Manual Servicio LGMG AR14JAR16J
Manual Servicio LGMG AR14JAR16J
Manual Servicio LGMG AR14JAR16J
AR14J/AR16J
△
! WARNING
Contents
Foreword ................................................................................................................ VI
Safety Notices .................................................................................................... VIII
Chapter 1 Safety and Environment .............................................................. 1
1.1 Terms and definitions................................................................................... 3
1.2 Compliance ................................................................................................... 3
1.3 Before maintenance .................................................................................... 3
1.4 Workplace requirements ............................................................................. 4
1.5 Safety considerations for maintenance and repair ................................. 4
1.6 Intended use ................................................................................................. 6
1.7 Instructions .................................................................................................... 6
Chapter 2 Product Introduction ............................................................................ 7
2.1 Parameters of machine ............................................................................... 9
2.1.1 Parameters of AR14J (A0014JNDCH20) articulated lifting platform ................ 9
2.1.2 Parameters of AR16J (A0016JNDCH20) articulated lifting platform .............. 13
2.2 Pressure parameters of filters and valves ............................................. 15
2.3 Tightening torque of joints and plugs ...................................................... 16
2.4 Tightening torque of nuts and bolts ......................................................... 18
Chapter 3 Maintenance ....................................................................................... 21
3.1 Platform assembly ..................................................................................... 23
3.1.1 Assembling the file box .......................................................................................... 23
3.1.2 Assembling the foot switch .................................................................................... 23
3.1.3 Assembling the lifting cross bar ............................................................................ 23
3.1.4 Assembling the platform support .......................................................................... 24
3.1.5 Assembling the load cell ........................................................................................ 24
3.1.6 Assembling the swing motor mounting bracket .................................................. 25
3.1.7 Assembling the platform control unit (PCU) ........................................................ 25
3.1.8 Assembling the anti-collision rubber pad ............................................................. 26
3.1.9 Assembling the platform ......................................................................................... 26
3.2 Axle assembly ............................................................................................. 26
3.2.1 Disassembling the front axle assembly ............................................................... 26
3.2.2 Assembling the front axle assembly ..................................................................... 28
3.2.3 Disassembling the rear axle assembly ................................................................ 31
3.2.4 Assembling the rear axle assembly...................................................................... 32
3.2.5 Disassembling the wheel ....................................................................................... 33
3.2.6 Assembling the wheel ............................................................................................. 33
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3.3 Jib assembly ............................................................................................... 34
3.3.1 Disassembling the swing cylinder, the fly jib cylinder and the jib .................... 34
3.3.2 Assembling the swing cylinder, the fly jib cylinder and the jib .......................... 36
3.4 Engine assembly ........................................................................................ 39
3.4.1 Subassembling the engine .................................................................................... 39
3.4.2 Assembling the engine cooling system ................................................................ 42
3.4.3 Assembling the engine fuel pipeline ..................................................................... 43
3.5 Cable carrier assembly ............................................................................. 45
3.5.1 Disassembling the cable carrier ............................................................................ 45
3.5.2 Assembling the cable carrier ................................................................................. 47
3.6 Boom/extension jib assembly .................................................................. 49
3.6.1 Disassembling the boom ........................................................................................ 49
3.6.2 Assembling the boom assembly ........................................................................... 51
3.6.3 Disassembling the extension jib assembly .......................................................... 52
3.6.4 Assembling the extension jib assembly ............................................................... 53
3.6.5 Assembling the telescopic boom assembly ........................................................ 55
3.7 Hydraulic tank/fuel tank ............................................................................. 57
3.7.1 Assembling the hydraulic tank............................................................................... 57
3.7.2 Disassembling the hydraulic tank ......................................................................... 58
3.7.3 Assembling the fuel tank ........................................................................................ 59
3.7.4 Disassembling the fuel tank ................................................................................... 60
3.8 Cylinder assembly...................................................................................... 61
3.8.1 Disassembling the boom luffing cylinder ............................................................. 61
3.8.2 Assembling the boom luffing cylinder .................................................................. 62
3.8.3 Disassembling the boom telescopic cylinder ...................................................... 63
3.8.4 Disassembling the lower leveling cylinder ........................................................... 64
3.8.5 Assembling the lower leveling cylinder ................................................................ 65
3.8.6 Disassembling the upper leveling cylinder .......................................................... 66
3.9 Bleeding cylinder ........................................................................................ 68
3.9.1 Bleeding function pump .......................................................................................... 68
3.9.2 Bleeding slewing motor .......................................................................................... 68
3.9.3 Bleeding walking motor .......................................................................................... 68
3.9.4 Bleeding steering cylinder ...................................................................................... 68
3.9.5 Bleeding folding jib luffing cylinder ....................................................................... 69
3.9.6 Bleeding main boom luffing cylinder and lower leveling cylinder .................... 69
3.9.7 Bleeding main boom telescopic cylinder ............................................................. 70
3.9.8 Bleeding fly jib luffing cylinder and upper leveling cylinder .............................. 70
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3.9.9 Bleeding platform swing cylinder .......................................................................... 71
3.10 Folding jib assembly ................................................................................ 72
3.10.1 Removing folding jib ............................................................................................. 73
3.10.2 Assembling folding jib assembly ......................................................................... 77
3.10.3 Removing folding jib lift cylinder ......................................................................... 79
3.10.4 Assembling folding jib lift cylinder ....................................................................... 80
3.11 Rotary table swing assembly ................................................................. 82
3.11.1 Removing slewing drive assembly ..................................................................... 82
3.11.2 Assembling slewing drive assembly................................................................... 82
3.11.3 Lifting rotary table .................................................................................................. 83
3.12 Other components ................................................................................... 83
3.12.1 Assembling battery ............................................................................................... 83
3.12.2 Assembling tilt sensor........................................................................................... 83
3.12.3 Assembling horn .................................................................................................... 84
3.12.4 Assembling slewing ring grease filler hose ....................................................... 84
3.12.5 Assembling ground control system .................................................................... 85
3.12.6 Assembling hydraulic oil radiator ........................................................................ 86
3.13 Valve group ............................................................................................... 87
3.13.1 Multi-way valve assembly AR16JEDC-5 ........................................................... 87
3.13.2 Platform swing control valve ST4277-AB00 ..................................................... 88
3.13.3 ST5093-AB0C walking control valve group ...................................................... 89
Chapter 4 Maintenance ....................................................................................... 91
4.1 Observing the regulations ......................................................................... 93
4.2 Checking the battery.................................................................................. 93
4.3 Checking the hydraulic filter ..................................................................... 94
4.4 Replacing the air filter of the hydraulic tank .......................................... 96
4.5 Checking the hydraulic oil level ............................................................... 96
4.6 Checking the oil level of the reducer....................................................... 97
4.7 Changing the reducer gear oil ................................................................. 97
4.8 Maintenance of worm-type slewing drive ............................................... 98
4.9 Maintenance of Deutz engine .................................................................. 99
4.9.1 Checking the engine oil level ................................................................................. 99
4.9.2 Changing engine oil and replacing oil filter ....................................................... 100
4.9.3 Checking fuel leaks ............................................................................................... 102
4.9.4 Bleeding or replacing the fuel filter ..................................................................... 102
4.9.5 Checking the air cleaner of the engine .............................................................. 104
4.9.6 Cleaning or replacing the air cleaner ................................................................. 105
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4.9.7 Checking the coolant level ................................................................................... 105
4.9.8 Adding or changing engine coolant .................................................................... 106
4.9.9 Checking the engine belt...................................................................................... 107
4.10 Scheduled maintenance ....................................................................... 108
4.11 Fault diagnosis of engine ...................................................................... 109
Chapter 5 Commissioning ................................................................................. 121
5.1 Safety instructions.................................................................................... 123
5.2 Commissioning process .......................................................................... 124
5.3 Machine inspection .................................................................................. 125
5.4 Basic test ................................................................................................... 126
5.4.1 Start test.................................................................................................................. 126
5.4.2 Basic operation test of ground control unit ........................................................ 128
5.4.3 Basic operation test of platform control system ................................................ 131
5.4.4 Hydraulic oil level test ........................................................................................... 134
5.4.5 Load test (1.1 times rated load) .......................................................................... 135
5.4.6 Travel speed (high speed) test............................................................................ 135
5.4.7 Braking distance test............................................................................................. 136
5.4.8 Drive speed limit test............................................................................................. 136
5.4.9 Braking distance test (at slow speed) ................................................................ 137
5.4.10 Drive enable system test.................................................................................... 137
5.4.11 Tilt sensor test ..................................................................................................... 138
5.4.12 Gradeability test (45%) ....................................................................................... 138
5.4.13 Gradeability test (25%) ....................................................................................... 139
5.4.14 Floating test.......................................................................................................... 139
5.4.15 Operation time test .............................................................................................. 140
5.4.16 Lifting height test ................................................................................................. 142
5.4.17 Load test (1.25 times) ......................................................................................... 143
5.4.18 Rated load calibration ......................................................................................... 143
5.5 Pressure test ............................................................................................. 144
5.5.1 Function valve relief pressure test ...................................................................... 144
Chapter 6 Appendix ............................................................................................ 145
6.1 DTCs of COBO system ........................................................................... 147
6.2 Schematic diagram .................................................................................. 148
6.2.1 AR14J/AR16J hydraulic schematic diagram (Rexroth) ................................... 148
6.2.2 AR14J/AR16J hydraulic schematic diagram (Sant main valve) .................... 149
6.2.3 AR14J/AR16J electrical schematic diagram (Rexroth) ................................... 150
6.2.4 AR14J/AR16J electrical schematic diagram (Sant main valve) ..................... 151
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6.3 Diagram of common hydraulic part symbols ....................................... 152
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Foreword
Thanks for purchasing the product produced by Lingong Group Jinan Heavy Machinery Co., Ltd.
This manual introduces the technical parameters and maintenance & adjustment data of the articulated
lifting platform, and also the troubleshooting and maintenance process for reference by qualified
The information contained in this manual are correct at the time of publication, but due to the
continuous improvement of the structure and performance of our products, the design as well as
operation and maintenance instructions of the product may be subject to change without notice. For the
latest information of the machine or any question about this manual, please consult us. In additions,
readers of this manual are encouraged to feedback the errors and put forward suggestions to Lingong
Group Jinan Heavy Machinery Co., Ltd., which will be carefully considered in the future publication and
This manual is the property of Lingong Group Jinan Heavy Machinery Co., Ltd., and is not allowed to
△
! WARNING
Only the personnel who have professionally trained and qualified are
Incorrect operation, maintenance and repair are dangerous and may lead to
Please load the machine in strict accordance with the rating, otherwise all
The operation instructions and precautions in this manual apply only to the
intended use of the machine. If the machine is used for an operation that is
out of the specification herein but not prohibited, always make sure that this
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Safety Notices
The operator shall understand and abide by the current national and local safety regulations. If such
regulations are not available, the safety instructions in this manual shall prevail.
Most accidents are caused by failure to obey operation and maintenance specifications of the
machine. To avoid unnecessary accident, please read and follow all warnings and precautions in this
manual and on the machine before operation or maintenance. Failure to comply with the instructions and
safety rules in this manual and the corresponding manual on the machine will result in death or serious
injury.
Considering the fact that not all possible hazards are foreseeable, it is impossible for safety notices in
this manual and on the machine to cover all safety precautions. If it is necessary to take steps and
operations not recommended herein, always protect the safety of yourself and others, and keep the
machine from any damage. If the safety of some operations remains uncertain, please consult us or
dealers.
Some operations to the machine require not only basic mechanical, hydraulic and electrical skills, but
also professional skills, tools, lifting equipment and suitable workshop. Considering this, it is strongly
recommended for you to get the machine maintained and repaired in the service center authorized by
The operation and maintenance precautions referred to herein apply only to the intended use of this
machine. If the machine is to be used for other purposes than those listed herein, it is the user or
For the purpose of this manual, the following signal words are applied to identify safety instructions:
△
! DANGER - Indicating any existing dangers that, if not avoided, will cause
serious injury or even death, and also serious machine damage.
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△
! WARNING - Indicating any potential dangers that, if not avoided, may cause
death or serious injury, and also serious machine damage.
△
! CAUTION - Indicating situations that, if not avoided, may cause minor or
moderate injury, and also machine damage or shortened machine service life.
