. AB22EJ Plus Maintenance Manual 2-11 © Nov. 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 © Nov. 2022 2-12 AB22EJ Plus Maintenance Manual...
Page 39: System Descriptions
All batteries are charged from an external power source through the same charger. The machine is also equipped with a circuit breaker to protect the control system. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 41: 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 AB22EJ Plus Maintenance Manual ©...
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 each 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 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. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 44: Cleanliness
• The static and dynamic load tests of the machine suggest a compliance with the relevant standard. © Nov. 2022 AB22EJ Plus 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. AB22EJ Plus Maintenance Manual © Nov. 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. © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 47: Maintenance
& counterbalance valve on the cylinder. inspection report. • Immediately remove a damaged or malfunctioning machine from service, mark and stop using it. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 48: 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 AB22EJ Plus Maintenance Manual...
Page 49: Completing A Repair & Inspection
A-9 Check Battery Level Checklist B Procedures REPAIRED/ Problem YES/Good NO/Damaged or Items Repaired Description Machine Faulted Machine Machine B-1 Inspect and Replace Hydraulic Oil Tank Return Filter Element B-2 Inspect Rim, Tire and Fasteners AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 50 B-20 Test Braking Distance Checklist C Procedures REPAIRED/ Problem YES/Good NO/Damaged or Items Repaired Description Machine Faulted Machine Machine C-1 Replace Air Filter of Hydraulic Tank C-2 Inspect Weighing System Checklist D Procedures © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 51: 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 AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 52: Checklist Aprocedures
If needing to replace the manuals, contact Hunan Si- and unauthorized changes: noboom Intelligent Equipment Co., Ltd.. • Electrical components, wiring, cables and safety ropes • Hydraulic hoses & fittings, hydraulic cylinder and manifolds © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 53: Inspect Hydraulic Oil Level
A-5 Check for Hydraulic Oil Leakage Preventing hydraulic oil from leaking is vital to safe and normal operation of the machine. If a leak goes AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 54: Perform Functional Test
15. Turntable rotation switch (see the figure and table below) 2. Ground control position 9. Jib boom up/down switch 16. Articulated boom luffing switch 3. OFF (neutral) position 10. Platform leveling switch 17. Emergency power switch © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 55 Figure 5-3 Ground controller display screen Table 5-7 1. Diesel/Battery gauge 3. Tachometer 5. Platform load 2. Accumulated work hours 4. Current work hours CAUTION Scope 9 10 11 12 14 15 16 17 AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 56: Perform Maintenance After
Before the first use of the new machine, the oscillate cylinder must be exhausted. This procedure must also be performed if the oscillate cylinder or counterbalance valve is replaced. © Nov. 2022 5-10 AB22EJ Plus Maintenance Manual...
Page 57: Checklist Bprocedures
7. Clean the oil that may spill during the process. environments. 8. Start the engine from the ground controller. AB22EJ Plus Maintenance Manual 5-11 © Nov. 2022...
Page 58: Fasteners
2. Check the cable track system for damaged or corroded power cords. 3. Check each adjustable joint for loose connection and ensure the sensor wiring is free of damage. © Nov. 2022 5-12 AB22EJ Plus Maintenance Manual...
Page 59: Inspect Emergency Lowering
The air filter of hydraulic tank should be inspected more frequently in hostile working BURN HAZARD environment. Be cautious of hot hydraulic oil. Bodily contact with hot hydraulic oil may result in severe burn. AB22EJ Plus Maintenance Manual 5-13 © Nov. 2022...
Page 60: Test Drive Speed
4. Replace the filter element as needed. 5. Clean up the spilled hydraulic oil. 6. Start the engine from the ground controller. 7. Inspect the high-pressure filter and relevant components for leakage. © Nov. 2022 5-14 AB22EJ Plus Maintenance Manual...
Page 61: Inspect Tilt Protection
The wooden blocks should be (L × W × H): 750×250×217mm The boom can be fully retracted. (29.5 in.×9.8 in.×8.6 in.). AB22EJ Plus Maintenance Manual 5-15 © Nov. 2022...
Page 62: Inspect Drive Reducer Oil
Level Inappropriate gear oil level of slewing reducers will reduce the machine performance, and continued use could result in component damage. Figure 5-13 Inspecting the connecting bolts between chassis and slewing bearing © Nov. 2022 5-16 AB22EJ Plus Maintenance Manual...