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Administrator: the entity or individual that directly controls the use and application of the lifting platform,
which usually refers to the owner, the renter or the authorized personnel of owner who obtains the
Operator: personnel who has been professionally trained and mastered qualified knowledge and
Qualified personnel: personnel who has recognized academic qualifications, certificates, professional
status or relevant professional knowledge, has been professionally trained and experienced,
and has evidences to prove that he/she has the ability to solve difficulties encountered in related matters,
work or projects.
Safety Bulletin: relevant safety information issued by Lingong Group Jinan Heavy Machinery Co., Ltd.
1.2 Compliance
1. The maintenance is required to be carried out by personnel who have received and qualified in the
2. Immediately mark the machine if it is damaged or faulty, and withdraw it out of service.
1. Read and follow the safety rules and maintenance instructions in the corresponding operation
3. Do not use parts not sold by Lingong Group Jinan Heavy Machinery Co., Ltd.
4. Please read each step thoroughly and follow the instructions, and do not try to perform repair by
6. When lifting or placing loads, pay attention to the potential pinch risk by parts which are moving, freely
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Unless specially specified, the machine shall be able to operate safely under the following conditions:
1. Altitude ≤ 1000m;
3. The machine shall be able to operate normally under the following safe conditions:
4. During normal operation or maintenance, please set up protective devices as the movement of
5. Take measures to prevent the danger caused by parts falling from the platform.
6. During maintenance, please place a satisfactory fire extinguisher in a readily available position.
7. Keep the workplace tidy and clean, so as to avoid dirt entering machine parts and causing damage
thereafter.
8. Make sure that the forklift, crane or other lifting or supporting equipment has a sufficient lifting
9. Do not reuse disposable fasteners (such as cotter pins and lock nuts) during maintenance, as they
11. Please ensure that the workplace is well ventilated and illuminated.
1. Before adjusting and repairing the machine, please take the following preventive measures:
Set all controls in “OFF” position to prevent the operating system from being started by accident;
If possible, lower the platform as much as possible; otherwise, ensure that it will not fall;
Before loosening or removing hydraulic components, release the hydraulic oil pressure in the hydraulic
pipeline;
Maintenance personnel are required to be trained by qualified personnel, and then check and maintain the
3. Replacement of parts
The genuine parts of our company must be used for replacement; otherwise, we have the right to refuse to
4. Service Bulletin
Users should maintain and repair the machine in strict accordance with the Service Bulletin issued by Lingong
1) Shut down the engine and switch off the low-voltage power supply before repair;
2) Ensure that the maintenance personnel has the special operation certificate;
3) Clean up the flammable materials around the welding position, and apply for a welding permit;
1) Do not store the battery which is fully discharged, and charge the battery in time after use.
2) In the process of use, correctly control the charging time according to the actual situation, and determine
3) Prevent exposure to the sun, as a high temperature will increase the internal pressure of the battery and
cause electrolyte loss in the battery, leading to decrease of battery activity and faster aging of polar plate.
4) In the process of use, check the battery for faults on a regular basis. If any problem is found, drive the
vehicle to the sales center or dealer for inspection and repair, so as to prolong the service life of the battery
7. Coolant
When the radiator is hot, do not open the radiator cover for fear of scalding by the boiling coolant. Therefore,
be sure to open the radiator cover after the coolant temperature drops to an acceptable level.
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This machine is only intended for lifting people and their tools and materials to a high-altitude workplace.
1.7 Instructions
Most maintenance processes can only be performed by professionally trained maintenance personnel in a
properly equipped workshop. After troubleshooting, select the appropriate maintenance procedure.
Perform removal to such an extent that the fault can be eliminated by repair. Then perform refitting in the
It is strongly recommended to get the machine maintained and repaired in the service center authorized
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drive
Max. allowed Along the boom 4.5° Front wheel
inclination of steering
chassis Orthogonal to
4.5°
boom
2) Main dimensions
Item Parameter Item Parameter
Overall length (mm) 6766 Track width (mm) 1981.5
Overall width (mm) 2310 Wheelbase (front/rear) (mm) 2059
Overall height (mm) 2170 Min. ground clearance (mm) 360
Dimension of working platform
1830×760 Tire specification 315/55D20
(length × width) (mm)
3) Engine system
Item Parameter Item Parameter
Model Deutz D2.9L4 Number of cylinders 4
In-line, water-cooled,
Type Bore/stroke (mm) 92/110
four-stroke
Rated fuel consumption
Rated power (kW) 36.4 233
(g/kW.h)
Max. torque (N.M)/speed
Rated speed (r/min) 2600 150/1600
(r/min)
Displacement (ml) 2900 Emission standard EU StageⅤ
4) Hydraulic system
Item Parameter
Type Closed
Pump displacement (ml/r) 46
Walking system Max. working pressure
28
(MPa)
Motor displacement (ml/r) 38
Type Open
Functional Pump displacement (ml/r) 18
system Lifting Max. working pressure
22.5
system (MPa)
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Max. working pressure
Slewing 15
(MPa)
system
Motor displacement (ml/r) 160
Steering Max. working pressure
15
system (MPa)
Boom luffing cylinder (mm) Φ90×Φ45-595-1135
Boom telescopic cylinder (mm) Φ50×Φ32-1828-2122
Up-and-down leveling cylinder (mm) Φ75×Φ40-345-645
Folding jib luffing cylinder (mm) Φ63×Φ45-670-924
Fly jib cylinder (mm) Φ55×Φ35-436-789
Steering cylinder (mm) Φ50×Φ30-260-500
Floating cylinder (mm) Φ88.9-96-380
5) Transmission system
Item Parameter
Rated output torque
3500
Walking reducer (Nm)
Speed ratio 57.49:1
Rated output torque
8729
Slewing reducer (Nm)
Speed ratio 86:1
7) Refilling capacity
Item Parameter
Hydraulic oil (L) 130 (in case of oil change)
Engine oil (L) 8.5
Diesel (L) 65
Gearbox oil (L) 0.68L*4
Engine antifreeze (L) 8.5
Note: The type of hydraulic oil or diesel for refilling shall be selected according to the working
environment and temperature:
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Ambient temperature ≥ 4℃: 0# diesel; ambient temperature ≥ -5℃: -10# diesel; ambient temperature
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Fly jib cylinder (mm) Φ55×Φ35-436-789
Steering cylinder (mm) Φ50×Φ30-260-500
Floating cylinder (mm) Φ88.9-96-380
5) Transmission system
Item Parameter
Rated output torque
3500
Walking reducer (Nm)
Speed ratio 57.49:1
Rated output torque
8729
Slewing reducer (Nm)
Speed ratio 86:1
7) Refilling capacity
Item Parameter
Hydraulic oil (L) 130 (in case of oil change)
Engine oil (L) 8.5
Diesel (L) 65
Gearbox oil (L) 0.68L*4
Engine antifreeze (L) 8.5
Note: The type of hydraulic oil or diesel for refilling shall be selected according to the working
environment and temperature:
Ambient temperature ≥ 4℃: 0# diesel; ambient temperature ≥ -5℃: -10# diesel; ambient temperature
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Code Name Pressure (bar)
4120705740 Luffing balance valve A-VBSO-SE30-FC2-PI-PL-38-28-1.4:1 350
4120705322 Telescopic balance valve ST4921-A00B 350
4120704727 Check valve SY-RV-L15-M22*1.5-0.5 350
4120705965 Multi-way valve AR16JEDC-5 270
4120704690 Relief valve block 250
4120704392 6/2 electromagnetic switching valve 250
4120706178 Solenoid valve ST0010-AB0F 250
4120703874 Ball valve Q11F-16P-1'' 16
4120703386 Floating valve DCV20/1-0145 350
4120705600 Floating balance valve 280
4120707095 Platform swing control valve ST4277-AB00 207
4120704705 Jib luffing balance valve 350
Table 2: Pressure parameters of filters
Code Name Pressure
4110001498 Air cleaner G068663 2.5Kpa
4120001428 High-pressure filter KGLB-0080005L 32Mpa
4120001891 Suction filter WU-100*180-J 0.7Mpa
6L M10X1.0 27 22 16 6L G1/8A 22 16 16
8L M12X1.5 37 32 27 8L G1/4A 37 32 32
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22L M28X2.0 190 160 140 22L G3/4A 190 160 140
28L M33X2.0 325 220 235 28L G1A 325 220 210
35L M42X2.0 470 295 380 35L G11/4A 470 315 470
6S M12X1.5 42 37 / 6S G1/4A 42 37 /
8S M14X1.5 53 48 / 8S G1/4A 42 37 /
7/16-20 UN(F) 23 18
1/2-20 UN(F) 28 28
9/16-18 UN(F) 34 34
3/4-16 UN(F) 60 55
7/16-20 UN(F) 20 20
1/2-20 UN(F) 40 40
9/16-18 UN(F) 46 46
3/4-16 UN(F) 80 80
EO-S
7/8-14 UN(F) 135 135
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1-7/8-12 UN(F) 415 415
Note:
1. Table 1 gives the torques for metric-threaded joints and inch-threaded joints, and Table 2 gives
the torques for UN-threaded joints, and for those torques, an error of +10% is allowed;
2. The torque values given in Table 1 and Table 2 are based on the condition that the connected
part is made of steel, and for connected part made of aluminum, the tightening torque equal to 60%
of the corresponding torque in Table 2 and Table 3 shall apply and shall be rounded to the nearest
3. For Parker joints, the torque is to be selected according to the name and specification, and for
For example:
1) GE 28 L M ED OMD A3C: GE for straight-through joint, 28 for pipe diameter, L for normal
pressure, M for metric thread, ED for E-type elastic seal, OMD for no nut sleeve, A3C for
galvanizing; then according to 28L MED, the torque selected from Table 1 is 325N.m
2) GE O 22L R 3/4 OMDA3C: O for F-type O-ring, R for inch thread, and 3/4 for thread
specification G3/4; then according to O 22L R3/4, the torque selected from Table 2 is 160N.m;
3) GE O 20S R OMDCF: S for heavy pressure; then according to O 20S R, the torque selected is
160N.m;
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Note:
2. The torque values given in Table 3 are based on the condition that the connected part is made of steel,
and for connected part made of aluminum, the tightening torque equal to 60% of the corresponding
torque in Table 1 shall apply and shall be rounded to the nearest integer after calculation;
3. For Parker rubber hoses, right-angle joints and tee joints, the torque is to be selected according to the
name and specification, and for ordinary rubber hoses, right-angle joints and tee joints, the torque is to
For example:
1) F481 CACF 2815 16: F481 for crimping form and hose type, CACF for joint type at both ends, CA for
24°conical swivel nut with O-ring, CF for 90°elbow of 24°conical swivel nut with O-ring, and 2815 for
connection specification of joint at both ends of hose. According to this, the torque selected for end 28 is
2) F412 SN CACF 1210 06: SN for heavy pressure hose. According to this, the torque selected for end
3) EW15LOMDA3C: EW for right-angle combined joint. According to 15L, the torque selected from Table
1 is 32N.m.