Page 63 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 AB22EJ Plus Maintenance Manual 5-17 © Nov. 2022...
Page 64: Lubricate Slewing Bearing
4. Ensure the feeler gauge won’t go through the outside of bolt head to the bolt shank. 5. Lower the main boom to be horizontal and fully extend it. © Nov. 2022 5-18 AB22EJ Plus Maintenance Manual...
Page 65: Test Cylinder Drift
(mm/in) (mm/in) evidence of retracting, and then retract the boom. 63/2.48 0.96/0.037 7. Move the reverse drive switch to drive the machine off the wooden block. 80/3.15 0.63/0.025 100/3.94 0.39/0.015 AB22EJ Plus Maintenance Manual 5-19 © Nov. 2022...
Page 66: Test Oscillate Outriggers
Improper level of battery electrolyte or damaged cable and wiring may damage battery parts The instructions below are applied only for batteries and pose dangerous conditions. requiring maintenance： © Nov. 2022 5-20 AB22EJ Plus Maintenance Manual...
Page 67: Test Braking Distance
2. Slowly deflect the drive/steer proportional control more than 15° above the horizontal plane separately, joystick to full drive speed position. gradually apply loads on the platform. The test results shall be as follows: AB22EJ Plus Maintenance Manual 5-21 © Nov. 2022...
Page 68: Checklist Dprocedures
7. Remove the #1 and #2 bolts as indicated. 8. Add new gear oil to the port #1 until the oil level is even with that of the port #2. © Nov. 2022 5-22 AB22EJ Plus Maintenance Manual...
Page 69: Replace Hydraulic Tank
Dirty hydraulic oil may cause the machine to function improperly and continued use may result in hydraulic component damage. Extremely dirty working environment requires the oil change to be performed more frequently. AB22EJ Plus Maintenance Manual 5-23 © Nov. 2022...
Page 70 3mm (0.118in.), the wear pad assembly should be replaced immediately. NOTICE The wear pad disassembled from the boom should never be reused. Make sure to replace it with a new wear pad assembly. © Nov. 2022 5-24 AB22EJ Plus Maintenance Manual...
Page 71: Repair Procedures
OFF position. perform any function, and will remain enabled 7 seconds after the last function is stopped. While the AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 72: Platform
7. Remove the platform oscillating motor. Platform Oscillating Motor Jib Boom Assembly NOTICE Perform this procedure with the machine in stowed position. MOVING OBJECT HAZARD Wear eye protection when tapping the brass drift with a wooden hammer. © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 73: Platform Leveling Cylinder
4-5. #1 of the platform leveling cylinder, and do not move the pivot pin. • Check the pivot pin for wear, scratch, deformation or other damage, and replace the pivot pin if needed. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 74: Cable Track Assembly
4. Remove the bolts as indicated by the arrows in the the brass drift with a wooden above figure. hammer. 5. Using the lifting device, slowly move the cable track away from the boom. © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 75: Telescopic Boom Assembly
6. Using a brass drift and wooden hammer, tap the pivot pin #1 out. 7. Remove the bolt and nut at the pivot pin #3 connecting the piston rod end of lower platform leveling cylinder with the main boom. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 76: Articulated Boom Assembly
#2 connecting the upper leveling cylinder end with the upper connecting frame. © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 77: Chassis And Turntable Components
16. Using a lifting device, slowly move the lower linkage Replacing tires and rims away. Hunan Sinoboom Intelligent Equipment Co., Ltd. 17. Support the upper articulated boom, articulated recommends the replacement tires be of the same size, boom luffing cylinder, lower connecting frame and ply rating and brand as the original tires.
Page 78: Reducer And Drive Motor
1. First apply the threadlocker Loctite 272 to the nuts, then hand tighten all nuts to prevent loosening. Do not use lubricants on threads or nuts. 2. Tighten the nuts in the sequence as shown below. Figure 6-10 © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 79: Turntable Slewing Mechanism
8. Apply the threadlocker Loctite 272 to the bolts and measure the gear backlash relative to the slewing torque the bolts after pre-tightening. bearing. Make sure the gear backlash falls within 0.15-0.25mm (0.006–0.01in). 9. Attach the hydraulic hoses. 10. Install the wheels. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 80 Loctite 272 to the bolts, and install the bolts one by one. 4. Tighten the bolts in the sequence as shown in the figure below. © Nov. 2022 6-10 AB22EJ Plus Maintenance Manual...