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Table 4: Tightening torque of ordinary bolts (unit: N.m)
Nominal diameter of bolt, mm
Bolt strength Yield strength,
6 8 10 12 14
grade N/MM2
Tightening torque, N·m
4.6 240 4~5 10~12 20~25 36~45 55~70
5.6 300 5~7 12~15 25~32 45~55 70~90
6.8 480 7~9 17~23 33~45 58~78 93~124
8.8 640 9~12 22~30 45~59 78~104 124~165
10.9 900 13~16 30~36 65~78 110~130 180~210
12.9 1080 16~21 38~51 75~100 131~175 209~278
Nominal diameter of bolt, mm
Bolt strength Yield strength,
16 18 20 22 24
grade N/MM2
Tightening torque, N·m
4.6 240 90~110 120~150 170~210 230~290 300~377
5.6 300 110~140 150~190 210~270 290~350 370~450
6.8 480 145~193 199~264 282~376 384~512 488~650
8.8 640 193~257 264~354 376~502 521~683 651~868
10.9 900 280~330 380~450 540~650 740~880 940~1120
1098~14
12.9 1080 326~434 448~597 635~847 864~1152
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Nominal diameter of bolt, mm
Bolt strength Yield strength,
27 30 33 36 39
grade N/MM2
Tightening torque, N·m
928~123
4.6 240 450~530 540~680 670~880 900~1100
7
1120~140 1160~154
5.6 300 550~700 680~850 825~1100
0 6
969~129 1319~17 1694~22 1559~20
6.8 480 714~952
3 59 59 79
952~126 1293~17 1759~23 2259~30 2923~38
8.8 640
9 23 45 12 98
1400~16 1700~20 2473~32 2800~33 4111~548
10.9 900
50 00 98 50 1
1606~21 2181~29 2968~39 3812~50 4933~65
12.9 1080
42 08 58 82 77
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Chapter 3 Maintenance
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6N.m
1. Platform frame 2. File box 3. Bolt 4. Washer 5.
Tools: Allen wrench M4
Nut
1) Assemble part 2 with part 3/4 (nut end)/5 to 3.1.3 Assembling the lifting cross bar
Note: Pay attention that the simple removal 1. Lifting cross bar 2. U-bolt 3. Rubber hose 4.
process will not be described. Please refer to Nut 5. Washer 6. Nut 7. Lifting side bar
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platform with U-bolts, fix it with parts 5/6, and wrench 1/2-16mm
12±1N.m
1 2 4
3
1. Platform support 2. Bolt 3. Washer 4. Nut 5. 8. Stop block 9. Screw 10. Washer 11. Nut
U-bolt 6. Washer Install part 1 with parts 2/3 (nut end)/4 to part 5
Place part 1 on the subassembling bench, then (one of them), then screw part 7 on part 6, install
hoist the platform frame to the platform support, part 6 to part 1 with the farthest end of part 6
fix it with part 2 (inserting from top to bottom)/3 about 27-29mm from the surface of the load cell,
(for both bolt end and nut end)/4, and then fix tighten part 7 on triangular bracket where the
the platform support and platform frame with load cell is not installed, and assemble parts
Tools: open-end ratchet wrench 16, socket Tightening torque of part 6: 52±5N.m
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Reference tightening torque of part 9: 2) Insert part 4, fix it with part 5 (to be
Tools: open-end wrench 16-18, open-end 1, then add lithium grease 2# until the grease
Socket wrench 1/2-18mm, QSP100N4, S6 assembly, and then assemble part 7 to part 6.
1) Connect the triangular bracket assembly to 3.1.7 Assembling the platform control
52±5N.m
1. Transition support pin 2. Adjusting washer 3.
Tools: open-end ratchet wrench 16
Swing motor mounting bracket 4. Bolt 5. Bolt 6.
Bolt 7. Bolt
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rubber pad
QSP100N4
Tools: 9-piece Allen wrench set/open-end
fly jib, and after the adjustment, apply adhesive O-ring of the removed fitting and/or hose
to parts 4 and pre-tighten them symmetrically assembly must be replaced and then
(do not torque tighten them for the time being), tightened to the specified torque. Please
then apply adhesive to parts 1 and torque refer to hydraulic hose and fitting torque
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Service Manual
them.
bracket under the chassis for the purpose of 9) Remove the floating cylinder carefully.
4) Fix the sling connected to the crane to the fittings connected to the walking motor.
△
! Caution: Risk of crushing. If not Sprayed hydraulic oil can penetrate and
supported, the chassis may fall. burn the skin. Therefore, please loosen
5) Unscrew the wheel nuts and remove the tires. the hydraulic fitting connection very slowly
7) Mark, disconnect and plug the hoses and not spray or eject the oil.
fittings connected to the floating cylinder. 11) Remove the securing fastener of center
△
! WARNING: Risk of personal injury
shaft for connecting the front axle to the chassis,
not spray or eject the oil. supported correctly by the sling, the front
plate 3. Screw
3.2.2 Assembling the front axle
4. Washer 5. O-ring 6. Shaft sleeve
assembly
Tightening torque of part 3: 260±26N.m
1) Lift part 1 to the subassembly tooling, and lift
Tool: QSP420N4/ hexagon head socket
part 2 onto part 1. Then rotate part 2 to adjust
wrench S14
the assembly position so that the illustrated
2) Install the subassembled walking motor onto
motor mounting bolt hole is parallel with the pin
the walking reducer, making the brake oil ports
mounting hole. Next, remove the plug in the
coincident. Then install part 1, and fasten it with
illustrated yellow circle, which is located at
part 2 (coated with sealant) / 3. See the figure
right-hand end of the operator. After the
below:
adjustment, use part 3 (coated with sealant)/ 4
Note: The right steering connecting plate should Tightening torque of part 2: 110±11N.m
be connected to the reducer in the same way. Tool: QSP200N4/ hexagon head socket
wrench S14
1. Walking reducer 2. Left steering connecting bottom (from bottom to top for the lower part),
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Service Manual
adjust its position and fix it with parts 3, 4 and 5. install the rod end of steering cylinder to the
Latch
Note: Wear washers should be installed on both Latch 4. Bolt 5. Washer 6. Rod pin 7. Cotter pin
upper and lower surfaces of the steering Tightening torque of part 4: 52±5N.m
Tightening torque of part 4: 52±5N.m 5) Connect and install the hoses and fittings of
4) Remove the plug of the steering cylinder (part 6) Install part 1 to the front axle, and connect the
1). Note that residual oil in the cylinder will flow two ends to the left and right steering
out during removal, and should be collected with connecting plates. Then install part 2 from top to
an oil collector. Install the steering cylinder rod bottom, install part 3, and fix with part 4.
and install part 2 from top to bottom. Next, fix 1. Steering rod 2. Rod pin 3. Washer 4. Cotter
the pin with part 3/4/5 at the upper part, and pin
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Service Manual
7) Lift the subassembled front axle assembly Tool: QSP100N4/ socket wrench 16
with the lifting rope. Note: The lifting rope should 10) Pull out the floating cylinder, and make the
be laid such that the front axle is horizontal upper opening of the cylinder parallel with the
front axle to make the axes of two connecting 11) As shown (at the part of front axle indicated
holes between the chassis and the front axle in the yellow circle), thread the lower pin (part 1)
8) Thread the front axle connecting pin (part 1) hole of floating cylinder from outside to inside,
through the lower connecting hole of the floating and bring it out of the inside welded plate of
cylinder from outside to inside, and add the front axle; adjust the position of pin, and fasten
adjusting washer (part 2) at the inside welded the floating cylinder to the outside weld surface
plate of front axle until it can be no longer of front axle with parts 2, 3 and 4 tightened to
9) Adjust the position of pin, and fasten part 1 to See the figure below:
figure below:
4. Washer
assembly
△
! CAUTION: Before refitting, the
tightened to the specified torque Sprayed hydraulic oil can penetrate and
. Please refer to hydraulic hose and fitting burn the skin. Therefore, please loosen
2) Unscrew the wheel nuts, but do not remove shaft for connecting the rear axle to the chassis,
them. and knock the pin out with the copper bar, as
supporting.
5) Mark, disconnect and plug the hoses and 7) Move away the front axle slowly with the
△
as shown below:
! Caution: Risk of crushing. If not
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Service Manual
on the reducer, and install the O-ring. After that, 1. O-ring 2. Bolt 3. Washer
press-fit the shaft sleeves at two ends of the pin Tightening torque of part 2: 110±11N.m
mounting hole in the middle of rear axle. Tool: QSP200N4/ socket wrench 19
1. Screw 2. Washer the shaft, adjust the gap between the rear axle
Tightening torque of part 1: 260±26N.m and the chassis with part 2 until the part can no
Tool: QSP400N4/ hexagon head socket longer be added. Install the part from outside to
2) Remove the plug (indicated by the illustrated whole. Afterwards, fasten the part with parts 3, 4
32
Service Manual
them .
3. Bolt 4. Washer
steering axle.
5. Latch
3) Raise the machine by 15 cm, and place a
Tightening torque of part 3: 52±5N.m cushion block under the chassis for the purpose
Note: The left and right tires may not be platform bracket.
mistaken during installation: 3) Mark, disconnect and plug all hydraulic hoses
Forward
Tire pattern
3.3.1 Disassembling the swing cylinder, Sprayed hydraulic oil can penetrate and
the fly jib cylinder and the jib burn the skin. Therefore, please loosen
not spray or eject the oil. 11) Remove the hose/ cable cover from the jib
4) Remove the platform mounting weldment. (upper link) side, and then take off the hose/
the swing cylinder for the purpose of supporting. 12) Attach the sling from the overhead crane to
6) Remove the fastener of dowel pin from the the fly jib.
cylinder mounting shaft at the fly jib cylinder 13) Use a suitable lifting device to support the
barrel end. But do not remove the cylinder fly jib cylinder barrel end.
7) Remove the fasteners of dowel pins at two hoses of the fly jib cylinder. And plug the fittings
ends of the jib link. But do not remove the pin. on the cylinder.
△
! WARNING: Risk of crushing
10) Slide the two jib leveling arms away from the jib may fall during removal of the pivot pin
pivot pin at the boom cylinder rod end. at the barrel end.
35
Service Manual
△
! WARNING: Risk of crushing
1. Lower connecting bracket assembly 2. Lower
If not properly supported by the crane, the
link 3. Upper link 4. Upper connector assembly
jib may fall due to loss of balance during
2) Connect the upper/lower connector assembly
removal from the machine.
to the upper link with part 1, and then fix them
18) Attach the sling from the overhead crane to
with part 2/3/4/5, as shown below:
the lifting lug at the fly jib cylinder rod end.
△
! WARNING: Risk of crushing
1. Shaft 2. Latch 3. Bolt 4. Washer 5. Nut
If not properly supported by the crane, the
Tool: Open-end ratchet wrench 16
jib may fall due to loss of balance during
3) Install the cushion block, use part 1/2 to
removal from the machine.
install part 3/4 to the assembly position at front
3.3.2 Assembling the swing cylinder, end of upper link, and tighten the bolt, as shown
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Service Manual
lower link with the shaft (part 1), and fix them
1. Cushion block 2. Bolt 3. Washer
with part 2/3/4/5. Similarly, connect the lower
Reference tightening torque of part 3:
link to the upper connecting bracket assembly
12±1N.m
with part 1/2/3 (coated with sealant)/ 4/5,
Tool: Open-end ratchet wrench 13
connect the cylinder base to the upper link with
4) Install the balance valve (part 2) onto the fly
part 6, and fix them with part 2/4/5/7 (coated
jib cylinder (part 1), and fasten it with the bolt
with sealant). See the figure below:
(part 4). Then remove the attached plugs at
below:
1. Shaft 2. Latch 3. Bolt 4. Washer 5. Nut 6.
Shaft 7. Bolt
wrenches 16-18
1. Fly jib cylinder 2. Jib luffing balance valve 3. assembly with part 2 (coated with sealant)/ 3/4,
wrench 16-1
wrench 3/4-24
Platform
control
connecting wire
7) Lift the subassembled jib to the mounting
Inner Oute
r
position of telescopic boom, and connect the
Oil pipe
telescopic boom to the lower connector
12±1N.m
13
1. Shaft 2. Latch 3. Bolt 4. Washer 5. Nut 6. wire and the fly jib valve block pipe at the
8) Install part 2/3 (coated with sealant)/ 4/5 for pipe at the fly jib with part 1/2/3, as shown
38
Service Manual
11) Install the guard plate onto the fly jib upper
torque.
looseness.
around them at the point 100 mm from the pipe
cover 5. Screw
figure below:
wrench 1/2-16mm, QSP100N4
, QSP25N4
39
Service Manual
Nut 5. Bolt
1. Rear outrigger 2. Bolt 3. Washer
Tightening torque of part 2: 52±5N.m
Tightening torque of part 2: 90±9N.m
Tightening torque of part 5: 32±3N.m
Tools: QSP100N4, socket wrench 21
Tools: QSP100N4, open-end wrench 16,
4) Install part 1/3 on the right front side of
QSP50N3, socket wrench 16/18
engine with part 4/5, and install part 2 on the left
6) Fix part 1 onto the engine with part 2 and
front side of engine with part 4/5.
fasten part 1 with part 3/4/5/6;
Washer
clamp
41
Service Manual
steel pipe mounting bracket 8. Bolt 9. Washer 1. Radiator flitch weldment 2. Bolt 3. Washer 4.
42
Service Manual
part 5.
1. Engine water outlet pipe 2. Engine vent pipe Tightening torque of part 6: 6±1N.m
3. Engine makeup water pipe 4. Engine water Tightening torque of part 2: 28±3N.m
inlet pipe 5. Hose clamp 6. Hose clamp 7. Tools: QSP100N4, QSP50N3, socket wrench
Reference tightening torque of part 5/7: 3) Install part 1 onto the engine tray with part
5-5.5N.m; 2/3/4.