Page 81: Battery Box
(as indicated by the arrow in 6-13 , page 6-11) to support the battery box. 4. Remove the mounting bolts on the left and right sides of the battery box. AB22EJ Plus Maintenance Manual 6-11 © Nov. 2022...
Page 82: Hydraulic System
REPAIR PROCEDURES HYDRAULIC SYSTEM Layout of Hydraulic Elements © Nov. 2022 6-12 AB22EJ Plus Maintenance Manual...
Page 83 15. Leveling counterbalance valve displacement pump 4. Hydraulic oil tank 10. Telescoping counterbalance 16. Piston accumulator valve 5. High-pressure filter 11. Luffing control valve 6. Slewing buffering valve 12. Luffing control valve AB22EJ Plus Maintenance Manual 6-13 © Nov. 2022...
Page 84: Function Valves
Figure 6-16 Boom function manifolds (PN.202040003308) Table 6-5 Boom function manifolds (PN.202040003308) NAME TORQUE FUNCTION 40–45Nm (30–33ft-lb) Keep fluid flowing in one way Check valve Proportional 60Nm (44ft-lb) Control the speed of main boom extending/retracting 2–1 valve © Nov. 2022 6-14 AB22EJ Plus Maintenance Manual...
Page 85 15–2 Control the retraction of main boom valve 30Nm (22ft-lb) Maintain the stability of leveling movement Flow valve 14Nm (10ft-lb) Coil 14Nm (10ft-lb) Coil Choke plug 11–12Nm (8–9ft-lb) Choke plug 25–28Nm (18–21ft-lb) AB22EJ Plus Maintenance Manual 6-15 © Nov. 2022...
Page 86 67.8Nm (50ft-lb) Keep fluid flowing in one way Check valve Figure 6-17 Oscillating counterbalance valve (PN.202040003032) Table 6-6 Oscillating counterbalance valve (PN.202040003032) TORQUE NAME FUNCTION Counterbalance 40～45Nm (30～33ft-lb) Maintain balanced load valve © Nov. 2022 6-16 AB22EJ Plus Maintenance Manual...
Page 87 REPAIR PROCEDURES Figure 6-18 Slewing buffering valve (PN.202040003061) Table 6-7 Slewing buffering valve (PN.202040003061) TORQUE NAME FUNCTION Counterbalance 40～45Nm (30～33ft-lb) Maintain balanced load valve Shuttle valve Switch oil lines AB22EJ Plus Maintenance Manual 6-17 © Nov. 2022...
Page 88 33.9Nm (25ft-lb) Control the flow of oil pipes Flow valve 40Nm (30ft-lb) Control oscillating operation Solenoid valve 12～15Nm (9～11ft-lb) Shuttle valve Switch oil lines Damper 5Nm (9ft-lb) Damper 5Nm (9ft-lb) © Nov. 2022 6-18 AB22EJ Plus Maintenance Manual...
Page 89 45～50Nm (33～37ft-lb) Keep fluid flowing in one way controlled valve Figure 6-20 Leveling counterbalance valve (PN.202040000011) Table 6-9 Leveling counterbalance valve (PN.202040000011) TORQUE NAME FUNCTION Counterbalance 70～75Nm (52～55ft-lb) Maintain balanced load valve AB22EJ Plus Maintenance Manual 6-19 © Nov. 2022...
Page 90 TORQUE NAME FUNCTION 40～45Nm (30～33ft-lb) Control the direction of jib boom luffing 1–1 Solenoid valve 40～45Nm (30～33ft-lb) Control the direction of platform rotation 1–2 Solenoid valve Damper 5Nm (9ft-lb) Damper 5Nm (9ft-lb) © Nov. 2022 6-20 AB22EJ Plus Maintenance Manual...
Page 91 Figure 6-22 Telescoping counterbalance valve (PN.202040003016) Table 6-11 Telescoping counterbalance valve (PN.202040003016) NAME TORQUE FUNCTION Counterbalance 45–50Nm (33–37ft-lb) Maintain balanced load valve Counterbalance 45–50Nm (33–37ft-lb) Maintain balanced load valve Choke plug 72–82Nm (51–61ft-lb) AB22EJ Plus Maintenance Manual 6-21 © Nov. 2022...