Reference tightening torque of part 6: 4) Fix part 5 onto part 1 with part 6/7/8.
43
Service Manual
part 2.
Bolt 7. Washer
bent wrench with straight shank Tools: QSP100N4, socket wrench 8/22, bent
9) Connect one end of part 1 to the water wrench with straight shank
separator outlet, and fix it with part 5/6. Connect 3.5 Cable carrier assembly
the other end to the EFP inlet, and fix it with part
3.5.1 Disassembling the cable carrier
4.
and fix it with part 4. Connect the other end to removed fitting and/or hose assembly
the secondary filter inlet, and fix it with part 5/6. must be replaced. During installation, all
11) Connect one end of part 3 to the secondary connections must be tightened to
filter outlet, and fix it with part 5/6. Then connect specified torque. Please refer to the
the other end to the engine fuel inlet, and fix it specification for selection of tightening
onto the quick connector with part 4. Avoid torque of the lifting platform.
interference with engine edges through 1) Determine the position of cable from the
control unit.
control unit.
Washer
4) Remove the hose clamp on the boom head
5) Pull out all cable harnesses from the cable 9) Lift the boom to a horizontal position.
carrier. Do not pull out the hydraulic hose. 10) Place the cushion block between the upper
6) Mark, disconnect and plug the hydraulic and lower cable carriers, and fix the moving
hoses on ports V1 and V2 of the balance valve parts of upper and lower rails.
△
! WARNING: Risk of personal injury cable carriers may become unbalanced
Sprayed hydraulic oil can penetrate and and fall during removal from the machine.
burn the skin. Therefore, please loosen 11) Attach a sling from an overhead crane with
the hydraulic fitting connection very slowly the lifting capacity of 5 t/5,000 kg to the platform
to reduce the oil pressure gradually. Do end of the boom for purpose of supporting. But
7) Mark, disconnect and plug the hydraulic 12) Remove all hoses and harness clamps from
hoses on the fly jib/ swing cylinder. And cover the underside of the boom.
the hose fitting. 13) Support the rod end of the boom luffing
8) Mark, disconnect and plug the hydraulic cylinder with a suitable lifting device.
hoses on the leveling cylinder. And cover the 14) Remove the latches and other securing
fittings on the cylinder. fasteners from the cylinder mounting shaft at the
△
! WARNING: Risk of personal injury
rod end of the boom luffing cylinder. But do not
cylinder rod end with the copper hammer. crane, the cable carrier may become
△
! WARNING: Risk of crushing
unbalanced and fall.
device, the boom luffing cylinder may If being kinked or squeezed, the cable
17) Lower the rod end of the boom luffing being twisted, the boom cable carrier may
telescopic boom.
22) Remove the mounting fastener of the lower The washer is at the
bolt end
telescopic boom.
△
! WARNING: Risk of crushing 1. Cable carrier support plate 2. Pipe clamp 3.
If not properly connected to the overhead Pipe clamp pressure plate 4. Bolt 5. Washer 6.
47
Service Manual
Reference tightening torque of part 4: to be fixed at both ends of the cable carrier with
Tool: 13mm open-end ratchet wrench then wrap the reserved pipes and harnesses
2) Arrange the oil pipes and harnesses under with 100mm long PVC (PVC ends are wrapped
the support plate, then install clip rubber strips with black insulating tape) for protection, as
(with applied adhesive) at both ends of part 1, shown in the figure below:
m;
48
Service Manual
platform.
1. Screw 2. Washer 3. Nut 4. Pipe clamp 5. Pipe
1) Remove the platform.
clamp pressure plate 6. Bolt 7. Washer 8. Nut
2) Remove the fly jib. Refer to "Disassembling
3.6 Boom/extension jib assembly
the fly jib".
△
! WARNING: Risk of personal injury "Disassembling the cable carrier".
△
! CAUTION: This procedure should △
! CAUTION: Risk of part damage
be implemented when the boom is When lowering the cylinder, make sure
damaged.
△
! CAUTION: The O-ring (if any) of
7) Position the boom speed limit switch on the
the removed fitting and/or hose
49
Service Manual
inner side of the upper pivot. 15) Connect similar lifting equipment to the
mounting fasteners. Do not disconnect the 16) Place the support block under the boom
9) Position the main telescopic boom drive 17) Remove the fastener of dowel pin from the
speed limit switch inside the telescopic boom. boom luffing cylinder mounting shaft. Remove
10) Remove the main telescopic boom drive the pin with a copper hammer.
△
! WARNING: Danger of injury boom spindle.
Sprayed hydraulic oil can penetrate and 20) Remove the boom pivot with a copper
burn the skin. Therefore, please loosen hammer, then carefully remove the boom from
the hydraulic fitting connection very slowly the machine and place it on a structure capable
Note:
middle of the tooling to prevent the
telescopic boom from falling, as shown in ① In this step, it is required to adjust the travel
51
Service Manual
Note:
of the boom telescopic cylinder for support.
① In this step, the travel switch roller faces the 3) Remove the fastener of dowel pin from the
right side;
telescopic cylinder mounting shaft at the spindle
② The bolt passes outward from the travel end of the boom. Knock out the cylinder
③ In this step, it is required to use the packing from the platform end of the boom and mark its
switch.
Note: Pay attention to the position and quantity
3±0.3 N.m;
cushion block.
Tools: open-end wrench 8-10 5) Make sure the support is secure and pull the
52
Service Manual
△
! WARNING: Risk of crushing
to achieve proper balance.
If the support is improper, the boom may 3.6.4 Assembling the extension jib
inner telescopic boom is removed from 1) Lift the extension jib (part 1) onto the
Assembling the
achieve proper balance. bottom slider at
rear end of
△
! WARNING: Risk of crushing
2) Install the sliders (parts 2/3) at the rear end of
If the support is improper, the telescopic the extension jib respectively, as shown in the
② After the slider is installed, measure the Note: Perform visual inspection for confirmation,
outer dimensions of the upper, lower, left rather than touch with hands.
and right sliders, then measure the front 6) Install parts 2/3 at both ends of the shaft (part
Part 1
Part 4/5
The assembled oil
pipe of the upper Part 2 Part 3
leveling cylinder
faces down
① Install the slider in front of the riser, with the rather than touch with hands.
riser protruding from the lower part of the 12) Install parts 2/3 at both ends of the shaft
slider, and the nut and washer on the slider (part 1) respectively;
side;
3.6.5 Assembling the telescopic boom
② Apply 242 threadlock to the bolt end.
assembly
8) Remove the accompanying blind at the fixed
1) Install the rear end of the extension jib
end of the cylinder, and clean impurities such as
assembly from the front end of the boom, as
paint residue on the surface;
shown in the figure:
9) Pull the front end of the cylinder out about
For the
locations of
1500mm; the slider
and bolt,
Part 2
55
Service Manual
Note:
Part
2/3
○1 After the slider is installed, check
the gap between the slider and the
The gap between the sliders on 1. Cylinder pressure plate 2. Bolt 3. Washer
both sides and the telescopic boom Note: Do not pry the rear end face of the
shall be ≤ 1mm, otherwise washers telescopic cylinder directly with hard objects.
○2 After adjustment according to the assembly: install the straight fitting (part 2) onto
gap requirements, apply 242 the telescopic balance valve (part 1), as shown
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Service Manual
5) Install the telescopic balance valve assembly 1. Air cleaner 2. Hydraulic tank weldment
onto the fixed end of the telescopic cylinder with 3. Oil return filter element assembly 4.
3.7 Hydraulic tank/fuel tank 3) Install the oil suction filter together with the
flange assembly
57
Service Manual
Tightening torque of part 4: 12±1N.m; parts 2/4 (indicated by the red box in the figure).
SP160N*41
△
! Risk of part damage. The working
58
Service Manual
(1) Close the two hydraulic ball valves on the securing fasteners of the hydraulic tank.
△
! CAUTION: Risk of part damage. The
machine.
of the hydraulic tank is closed, otherwise properly supported and fixed on the lifting
parts may be damaged. If the valve is equipment during removal from the
closed, remove the key from the key machine, the hydraulic tank may become
△
! WARNING: Risk of personal injury.
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Service Manual
(2) Remove the fuel filler cap from the fuel tank.
container.
1. Bolt 2. Washer
Tools: QSP100N4/ socket wrench 16, fire When delivering fuel, connect a
the oil inlet and return ports at the rear end of Note: Ensure that only manual pumps suitable
the fuel tank, and tighten the bolts. for gasoline and/or diesel are used.
△
! WARNING: Risk of explosion and (5) Support the fuel tank and fix it to appropriate
this procedure in an open, well-ventilated (6) Remove the fuel tank from the machine.
area away from heaters, sparks, flames, Note: Before installation, please clean the fuel
and fireworks. Acceptable fire tank and check for cracks and other damage.
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Service Manual
△
! WARNING: Danger of injury shaft pin of the boom luffing cylinder.
This procedure requires specific 5) Support the rod end and barrel end of the
maintenance skills, lifting equipment and boom luffing cylinder with a second overhead
process without these skills and tools may 6) Mark, disconnect and plug the hydraulic hose
result in death or serious injury, as well as of the boom luffing cylinder. And cover the
△
is strongly recommended that this service
! WARNING
is performed by dealers.
Risk of personal injury. Sprayed hydraulic
△
! CAUTION: The O-ring (if any) of the oil can penetrate and burn the skin.
removed fitting and/or hose assembly Therefore, please loosen the hydraulic
must be replaced. During installation, all fitting connection very slowly to reduce
specification for selection of tightening 7) Remove the fastener of dowel pin from the
torque of the lifting platform. rod end cylinder mounting shaft of the boom
1) Lift the boom to a horizontal position. luffing cylinder. Remove the cylinder mounting
2) Lift the folding jib until the cylinder mounting shaft with a copper hammer.
△
shaft pin at the barrel end of the boom luffing
! WARNING: Risk of crushing
cylinder is higher than the cover.
During removal of the mounting shaft of
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Service Manual
the boom rod end cylinder, the boom will become unbalanced and fall.
damage.
△
! WARNING: Risk of crushing
machine.
in.
△
! WARNING: Risk of crushing 2) Install the fixed end of the cylinder (part 1)
Note: The end of the shaft with latch hole is on maintenance skills, lifting equipment and
3) Fix the shaft with parts 3/4/5, as shown in Fig. process without these skills and tools may
2. Note: After fixation, there shall be no gap result in death or serious injury, as well as
between the inner surface of the latch and the serious component damage. Therefore, it
telescopic cylinder 2) Extend the boom until the pivot at the link end
upper pivot.
valve to prevent movement in case of hydraulic
△
! WARNING: Risk of personal injury fittings on the cylinder.
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Service Manual
cylinder
remove the cylinder pin by turning it outward.
8) Support the telescopic cylinder and pull it out The lower leveling cylinder are in the same
△
and is intended for leveling the work gate. It is a
! WARNING: Risk of crushing
part of the closed-loop hydraulic circuit, which
If the support is improper, the telescopic
keeps the platform level throughout the
cylinder may fall off when it is removed
movement range of the boom. The lower
from the telescopic boom.
leveling cylinder is located on the base of the
△
! CAUTION: Risk of part damage
boom.
a suitable workshop. Carrying out this reduce the oil pressure gradually. Do not
process without these skills and tools may spray or eject the oil.
result in death or serious injury, as well as 3) Connect the overhead crane or similar lifting
is strongly recommended that this service 4) Remove the fastener of dowel pin from the
△
! CAUTION: The O-ring (if any) of
5) Pass a rod through the barrel end pivot, and
contact with the link end and barrel end pivots of If not properly connected to the overhead
the lower leveling cylinder. crane, the lower leveling cylinder may
(2) Mark, disconnect and plug the hydraulic become unbalanced and fall.
△
! WARNING: Risk of personal injury
1) Install the lower leveling cylinder onto the
Sprayed hydraulic oil can penetrate and
upper pivot, as shown in the figure:
burn the skin. Therefore, please loosen
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Service Manual
Fig. 2 Part
4/5/6
Part 3
The latch
end of the
pin is on
this side
Part 1 Part 2
1) Install the shaft sleeve (part 1) in the Coat the latch fixing bolt (part 5) with AT262
the middle plate of the upper pivot, as shown in Tool: QSP100N4/socket wrench 16#
Fig. 1;
3.8.6 Disassembling the upper leveling
2) Install the lower leveling cylinder (part 2) onto
cylinder
the upper pivot, and fix it with part 3;
Note:
Note: ①. Install the telescopic end of the lower
1. Make sure there is no air in the closed
leveling cylinder onto the upper pivot, with the
circuit before removing the cylinder.
oil port of the cylinder barrel facing down without
1) Extend the boom until it can come into cylinder mounting shaft at the rod end of the
contact with the cylinder mounting shaft at the upper leveling cylinder. Do not remove the
2) Lift the boom slightly and place the cushion 6) Remove the fastener of dowel pin on the
block under the platform for support; cylinder mounting shaft at the barrel end of the
3) Lower the boom until the platform rests on swing cylinder. Do not remove the cylinder
Note: Do not concentrate all the weight of the 7) Place a cushion block under the upper
boom on the cushion block. leveling cylinder for support. Protect the cylinder
4) Mark, disconnect and plug the hydraulic hose rod from damage.
of the swing cylinder at the fitting as shown 8) Support the rotating mechanism of the
below, and then connect them together with the platform with suitable lifting equipment;
fitting. Connect the hoses on the cylinder with 9) Knock out the cylinder mounting shaft at the
△
! WARNING: Risk of crushing
cylinder.
△ ! WARNING: Risk of personal injury
burn the skin. Therefore, please loosen If the lifting equipment does not provide
the hydraulic fitting connection very slowly
proper support and causes the slave
to reduce the oil pressure gradually. Do
leveling cylinder to fall, the cylinder may
not spray or eject the oil.
operation.
function pump running at a low speed for 3.9.4 Bleeding steering cylinder
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Service Manual
steps are as follows: operate the machine to retract and extend the
Step 1: Operate the machine so that the piston folding jib luffing cylinder. The folding jib luffing
rod of the steering cylinder moves slowly 5 cylinder can be divided into three parts, as
Step 2: Operate the machine so that the piston rod should count as one cycle. The operation
rod of the steering cylinder moves slowly twice steps are as follows:
in the minimum (C) and maximum (B) stroke Step 1: Operate the machine so that the piston
1. Take care when bleeding the machine, and Step 2: Operate the machine so that the piston
operate the machine gently; rod of the folding jib luffing cylinder moves
3.9.5 Bleeding folding jib luffing 3.9.6 Bleeding main boom luffing
1) Activate the “Rabbit” position to keep the 1) Activate the main boom luffing lifting button to
machine at a high speed; bleed the main boom luffing cylinder and lower
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Service Manual
requirements.
Lower
leveling
Bleeding main boom telescopic cylinder
cylinder
Main
boom
luffing 3.9.8 Bleeding fly jib luffing cylinder
cylinder
3.9.7 Bleeding main boom telescopic the fly jib luffing cylinder and upper leveling
cylinder cylinder;
1) Activate the main boom telescoping button to 2) Taking the fly jib luffing cylinder as the
bleed the main boom telescopic cylinder; reference, it can be divided into three parts, as
2) The main boom luffing cylinder can be shown. Refer to "Bleeding folding jib luffing
divided into three parts by taking the extension cylinder” for the bleeding steps and
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Service Manual
carry out left and right slewing for 1~2 min. The
safety.
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Service Manual
(1) Upper 2nd jib assembly (#1 jib) (6) Folding jib cylinder
(2) Upper 1st jib assembly (#2 jib) (7) Lower 2nd jib assembly (#4 jib)
(3) Lower 1st jib assembly (#3 jib) (8) Rotary table assembly
(4) Middle pivot (9) Upper pivot
(5) Link
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Service Manual
△
! CAUTION: Risk of personal injury Spilled hydraulic oil can penetrate and
This procedure requires specific service burn skin. Release the hydraulic device
skills, lifting equipment and a suitable
slowly to reduce the oil pressure gradually.
workshop. Otherwise, performing this
procedure may lead to death or serious Avoid oil jet or splash.
injury and damage to important parts.
7) Remove the fastener of the center pin from
Therefore, it is strongly recommended
that this service is performed by dealers. the main boom cylinder barrel end.
△
! CAUTION: Before refitting, the 8) Remove the pin with a copper rod and
O-ring of the removed fitting and/or hose remove the main boom luffing cylinder from the
assembly must be replaced and then
machine.
tightened to the specified torque. Please
refer to hydraulic hose and fitting torque
specifications.
△
! WARNING: Risk of squeezing
2) Remove the jib. Refer to 3.3.1 for removing device, the main boom luffing cylinder
5) Fix the crane sling to the main boom luffing Spilled hydraulic oil can penetrate and
cylinder end, and then lift the main boom luffing burn skin. Therefore, please loosen
6) Mark the main boom luffing cylinder, reduce the oil pressure gradually. Do not
disconnect and plug the hydraulic hose. Cover spray or eject the oil.
the fittings on the cylinder. 10) Remove the pin securing fasteners at both
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Service Manual
sides of the pin at the connecting rod end and upper pivot for support. Do not lift it.
pivot at the barrel end of the folding jib lift
cylinder. But do not remove the pin. 16) Connect the sling of another overhead
11) Tie the sling from the crane to the crane to the #1 jib midway between the
connecting rod end of the folding jib lift cylinder upper and middle pivots.
for support. Do not apply any lifting force. 17) Remove the pin securing fasteners from the
12) Knock out half of the pivot pin at the middle and upper pivots of the #1 jib. But do not
Lower the barrel end of the folding jib lift cylinder 18) Knock out both pins with a copper hammer.
so that it hangs down. 19) Remove the #1 jib from the machine.
Knock out half of the pivot pin at the rod end with
a copper hammer. △
! WARNING: Risk of crushing
13) Remove the folding jib lift cylinder from the Without proper connection to the
14) Repeat steps 11 to 14 for the other folding loss of balance during removal from the
△
! WARNING: Risk of crushing △
! WARNING: Risk of crushing
Without proper connection to the crane, Without proper support from the overhead
crane, the upper pivot may fall during
the folding jib lift cylinder may fall due to removal of the #1 jib from the machine.
loss of balance during removal from the 20) Connect an overhead crane to the upper
removing the folding jib lift cylinder from 21) Insert a 10×10×28cm block between the #2
the machine, be careful not to damage the jib and the boom. Then lower the folding jib
balance valve at the cylinder barrel end. assembly to the cushion block.
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Service Manual
△
! WARNING: Risk of crushing
to the #2 jib at the upper pivot end.
the top of #2 jib. pivots of #2, #3 and #4 jibs at the middle pivot.
24) Pull all hoses and cables out of the upper Do not remove the pin.
pivot through the middle pivot. Place the 33) Knock out each pin with a copper hammer.
hoses and cables on the ground. Then remove the middle pivot from the folding
△
! WARNING: Risk of part damage
jib assembly.
due to loss of balance during removal crane to the center point of the #4 jib for support.
from the machine.
Do not lift it.
27) Connect the sling from the overhead crane
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Service Manual
△
! WARNING: Risk of crushing
△
! DANGER: Risk of explosion and fire
Without proper support from the overhead
crane, the #2 jib may fall during removal Fuel is flammable. Operate in an open,
of the link from the #2 jib. well-ventilated area, and always keep
△
! WARNING: Risk of crushing away from heaters, sparks, flames and
Without proper support, the link may fall ignited smoke. Acceptable fire
during removal from the boom assembly.
extinguishers should be provided in easily
40) Remove the #2 jib from the machine.
accessible places.
△
! WARNING: Risk of crushing
Without proper support from the overhead △
! DANGER: Risk of explosion and fire
crane, the #2 jib may fall due to loss of When delivering fuel, connect a ground
balance during removal from the folding wire between the machine and the pump
jib assembly. or container.
41) Remove upper and lower hose and cable CAUTION: Ensure that only a manual
pump suitable for diesel is used.
connectors from the #3 jib.
46) Mark, disconnect and plug the fuel hose of
42) Pull off all cables and hoses from #3 jib and
the fuel tank. Clean up any spilled fuel.
place them on the rotary table
47) Remove the fuel tank mounting fasteners.
counterweight.
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Service Manual
Carefully remove the fuel tank from the 54) Remove the #3 jib from the machine.
machine.
△
! WARNING: Risk of crushing
△
! CAUTION: Risk of part damage Without proper support from the crane, the #3
jib may fall due to loss of balance during
CAUTION: Risk of part damage. The fuel
removal from the machine.
tank may be damaged if it falls. Before
installation on the machine, clean the fuel 55) Remove upper and lower hose and cable
tank and check for cracks and other covers from the #3 jib.
damage.
56) Remove the mounting fasteners of folding
48) Remove the securing fasteners from the
jib drive speed limit switch from the #4 jib at the
ground control unit and main boom function
middle shaft end. Do not disconnect the wire.
valve fixing plate.
57) Remove the pin securing fasteners of rotary
49) Remove the ground control unit and main
table connecting shaft from the #4 jib. Do not
boom function valve fixing plate for easy access
remove the pin.
to the #3 jib pivot.
58) Connect the sling from the overhead crane
50) Connect the sling from the overhead crane
to the center point of the #4 jib. Do not lift it.
to the center point of the #3 jib for support. Do
59) Remove the #4 jib from the rotary table
not lift it.
riser with a copper rod through the ground
51) Remove the mounting fasteners from the
control unit side partition.
hood cover to get access to the pin fasteners for
60) Remove the #4 jib from the machine.
the pivots of #3 and #4 jibs at the rotary table
riser. △
! WARNING: Risk of crushing
52) Remove pin securing fasteners from the #3 Without proper support from the crane, the #4
jib may fall due to loss of balance during
jib of rotary table riser. Do not remove the pin. removal from the machine.
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Service Manual
in Fig. 2;
2) Use slings to tie the upper 1st jib assembly that the shaft holes at the rear ends of the lower
together with the lower 1st jib assembly, and tie 1st jib assembly and lower 2nd jib assembly are
the lower 1st jib assembly together with the
lower 2nd jib assembly, as shown by the red coaxial with the rotary table mounting holes, and
circles in Fig. 3; fix them with the shafts (part 1); fix part 1 with
Fig. 3
parts 2/3 (glued)/4.
of the leveling cylinder mounting plate. Pass the 1. Shaft 2. Latch 3. Bolt 4. Washer
sling above the cylinder, as shown in Fig. 1; Tightening torque of part 3: 90±9N.m;
4) The front lifting point of boom is in front of the Tools: QSP100N4/open-end ratchet wrench
△
! WARNING: Risk of personal injury
Sprayed hydraulic oil can penetrate and
burn the skin. Therefore, please loosen
hydraulic connectors very slowly to
1. Canvas reduce the oil pressure gradually. Do not
spray or eject the oil.
3.10.3 Removing folding jib lift cylinder
4) Remove the fasteners of the pins at the
In the structure of folding jib assembly,
there are two folding jib lift cylinders. The two connecting rod end and barrel end of the folding
cylinders work in parallel and extend and retract
jib cylinder. But do not remove the pin.
by hydraulic pressure. Each folding jib lift
cylinder is equipped with a balance valve to 5) Connect the sling from the overhead crane to
prevent movement in the event of a hydraulic
the connecting rod end of the folding jib lift
pipe failure.
cylinder for support. Do not apply any lifting
△
! WARNING: Risk of personal injury
force.
Removal requires specific maintenance
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Service Manual
hangs down.
Lower
7) Knock out half of the pivot pin at the rod end
2nd jib
assembly
with a copper hammer. Part 1
Parts 2, 3, 4
8) Remove the folding jib lift cylinder from the
1. Folding jib lift cylinder 2. Shaft 3. Bolt 4. Nut
machine. 2) Pass the shaft (part 2) through the lower
mounting seat of left cylinder, and fix it with
△
! WARNING: Risk of crushing parts 3/4 (pass the bolt through it from back to
Without proper connection to the overhead front);
crane, the folding jib lift cylinder may fall due to 3) Pass the lower shaft of left cylinder into the
loss of balance during removal from the
machine. front shaft hole of lower 2nd jib assembly, adjust
△
! CAUTION: Risk of part damage
the position of the upper hole of left cylinder, fix
shaft in;
Right
Left side side
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Service Manual
platform.
mounting fasteners.