Page 92 Adjust the speed of lowering caused by dead weight Solenoid valve (33.1～37.1ft-lb) 40Nm (29.5ft-lb) Control lowering caused by dead weight Solenoid valve Choke plug 11–12Nm (8–9ft-lb) Damper 5Nm (9ft-lb) Choke plug 25–28Nm (18–21ft-lb) Figure 6-23 Luffing control valve (PN.202040003309) © Nov. 2022 6-22 AB22EJ Plus Maintenance Manual...
Page 93: Hydraulic Symbols
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 AB22EJ Plus Maintenance Manual 6-23 © Nov. 2022...
Page 94: Hydraulic Schematic Diagram
DT2001 DT2002 DT2008 DT2007 S2014 S2001 S2004 S2002 DT2010 DT2009 DT2025 Hydraulic rotary coupler Multiple directional valve, oscillate float Right front oscillate cylinder Left front oscillate cylinder Figure 6-24 Hydraulic schematic diagram © Nov. 2022 6-24 AB22EJ Plus Maintenance Manual...
Page 95: Electrical System
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 AB22EJ Plus Maintenance Manual 6-25 © Nov. 2022...
Page 96 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 © Nov. 2022 6-26 AB22EJ Plus Maintenance Manual...
Page 97 Main boom relative Main boom relative angle Check the wiring of main boom relative angle angle sensor fault sensor fault sensor AB22EJ Plus Maintenance Manual 6-27 © Nov. 2022...
Page 98 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 6-28 AB22EJ Plus Maintenance Manual...
Page 99 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 AB22EJ Plus Maintenance Manual 6-29 © Nov. 2022...
Page 100 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 6-30 AB22EJ Plus Maintenance Manual...
Page 101 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 AB22EJ Plus Maintenance Manual 6-31 © Nov. 2022...
Page 102 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 6-32 AB22EJ Plus Maintenance Manual...
Page 103 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. AB22EJ Plus Maintenance Manual 6-33 © Nov. 2022...
Page 104 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 6-34 AB22EJ Plus Maintenance Manual...
Page 105 Low voltage at slider end of 0344 pot2 of RL motor controller Low voltage at slider end of 0444 pot2 of RR motor controller AB22EJ Plus Maintenance Manual 6-35 © Nov. 2022...
Page 106 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 6-36 AB22EJ Plus Maintenance Manual...
Page 107 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 AB22EJ Plus Maintenance Manual 6-37 © Nov. 2022...
Page 108 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 6-38 AB22EJ Plus Maintenance Manual...
Page 109 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 AB22EJ Plus Maintenance Manual 6-39 © Nov. 2022...
Page 110 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 6-40 AB22EJ Plus Maintenance Manual...
Page 111 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 AB22EJ Plus Maintenance Manual 6-41 © Nov. 2022...
Page 112 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 6-42 AB22EJ Plus Maintenance Manual...
Page 113: Use And Maintenance Of Battery
Sinoboom after-sales personnel. Use and Maintenance of Battery The battery falls into 3 types: lead acid, lead acid maintenance-free and lithium batteries. The lithium battery and lead acid maintenance-free battery are free of maintenance. AB22EJ Plus Maintenance Manual 6-43 © Nov. 2022...
Page 114 Apply a thin layer of petroleum jelly to the terminals or use terminal protector. 3. Keep the area around the battery clean and dry. Charging © Nov. 2022 6-44 AB22EJ Plus Maintenance Manual...
Page 115 The self-discharge process will accelerate in warmer temperatures. If storing the battery in hot temperatures or during hot weather, monitor the specific gravity or the voltage more frequently (about every 2 - 4 weeks). AB22EJ Plus Maintenance Manual 6-45 © Nov. 2022...
Page 116: Electrical Symbols
θ θ θ 兰棕 θ 黑 Two lines connected Delay relay 17.4787 46.7096 46.8000 34.4087 θ Power-off switch Motor 0000 28.5682 16.0000 28.5682 46.7096 Relay Storage battery 46.8000 © Nov. 2022 6-46 AB22EJ Plus Maintenance Manual + Li...