△
! WARNING: Risk of personal injury 9) Carefully remove the slewing drive assembly
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Service Manual
(glued) and 3.
1. Bolt 2. Washer
3/4/5.
Tightening torque of part 3: 28±3N.m right side of the rotary table, install parts
Tools: QSP50N3/ socket wrench 13, 3/4/5/6/7 to the mounting position on the
Note: The removal is carried out in reverse connect the hose to the bulkhead fitting.
order of assembly, and just corresponding
fasteners need to be removed, which is not Tightening torque of part 2: 22±2N.m
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Service Manual
2) Fill the grease into the grease filler hose with Tightening torque of part 2: 28±3N.m
the grease filling machine until the grease Tool: QSP50N3/ socket wrench 13
overflows from the oil bowl slightly. 2) Assemble part 1 to the ground control unit
Note: The removal is carried out in reverse bracket weldment on the right side of the rotary
order of assembly, and just corresponding table, and fix it with parts 2/3:
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Service Manual
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Service Manual
3 Coil /
4 Sandwich plate relief Secondary relief valve to
valve protect oil cylinder
5 Hexagon socket screw /
6 Slewing valve For slewing
7 Sandwich plate relief Secondary relief valve to
valve protect oil cylinder
8 End plate For fixing the valve block
9 Assembling bolts /
10 Platform working valve For leveling, jib flying and
swinging
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Service Manual
Mounting torque
S/N Name Code
(N.M)
Valve block
1 4120001998001 /
ST4277-A000M
Solenoid valve
2 4120001998002 /
SV08-31-0-N-0
3 Coil 4303612 4120001571010 /
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Service Manual
flow
5 Check valve 4120704190002 Unidirectional oil
CVC0.S10.0Y.000 flow
6 Flush valve 4120001571007 Closed system flush
HS50-43-0-P valve
7 Relief valve 4120001571008 Restricting flushing
RVC0.S08.0Y.000 pressure
8 Check valve 4120001490007 Unidirectional oil
STCV08-0-000A flow
9 Solenoid valve 4120001998002 2-speed, braking
SV08-31-0-N-0
10 Damper 4120001159010 Restricting flow rate
STTY002-0.6
11 Plug 4BN-02WD 4129900116002 Plug
12 Plug 4BN-04WD 4190001419 Plug
13 Plug 4BN-06WD 4120001493 Plug
14 Coil 4303612 4120001571010 Coil
15 Plug 4BN-08WD 4120001371 Plug
16 Damper 4120704576001 Restricting flow rate
STTY002-2.5
17 Plug CP10-20-N 4120704576002 Plug
18 Shuttle valve 4120704189010 Shuttle valve
7120012
19 Pressure reducing 4120704543006 Restricting float
valve pressure
PR10-32A-0-N-8/M35
20 Damper 4120704053013 Restricting flow rate
STTY002-2.0
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Service Manual
Chapter 4 Maintenance
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Service Manual
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Service Manual
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Service Manual
Check if the electrolyte leaks, and if the conduct further inspection of the battery.
be used.
Hydrometer Meaning and measures to protect the battery terminals and cables
White Lack of electrolyte; please shut 4.3 Checking the hydraulic filter
down the machine to stop using it The hydraulic filter shall be checked or replaced
△
! Risk of personal injury. Be careful of
③ Pull out the filter element and replace it
7) Check that the filter cover and relevant inspector can determine the hydraulic oil level
components are free of leakage. change which indicates that the hydraulic
hydraulic tank
△
! If the hydraulic oil isn’t changed
The air filter of the hydraulic tank shall be
during inspection in two years, it shall be
replaced once very 500h or every day. In a
checked on a quarterly basis. The
dusty working environment, it is required to
hydraulic oil shall be changed if any
increase the number of times for implementation
nonconformity is found during inspection.
of this step.
1) Make sure that the arm rod is retracted,
△
! This step shall be implemented when and then perform a visual inspection of the
1) Remove the filter element. Result: The hydraulic oil level shall be
2) Wipe the internal part and rear cover of the 20mm above and below the middle position of
Install a new air filter element. 2) Add the oil as needed, and do not add
4.5 Checking the hydraulic oil too much. See the table below for hydraulic oil
level grades.
Temperature Model
at an improper level, the hydraulic components Minimum temperature ≤ 10# aviation hydraulic oil
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Service Manual
4.6 Checking the oil level of the 4.7 Changing the reducer gear oil
This procedure shall be implemented every upon operation for 50h, thereafter reducer gear
If the oil level of the reducer is incorrect, the It is essential to change the reducer gear oil to
performance of the machine will be deteriorated, achieve superior performance and long service
and the parts will be damaged after continuous life of the equipment. If the reducer gear oil isn’t
oil temperature
Position 3 Position 2 Position 3
lubrication.
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Service Manual
Lubrication frequency: Every 3 1. Oil dipstick 2. Oil drain plug 3. Oil filter 4. Oil
first.
△
! No working on a running engine! No
every 1000h whichever comes first. provisions and local regulations. Dispose
drip to the ground. Add the engine oil until it reaches the MAX
△
! Perform a trial run after each
mark if necessary.
operation. Meanwhile, pay attention to the 4.9.2 Changing engine oil and
after 5 minutes, check the oil level. If the engine attention to the cleanliness of the outer
is cold, check the oil level immediately. surface. Carefully clean all areas involved.
△
! Please abide by the oil safety
1) Insert the oil dipstick, and wipe it with a drip to the ground.
months. After 50h of first use, the engine oil 7) Add oil at the oil filler.
shall be changed and the filter shall be replaced. 8) Warm up the engine (oil temperature > 80°C).
-10°C, the oil temperature is below 60°C, or the 10) After the oil is added, wait for more than 5
sulfur content in diesel is within 0.5%-1%, the oil minutes, check the oil level, and add oil if
reach the change cycle in one year, the oil shall Replacing the oil filter
△
! Risk of burns: Be careful of high
burns.
△
! Perform this function after the engine
temperature.
1. Oil filter 2. Oil drain plug
Changing engine oil
Every time the oil is changed, the oil filter
1) Warm up the engine (oil temperature > 80°C).
element shall be replaced.
2) Place the engine horizontally.
5) Unscrew the oil drain plug to drain the old oil. 1) If a torsion stop is installed, remove the
6) Install a new seal ring on the oil drain plug, clamp (optional).
screw the oil drain plug in and tighten it. 2) Loosen and unscrew the filter element using
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Service Manual
3) Collect the discharged engine oil. heaters, sparks, flames, and burning
4) Clean the sealing surface of the filter tobacco. A conforming fire extinguisher
new filter.
△
! Explosion and fire hazard. If a fuel
6) Screw in the new filter by hand until the seal
leak is found, irrelevant personnel shall be
ring fits, and then tighten it fully.
prevented from entering the area and
7) Secure the clamp of torsion stop (optional).
operation on the equipment is prohibited.
△
! Engine must be shut down! No 4.9.4 Bleeding or replacing the fuel
△
! Explosion and fire hazard. Fuel is
Dry the wet parts with compressed air.
machine. This step shall be performed in fuel and relevant local laws and
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Service Manual
ground.
△
! After the operation on the fuel
conduct a trial run and check the 1. Fuel inlet of pump 2. Bleed bolt 3. Electrical
Replace the filter every 500h, or more frequent Filter element 6. Fuel inlet of fuel tank
in case of extremely dirty working environment. Bleeding the primary fuel filter
△
! Risk of explosion and fire. Fuel is
Shut down the engine.
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Service Manual
5. Loosen the drain plug and drain the liquid. 5. Repeat this process at least 2 times until the
slightly with fuel and install the filter element the engine is shut down.
1. The fuel system is bled by the electric fuel 2) Check the maintenance indicator (if any) of
2. To ensure that no error message is sent, do indicator turns red, clean or replace the air
Perform the bleeding operation as follows: 3) Clean the air cleaner every 250h or quarterly,
1. Turn on the ignition switch. and replace the air cleaner every 1000h or
2. After the electronic fuel pump is turned on, when it is damaged. In a dusty working
run it for 20 seconds so that the fuel system is environment, it is required to increase the
bled completely and necessary fuel pressure is number of times for implementation of this step.
built.
(3).
1. Inner element 2. Outer element 3. Positioning Check the coolant level every 8 hours or
plate everyday.
△
! Never clean the inner element (1). 1) Carefully open the cover of the cooling
2) The coolant level should always be between 4) Reconnect and tighten the coolant port.
the Min. and Max. marks! Add the engine oil 5) Close the cooler cover.
△
! High temperature coolant can cause the maximum, so as to fill the heater circuit and
The cooling system is under pressure! The 4) Close the cooler cover.
cover can only be opened when it is cooled. 5) When the engine is still hot, start it to the
concentration specified for the cooling system! 6) Shut down the engine.
Please observe safety regulations on coolant 7) Check the coolant level when the engine
and relevant local laws and regulations. cools down, and add coolant to the Max. mark if
regulations and do not spill it on the ground. If the coolant reduces rapidly,
Never run the engine without coolant, even for 1) Check whether there is dust and dirt
a very short time. between the radiator fins and the radiator
1) Carefully open the cooler cover. 2) Check the fan belt tension.
2) Position the container under the coolant 3) Check the radiator water pipe for scale.
port.
△
! Work on the pulley only when the in the mounting hole. Then handle the slack
or the V-belt is damaged, it shall always 2) First remove the V-belt from the smallest
△
! Be careful of high temperature 3) Install a new V-belt.
1) Visually check all pulleys for damage. 5) Tension the V-belt by the tensioner and the
one.
Bolt 2: 30 Nm
Bolt 3 M8: 30 Nm
Bolt 3 M10: 42 Nm
machine.
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Service Manual
Engine fails to be The battery is damaged or not charged Check the battery
started or starting The starter cable connector is loose or oxidized Check the cable connector
is damaged Check/replace
Engine fails to be The EMS prevents starting Check the error according to the DTC
indicator flashes
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Service Manual
Engine speed changes The EMS detects a system error and activates the Check the error according to the DTC
indicator lights up
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Service Manual
The turbocharger air pipe is not tightly sealed Check the turbocharger air pipe
is damaged Check/replace
is damaged Check/replace
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Service Manual
The turbocharger air pipe is not tightly sealed Check the turbocharger air pipe
Insufficient engine The EMS reduces power Please consult DEUTZ service provider
indicator on
The engine has no oil The oil level is too low Add oil
The engine has no oil The engine is tilted too a great extent Check engine mount / lower the tilt
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Service Manual
pressure is too low Wrong engine oil SAE viscosity grade Change the oil
There is oil in the (< 20-30%) for a long time Check the load factor
The engine emits The air cleaner is dirty / the exhaust turbocharger Check/replace
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Service Manual
The turbocharger air pipe is not tightly sealed Check the turbocharger air pipe
The turbocharger air pipe is not tightly sealed Check the turbocharger air pipe
pipe Clean
Maintenan Quant
Material code Material name Spec. Unit Remarks
ce period ity
5301000007 Gear oil SAE 85W/90 GL-5 Liter 2.72 Walking reducer: 0.68L×4
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Service Manual
Return filter
4120000304 SJXHL-250*10 Piece 1 Hydraulic tank
element
Secondary diesel
4110702802001 04137456 Piece 1 Deutz-D2.9L4
filter
Primary diesel
4110702802002 04130241 Piece 1
filter
5301000007 Gear oil SAE 85W/90 GL-5 Liter 2.72 Walking reducer: 0.68L×4
Return filter
4120000304 SJXHL-250*10 Piece 1 Hydraulic tank
element
Secondary diesel
4110702802001 04137456 Piece 1 Deutz-D2.9L4
filter
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Service Manual
Return filter
4120000304 SJXHL-250*10 Piece 1
element
Hydraulic tank
hydraulic oil)
5301000007 Gear oil SAE 85W/90 GL-5 Liter 2.72 Walking reducer: 0.68L×4
△ ! Note: The working hours are based on the engine working time, and the operation cycle is
Maintenance
△ ! Note: The working hours are based on the engine working time.
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Service Manual
Clean the fuel filter of
● ● ● ● ●
fuel tank
Drain deposits from the
● ● ● ● ●
fuel tank
Replace the fine diesel
Every 500h or every six months, whichever comes first.
filter
Replace the primary fuel
Every 500h or every six months, whichever comes first.
filter element
Check the water level in
the water separator, and Daily
drain the water regularly
It can be
Clean or replace the air cleaned for
Clean the air cleaner outer element every 250h or when the indicator alarms,
cleaner outer element at most 5
and it is forbidden to clean the air cleaner inner element
and inner element times
generally.
Check the battery for
Daily
undervoltage
Check if buttons on the
PCU panel operate Daily
normally
Check if the PCU
harness connector is Daily
connected firmly
Check if the PCU
harness connector is Daily
stained
Check if the PCU
harness is extruded or Daily
broken
Check if the
inclinometer is wired Daily
firmly
Check the position of
the rotary table swing
Daily
limit switch rocker arm
Electrical
and if it is wired loosely
system
Check if the solenoid
valve connector of the
Daily
walking pump is loose
and is wired normally
Check if buttons on the
ground control panel Daily
operate normally
Check if the warning
lamp and horn function Daily
normally
Check if the solenoid
valve coils of main valve
Daily
block are wired normally
or loose
Check the starter motor
terminals for looseness, Daily
breakage, etc.
Load cell zero
● ● ● ●
calibration
Check if the battery Daily
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Service Manual
terminals are loose or
rusted
Check if the system
● ● ● ● ●
pressure is normal
Check if the steering
system pressure is ● ● ● ● ●
normal
Check if the traveling
system pressure is ● ● ● ● ●
normal
Check if the oil pipes
Daily
and joints are loose
Check if the oil cylinder
Daily
leaks oil
Check if the valve
Daily
spools leak oil
Check if the two ball
valves at the suction
Daily
port at the bottom of the
hydraulic tank are open
Check if the walking oil
Daily
pipe fixing clip is loose
Add
hydraulic oil
Hydraulic L-HV32
system Check the oil level in the when the
Daily
hydraulic tank level is
lower than
the M"
position
Replace hydraulic oil Hydraulic
Every 2,000h or every two years, whichever comes first
and suction filter oil L-HV32,
Replacement of the high
Every 500h or every six months, whichever comes first.
pressure filter element
Check the hydraulic
tank vent cap for Daily
leakage
Replace the air cleaner Every 1,000 hours or every year, whichever comes first
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Service Manual
Check the machine
bolts, nuts and other
Daily
fasteners for looseness
or abnormal noise
Check the structural
parts of the machine for
Daily
cracks and if there is
any open weld
Check if the machine
paint for falling off,
Daily
serious rust, corrosion
or oxidation
Check if the slider is
loose and if there is zero
● ●
clearance between the
slider and the arm rod
Lithium-bas
Lubricate the slewing
● ● ● ● ● ed grease
bearing
Lubricatio 3#
n Grease the slewing Lithium-bas
bearing and the gears of ● ● ● ● ● ed grease
the slewing reducer 3#
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Service Manual
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Service Manual
Chapter 5 Commissioning
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Service Manual
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Service Manual
Before commissioning, please make sure and other people are not allowed to operate the
Manual, familiarize yourself with the relevant 5) This machine is not insulated, and does not
safety precautions and basic operating provide protection against electric shock when it
requirements, and be particularly familiar with is in contact with or near wires, power supplies
(five-point), safety shoes, and your body is in Please follow the applicable laws and
3) The machine cannot be operated with the below to maintain a sufficient safety distance
hood open. Before starting the engine, confirm from wires, power supplies, and electrical
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Service Manual
If the machine comes into contact with a live openings or steep slopes, etc.;
wire, stay away from the machine immediately. 10. Do not sit, stand or climb on the protective
Before the power of the wire is cut off, personnel guard of the platform. Stand steadily on the
are forbidden to touch or operate the machine. platform base plate at all times.
6) Do not raise the arm rod when the wind 1 Pick-up inspection
exceeds 12.5m/s after the arm rod is raised, 3 Basic operation test of ground
or gusts. Do not increase the surface area of the 5 Oil level inspection
the wind will reduce the stability of the machine; 7 Folding jib lowering overflow
12 Travel speed test (high speed) water volume, electrical components, etc., as
13 Braking distance test shown in the above figure (left); any problem
color difference;
23 1.25 times load test
be done
25 Clearance inspection
Clearance inspection
control criteria: 4≤A≤5mm 3) Check the gap between the slider and the
arm rod
the sum of the left and right gaps and the sum of
Rear axle gap the upper and lower gaps of the boom
2) Check the gap between the left and right Control criteria: F/G<1mm.
should not be more than 2mm; Gap between the slider and the boom
then the beacon will flash, the screen will light Ground
control system
panel Emergenc
up, and the platform control unit will run; after y stop
Display Key switch
the key switch is turned to the neutral position, Engine start
Enable button
button
the machine will be turned off, and the beacon
Button Engine start
control button
will be turned off, the screen will be off; after the
Enable
button Control criteria: conforming to requirements
Engine start
Button button
control 4) Emergency stop switch
requirements
Control
lever
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Service Manual
With the enable button not held, all arm rods 3) Platform leveling switch
and platform functions should not operate after The platform level will rise if the platform
each boom and platform function toggle switch leveling switch is moved upwards; the platform
With the enable button held, all arm rods and moved downwards.
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Service Manual
Platform leveling
test
Short arm
lifting/lowering test
4) Platform rotary switch 6) First arm rod extension and retraction
rotary switch is moved upwards; the platform The arm rod will extend if the first arm rod
will rotate to the right if the platform rotary switch extension and retraction switch is moved
is moved downwards. leftward; the arm rod will retract if the first arm
rightward.
Platform
rotating test
short arm lift switch is moved downwards. The first arm rod will rise if the first arm rod lift
downwards.
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Service Manual
Rotary table
swing test
First arm rod
lifting/lowering test
8) Second arm rod lift switch
△
! CAUTION:
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Service Manual
ON position; move the auxiliary power switch to 3) Push the red emergency stop
either side, repeat all the above operations until button outward to the “ON” position.
all operations can be achieved. Control criteria: the function control lever or
Note: (1) When testing the auxiliary power button can be operated normally to operate the
test each function in a part of the cycle. 4) Do not press down the foot switch, and test
(2) The drive function shall not work with the control lever or button of each function of the
control system
Platform control
Platform rotary Drive enable button Engine speed selector
system panel Indicator Engine start button
button button
Foot switch
Horn button
Emergency
stop switch
Short arm luffing
button
Emergency lowering
5) Press down the foot switch, and test the
button (auxiliary)
Platform leveling
button
Folding jib
luffing lever
Drive speed selector
button Drive control lever
machine. Control criteria: all arm rods and
to the “OFF” position. Control criteria: all 6) When the emergency stop switch is in the
functions cannot be operated after each "ON” position, press the horn button. Control
function control lever or button of the machine is criteria: The horn sounds.
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Service Manual
The horn stops sounding. leveling switch if the platform leveling switch is
△
! CAUTION:
moved downwards.
the engine, and step on the foot switch. Control criteria: The short arm will rise if the
9) Platform leveling switch short arm lift switch is moved upwards; the short
Control criteria: The platform level will rise if the arm will drop if the short arm lift switch is moved
Rotary table
Short arm swing
lifting/lowering test
12) Control the lifting/lowering of the second
Boom luffing
arm rod via the middle lever.
Left control lever
Second arm rod retract if the first arm rod extension and
lifting/lowering test
retraction switch is moved upwards.
13) Control the rotation of the rotary table via
16) Control the drive travel of the machine via
the left control lever.
the right control lever.
Control criteria: The rotary table will rotate to the
Control criteria: The machine will be driven
right if the left control lever is moved rightward.
forward if the right control lever is moved
The rotary table will rotate to the left if the left
upwards. The machine will be driven backward
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Service Manual
if the right control lever is moved downwards. The machine is on a horizontal plane. Symbol:
control lever, the machine will turn to the right. 5.4.4 Hydraulic oil level test
tests respectively.
stop switch to the “OFF” position, pull open the
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Service Manual
<12.8 S
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Service Manual
Boom lifted
2) When the center of the front wheel of the by
90cm
machine passes the 20m test line, turn off the
1) In the platform control mode, depress the foot Control criteria: 0.8±0.05km/h, i.e. time: 85s<
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Service Manual
1) Follow the travel speed (low speed) test keep the vehicle retracted, and depress the foot
closely; switch; rotate the rotary table until the arm rod
2) When the center of the front wheel of the moves over one non-steered wheel (in both
machine passes the 20m test line, turn off the directions);
power switch and let the machine stop Control criteria: the drive indicator light is on at
Use a tape measure to measure the distance drive control lever away from the center, after
from the 10m line to the center line of the front which the drive function cannot be achieved.
△
! CAUTION:
Rotary table
1. The machine under test shall be kept in rotation
3) Turn and hold the drive enable toggle switch
the no-load state, with the boom retracted;
to one side, and move the drive control lever
2. Pay attention to driving safety.
away from the center slowly, after which the
5.4.10 Drive enable system test drive function can be achieved normally.
△
! CAUTION:
arm rod extension, slewing, leveling and
switch, after which the boom is lifted by about 6) Similarly, use the same method to test the
90cm (or the articulating boom、 is lifted by slope with a 4.5°angle between the chassis and
about 90cm, or the boom is extended by 30cm); the ground for both the front and rear axles.
△
2) Keep the arm rod in a direction consistent
! CAUTION:
with the travel direction, and drive the machine
1. Conduct the test in one of the three
up the slope (below the highest point) in the
states. For other two states, test the tilt
direction of the slope.
indicator light and buzzer under specific
Control criteria: the tilt indicator light does not
conditions;
come on, the buzzer does not sound, and all
2. Expect the test arm rod, the other arm
functions are normal.
rods are retracted;
3) Continue driving to the upper plane of the
3. Pay attention to driving safety.
slope, with an angle between the chassis and
Control criteria: the tilt indicator light stays on, 1) Drive the machine to the front of a 45% slope,
the buzzer sounds, and the functions of lifting, and adjust the machine state, with the platform
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Service Manual
3) Adjust the platform height, and drive the normally, the tires do not slip and the machine
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Service Manual
drive it, so that the left front wheel and the left 40°C. The time will be affected when the oil
Control criteria: the machine tires are not off the (2) Carry out the test for each
Rotary table
rotary switch
timing.
the same time, rotate the rotary table to the lift switch (down) at the same time to lower the
rightmost side, stop the rotary table, and stop boom and start timing simultaneously; when the
Note: (1) The control criterion of operation 5) Press the enable button and the second arm
time test is based on an oil temperature of rod lift switch (up) at the same time to lift the
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Service Manual
Second arm rod arm is lifted to the highest position, stop lifting
lifting/lowering test
7) Press the enable button and the first arm rod and timing.
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Service Manual
short arm and start timing simultaneously; when return each part, and then perform the
timing.
5.4.16 Lifting height test
Control criteria: 20S-35S.
1) Move the machine under test at rated load to
11) Press the enable button and the platform
a level ground in the test area;
rotary switch (up) at the same time, and rotate
2) In the ground control mode, lift the platform to
the platform to the leftmost side; then start the
the highest point, make it horizontal, and
platform rotary switch in the opposite direction,
measure the distance from the ground to the
rotate the platform and start timing
bottom of the platform with a laser range finder;
simultaneously; when the platform is rotated to
Test target value of AR16J: 15.70 ±0.16 (m);
the rightmost side, stop rotating and timing.
Test target value of AR14J: 14.09 ±0.14 (m);
Control criteria: 13S-26S.
3) Instructions for use of the laser range
finder:
△
press the upper left blue (Timer) button of the
! CAUTION:
laser range finder, and press the red (MEAS)
1. The control criterion of operation time
button again for 5s (adjustable). In this case, the
test is based on an oil temperature of
height data is shown on the display screen;
40±5°C. The time will be affected when
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Service Manual
5.4.17 Load test (1.25 times) 4) Lift the platform to the highest point, measure
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Service Manual
2) Use the ground control mode, enter the 4) In case of inconsistency with the target value,
3) Hang the rated load of 230kg at the platform and rotate the valve spool clockwise or
end, and calibrate the rated load. counterclockwise with the Allen wrench to
position.
10 bar.