Page 117 Symbol Description Key switch Warning lamp Preheating wire Valve 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 Horn 28.5682 AB22EJ Plus Maintenance Manual 6-47 © Nov. 2022...
Page 119: Electrical Schematic Diagram
OUT_25 2445 XJ2-13 XJ1-23/24 CGNDS XJ2-6 XJ1-22 XJ2-5 XJ1-13/14 XJ1-3/4 C206A SBE201 C205 C203 XJ1-17/18 XJ1-1/2 C204 XJ1-15/16 XJ1-19/20 XJ1-11/12 XJ1-9/10 CANL4 XJ1-7/8 CANH4 XJ1-5/6 Figure 6-25 Electrical schematic diagram of turntable AB22EJ Plus Maintenance Manual 6-49 © Nov. 2022...
Page 120 DT101 1416 1043 V(C)_IN_60 PWM_OUT_39 1044 V(C)_IN_56 PWM_OUT_40 IN_47 OUT_24 HR102 1404 WS101 IN_48 WS102 OUT_23 IN_49 OUT_26 IN_50 OUT_25 HG101 1056 WL101 SH117 SBE101 Figure 6-26 Electrical schematic diagram of platform © Nov. 2022 6-50 AB22EJ Plus Maintenance Manual...
Page 121: Rexroth Control System
Therefore, qualified personnel who have been professionally personnel who have not been professionally trained trained and authorized by Sinoboom, otherwise the and authorized by Sinoboom cannot disassemble consequences will be at your own risk. their housings, otherwise moisture and dust will enter the internal mechanism and normal operation will not be guaranteed.
Page 122: Home Interface After Booting
ON position, the system will be BOOTING powered on. Turn the ground/platform select switch on the ground controller to the ground control position, pull out the Figure 7-2 Home interface after booting © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 124: Fault Inquiry
后方检测开关折臂降到位开关水平开关折臂升到位开关主臂降到位开关 Home StateMonitor Setting Faults Personnel who have not been professionally trained and authorized by Sinoboom are not allowed to 主页面主页面状态监控状态监控参数设置参数设置故障查询故障查询 modify the options in parameter setting (including Figure 7-8 Password interface...
Page 125 OK button for 3 seconds to complete the calibration (after successful calibration, the corresponding actual value will be changed). AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 126 3s to confirm the setting. The corresponding confirming the setting, the program will implement the restrictions of KCS standard, indicator light will be light up with after and the icon of KCS standard ( ) will be © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 127 Under the D/B mode, the drive function and boom movement can be performed at the same 主页面主页面状态监控状态监控参数设置参数设置故障查询故障查询 Figure 7-14 Machine Parameter Setting (7/ time. 7) interface Note: AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 128: Time Setting
“Machine Info” through the up shift key and down shift key to enter the Machine Information interface. 1. On the Home interface, press the corresponding button of “Setting” to enter the System Setting interface. © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 129 Figure 7-18 System Setting interface 2. Change the selected item through the up shift key, down shift key, left shift key and right shift key, and press the OK button to complete unit setting. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 131: 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 result is “NO”, the machine must be stopped, and then re- inspected after repair is completed, and the box marked “REPAIRED” shall be checked. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 133: Appendix 2: Repair & Inspection Report
B-1 Inspect and Replace Hydraulic Oil Tank Return Filter Element B-2 Inspect Rim, Tire and Fasteners B-3 Check Hydraulic Oil B-4 Inspect Electrical Wiring B-5 Inspect Emergency Lowering B-6 Inspect Air Filter of Hydraulic Tank AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 134 C-2 Inspect Weighing System Checklist D Procedures REPAIRED/ Problem YES/Good NO/Damaged or Items Repaired Description Machine Faulted Machine Machine D-1 Replace Drive Reducer Gear Oil D-2 Replace Slewing Reducer Gear Oil D-3 Replace Hydraulic Oil © Nov. 2022 AB22EJ Plus Maintenance Manual...
Page 135 4. If any item is marked as “NO” based on the inspection result, the machine must be stopped, and then re- inspected after repair is completed, and the box “REPAIRED” should be checked. Select appropriate inspection procedure based on the inspection type. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 137: 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. AB22EJ Plus Maintenance Manual © Nov. 2022...
Page 138 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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