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Service Manual
Chapter 6 Appendix
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Service Manual
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Service Manual
DTC Description
1 Open circuit in control unit output power supply 1
2 Open circuit in control unit output power supply 2
3 Open circuit in control unit output power supply 34
4 Platform electric box extension module bus off
5 Carrier electric box display bus off
6 Weighing failure
7 Load cell 1 fault
8 Load cell 2 fault
9 Load cell check failure
10 Load cell 4 fault
11 Left joystick fault
12 Right joystick fault
13 Middle joystick fault
14 Boom luffing travel switch fault
15 Folding jib luffing travel switch fault
16 Boom telescopic travel switch fault
17 Rear detection travel switch fault
101 Chassis tilt
102 Traveling limit function not enabled in drive
103 Basket overload
104 Low oil level alarm
105 Oil pressure alarm
106 Oil temperature alarm
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Service Manual
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Service Manual
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Service Manual
Descriptio Descripti
Symbol Name Symbol
n on
Non-adjusta
Unidirectio ble one-way
One-way nal bounce
fixed cylinder
rotation,
displacem unidirectio Simplifie
ent nal flow, d symbol
hydraulic fixed
pump displacem
ent
Bidirection
Two-way al
fixed rotation,
displacem bidirection Detailed
Hydrau ent symbol
al flow,
lic hydraulic fixed
pump pump displacem Adjustable
ent Double-acti one-way
ng cylinder bounce
Unidirectio
nal cylinder
One-way
variable rotation,
displacem unidirectio Simplifie
ent nal flow, d symbol
hydraulic variable
pump displacem
ent
Bidirection
Two-way al
variable rotation,
displacem bidirection Detailed
ent al flow, symbol
hydraulic variable Non-adjusta
pump displacem ble two-way
ent bounce
cylinder
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Service Manual
One-way
Unidirection
fixed
al flow, Detailed
displaceme
unidirectiona symbol
nt hydraulic
l rotation
motor Adjustabl
e
two-way
Bidirectional
bounce
Two-way flow,
cylinder
fixed bidirectional
Simplified
displaceme rotation,
symbol
nt hydraulic fixed
motor displacemen
t
Hydrauli
c motor Unidirection
One-way al flow,
variable unidirectiona
Telescopi
displaceme l rotation,
c cylinder
nt hydraulic variable
motor displacemen
t
Bidirectional
Two-way flow,
variable bidirectional
One-way
displaceme rotation,
action
nt hydraulic variable
motor displacemen
t Air-liquid
converter
Bidirectional
Continuou
Swing motor swing, fixed
s action
angle
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Service Manual
Unidirection
Fixed al flow,
displaceme unidirection
One-way
nt hydraulic al rotation,
action
pump - fixed
motor displaceme
nt
Pressure
Turbocharg
transduc er
Bidirectiona
er
l flow,
Variable
Pum bidirectional
displaceme
p- rotation, Continuo
nt hydraulic
moto variable us action
pump -
r displaceme
motor
nt, external
oil drain
Unidirection
al rotation,
Hydraulic variable
integrated displaceme Accumulat General
transmissio nt pump, or symbol
n fixed
displaceme
nt motor
Gas
Detailed
isolation
symbol
type
Single
piston
rod
cylinder
Simplifi
Counterwei
ed Accumulat
or ght type
symbol
Single-acti Detailed
ng cylinder Spring type
Single symbol
piston
rod
cylinder
(with
spring
return) Simplifi
ed Auxiliary gas bottle
symbol
Plunger
Gas tank
cylinder
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Service Manual
Gener
Telescop Hydraulic
al
ic pressure
symbo
cylinder source
l
Air Genera
Detailed
sourc l
Single symbol
e symbol
piston
rod
cylinde
r Simplifie Energ
y Motor
d symbol
source
Double-actin
g cylinder
Detailed Prime Except
symbol motor motor
Double
piston
rod
cylinde
r
Simplifie
d symbol
Descriptio Descriptio
Name Symbol Symbol
n n
Internal
Hydraulic
Mechanic pressure
Positionin double pilot
al control control,
g device pressurization
parts internal
control
oil drain
External
air
pressure
*Control control,
Air-liquid pilot
Locking method internal
pressurization
device for hydraulic
control
unlocking pressure
control,
external
oil drain
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Service Manual
External
Electro-hydrau hydraulic
Bouncing
lic pilot pressure
mechanis
pressure control,
m
control internal
oil drain
Internal
pressure
Ejector rod
control,
type
internal oil
Hydraulic drain
pilot
depressuriza External
tion control
pressure
Variable
control
travel control
(with
type
remote
relief outlet)
Electromag
net control,
Electro-hydr external
Spring-contr
Pilot aulic pilot pressure
olled type
Mechani pressu control control,
cal re external oil
control control drain
methods metho
ds With
pressure
Operati
regulating
on in Pilot
spring,
Roller type two pressure
external oil
directio control valve
drain, with
ns
remote
relief outlet
Operati
Pilot level
on in
controlled
only Pilot
by
one proportional
One-way proportiona
directio solenoid
roller type l
n; pressure
electromag
arrows control valve
net, internal
can be
oil drain
omitted
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Service Manual
Electric
al leads
can be
omitted,
Gener Single-acting and the
Manual
al electromagne oblique
control
symbol t line can
also
face the
lower
right
Double-actin
Button g
type electromagne
t
Single-acting
Manual Electric adjustable
control al electromagne
Draw control t
method knob method (proportional
s type s electromagne
t, torque
motor, etc.)
Double-actin
g adjustable
Press-pu
electromagne
ll type
t (torque
motor, etc.)
Electrical
control
Handle
device of
type
rotational
motion
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Service Manual
Position
detection by
potentiomete
Two-way Feedba Electrical
rs,
pedal type ck feedback
differential
control transformers
method , etc.
s
Follower
Pressurizatio Internal
valve
n or mechani
profiling
depressurizat cal
control
ion control feedback
circuit, etc.
Differential
control
Direct
pressu Contr
re ol
control acces
Internal
metho s
pressure
ds inside
control
the
eleme
nt
Contr
ol
acces
External
s
pressure
outsid
control
e the
eleme
nt
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Service Manual
Descripti
Name Symbol Name Symbol Description
on
General Pilot
symbol proportio
or spring nal
Relief valve loaded solenoid
type pressure
relief reducing
valve valve
Proportio
Pressur
nal Pressure
Pilot relief e
pressure reducing ratio:
valve reducin
reducing 1/3
g valve
valve
Constant
Pilot
difference
electromagn (Normall
pressure
etic relief y closed)
reducing
valve
valve
Reli
ef
valv
e
General
Direct-acting symbol or
Sequenc
proportional harmonious-ac
e valve
relief valve ting sequence
valve
Pilot Pilot
proportional Sequen sequence
relief valve ce valve valve
One-way
Unloadin sequence
Unloading
g when valve
relief valve
p2>p1 (balance
valve)
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Service Manual
General
Two-w Direct-acti symbol or
ay ng, Unloading direct-acti
relief external oil valve ng
valve drain unloading
valve
Unloadi
General ng valve
Pilot
Pressu symbol or
electromagn
re direct-actin
etic p1>p2
reducin g pressure
unloading
g valve reducing
valve
valve
Pressu Pilot
re pressur Double
reducin e overflow
g valve reducin brake valve
g valve
Brake
valve
Overflo
w
Overflow oil
pressur
bridge brake
e
valve
reducin
g valve
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Service Manual
Descriptio Descriptio
Name Symbol Name Symbol
n n
Two-position
Detailed
five-way
symbol
hydraulic valve
Check Check
valve valve
Simplified
Two-position
symbol
four-way
(springs
motorized
can be
valve
omitted)
Detailed
symbol
Three-position
(valve
four-way
closed by
solenoid valve
control
pressure)
Simplified
symbol
Three-position
(internal
Simplified four-way
control
symbol electro-hydraul
and
ic valve
Hydrauli Hydraulicall external
c check y controlled leakage)
valve check valve
Detailed
symbol
Three-position
(valve
six-way hand
opened by
valve
control
pressure)
Simplified
symbol Three-position
(springs five-way
can be solenoid valve
omitted)
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Service Manual
Simplifi
ed Three-positio
symbol n five-way
(springs solenoid
can be valve
omitted)
External
control
Double and
hydraulica Three-positio internal
lly n four-way leakage
controlled electro-hydra (with
check ulic valve manual
valve emergenc
y control
device)
Three-positio Throttle
Detailed n four-way type,
symbol proportional overlappe
valve d center
Shuttle
Gate type
valve
Three-positio
Simplifi
n four-way Underlapp
ed
proportional ed center
symbol
valve
Direction
al
control Two-position
Normall valve four-way
y closed proportional
Two-positi valve
on
two-way
solenoid
valve Normall Four-way
y open servo valve
Two-positi
Direction on
al three-way Two stage
control solenoid
valve valve Four-way
electro-hydra
ulic servo
Two-positi Three
valve
on stage with
three-way electrical
solenoid feedback
ball valve
Two-positi
on
four-way
solenoid
valve
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Service Manual
Descripti Descripti
Name Symbol Name Symbol
on on
Flow
Detailed Simplifie
regulating
symbol d symbol
valve
Adjustable
throttle valve
Bypass
Simplifie flow Simplifie
d symbol regulating d symbol
valve
Flow
regulati
ng valve Temperatur
e
Non-adjusta
General compensat Simplifie
ble throttle
symbol ed flow d symbol
valve
regulating
Throttl valve
e
valve
One-way
Throttle flow Simplifie
check valve regulating d symbol
valve
Double Flow
throttle divider
check valve valve
One-way
Globe valve flow divider
valve
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Service Manual
Roller-contr
olled throttle Flow
valve combiner
(deceleratio valve
n valves)
Synchroniz
ation valve
Descript Descripti
Name Symbol Name Symbol
ion on
Descript Descripti
Name Symbol Name Symbol
ion on
General
Filter Air cleaner
symbol
Filter with
contaminati Thermostat
on indicator
Magnetic General
Cooler
filter symbol
Filter Cooler
Filter with Cooler with
bypass coolant
valve pipeline
164
Service Manual
p1: Oil
inlet p2: General
Duplex filter Heater
Oil symbol
return
Descriptio Descriptio
Name Symbol Name Symbol
n n
Flow
Pressure detector
indicator (liquid flow
indicator)
Pressure
gauge Flow Flowmeter
(meter) detect
or
Pressur
e Electric
detecto contact
r pressure
Accumulat
gauge
ed
(pressure
flowmeter
display
controller
)
Differenti
al
pressure Thermometer
control
gauge
Torque meter
165
Service Manual
Descriptio Descriptio
Name Symbol Name Symbol
n n
Pressure relay
(pressure switch)
General General
Sensor
symbol symbol
Senso
r
Detailed Pressure
symbol sensor
Travel switch
General Temperatur
symbol e sensor
Couplin General
g symbol
Couplin
Amplifier
g
Flexible
couplin
g
Descriptio Descripti
Name Symbol Name Symbol
n on
Two
pipelines
Pressure
Crossing crossing
Pipeline line and
pipeline and not
return line
connecte
d
Pipeline Pipeline
Two
pipelines
Connecti intersecti Flexible
ng line ng and line
connecte
d
166
Service Manual
One-way
It can
Control bleeder
indicate a
line (pressure
drain line
tap)
Quick
Single-w
connector
ay rotary
without
connecto
check
r
Quick valve Rotary
connect connect
or Quick or
Three-wa
connector
y rotary
with
connecto
check
r
valve
167
Service Manual
9 Circuit breaker
10 Isolating switch
168
Service Manual
12 Drop-out fuse
13 Fuse-switch
14 Fuse-switch-disconnector
169
Service Manual
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Service Manual
35 Connected brace
36 Umschaltlasche
171
Service Manual
38 Three-winding transformer
39 Autotransformer
Current transformer
41
Pulse transformer
Three-phase transformer
46
Star-delta connection
Three-phase transformer
48
Star-zigzag connection
172
Service Manual
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Service Manual
52 Gas relay
Variable resistor
55
Adjustable resistor
57 Preset potentiometer
Variable capacitor
59
Adjustable capacitor
62 Voltmeter
63 Ammeter
174
Service Manual
66 Varmeter
68 Frequency meter
70 Tachometer
72 Ampere-hour meter
175
Service Manual
74 Var-hour-meter
176
Service Manual
87 Noiseless grounding
88 Protective grounding
89 Equipotential
90 Cable terminal
177
Service Manual
95 Line detector
97 Heat
98 Smoke
99 Explosive gas
178