AB18EJ&18HJ Maintenance Manual

Part No.
503008110002
Rev: A
Maintenance
Oct 2020
Manual
产品说明书
PRODU
CT MANUAL
AB18EJ/AB600EJ
AB18HJ/AB600HJ
GTJZ 0608E (2132E)
GTJZ 0808E (2732E)
GTJZ 0808E (2732E)
GTJZ 0808E (2732E)
Operating, servicing and maintaining this vehicle or
equipment can expose you to chemicals including engine
exhaust, carbon monoxide, phthalates, and lead, which
are known to the State of California to cause cancer and
birth defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the engine
except as necessary, service your vehicle or equipment in
a well-ventilated area and wear gloves or wash your
hands frequently when servicing. For more information
go to: www.P65warnings.ca.gov.
Manual revision history：
REV DATE DESCRIPTION REMARK
A Oct, 2020 Original issue of the manual
Please contact us:

Website : www.sinoboom.com
E-mail : [email protected]
Sales Tel : 0086-0731-87116222

Service Tel : 0086-0731-87116333
Address : No.128, East Jinzhou Avenue, Ningxiang High-tech Industrial Park, Changsha,
Hunan, China
Zip Code : 410600
Copyright © Hunan Sinoboom Intelligent Equipment Co., Ltd. All Rights Reserved
The final interpretation right of this manual belongs to Hunan Sinoboom Intelligent Equipment Co., Ltd.
APPLICATION
Use the following table to identify the specific serial number for
models included in this manual. Check the model of your machine before
consulting the manual, and then use the correct manual according to the
serial number of the model. See the nameplate on your machine to
identify the model and serial number. (See Decals/Nameplates
Inspection of the Operation Manual for details).
Trade Identification
Models Serial No.
Metric Imperial
AB18EJ AB18EJ AB600EJ From 0300800100 to present
AB18HJ AB18HJ AB600HJ From 1200100100 to present
NOTE:
• Product model is applied in product nameplate for distinction of products of different main
parameters.
• Product trade identification is applied in marketing and machine decals for distinction of products of
different main parameters, and can be classified as metric type and imperial type: The metric type of
trade identification is applicable to machines for countries/regions using metric system or as
specially required by customers; The imperial type of trade identification is applicable to the
machines for countries/regions using imperial system or as specially required by customers.
This Page Intentionally Left Blank
STATEMENTS
Hunan Sinoboom Intelligent Equipment Co., Ltd. (Hereinafter referred to as Sinoboom) will upload the
latest product manual information to the website www. sinoboom. com as soon as possible. However,
due to continuous product improvement, the information in this manual is subject to change without prior
notice.
This manual covers the basic parts information of one or more products. Therefore, please use this
manual according to your needs. If you find problems in the manual or have suggestions for improve-
ment, feel free to share your feedback with Sinoboom, and we will address these issues as soon as
possible.
Feel free to consult and download the Operation Manual, Maintenance Manual and Parts Manual of the
products you need online at www.sinoboom.com.
Hunan Sinoboom Intelligent Equipment Co., Ltd. retains the right of final interpretation of the manual.
TABLE OF CONTENTS
Introduction .............................. v Electrical System. . . . . . . . . . . . . . . . . . . . . . 3-1
Electrical System. . . . . . . . . . . . . . . . . . . . . . 3-1
1 Safety ............................... 1-1
Safety Measures . . . . . . . . . . . . . . . . . . . . . . 3-1
Safety Definitions . . . . . . . . . . . . . . . . . . . . . 1-1
Reporting Accidents. . . . . . . . . . . . . . . . . . . 1-1 4 Service and Guidelines......... 4-1
Electrocution Hazards. . . . . . . . . . . . . . . . . 1-1 Machine Preparation, Inspection and
Tipping Hazards and Rated Load . . . . . 1-2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Work Environment Hazards . . . . . . . . . . . 1-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Unsafe Operation Hazards. . . . . . . . . . . . 1-7 Preparation, inspection and
Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 maintenance . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Collision Hazards . . . . . . . . . . . . . . . . . . . . . 1-8 Qualified Sinoboom equipment
Crush Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-9 mechanic . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Explosion and Fire Hazards. . . . . . . . . .1-10 Pre-operation inspection. . . . . . . . . . . . 4-1
Damaged Machine Hazards . . . . . . . . .1-10 Pre-delivery inspection and
Bodily Injury Hazards . . . . . . . . . . . . . . . .1-10 frequent inspection . . . . . . . . . . . . . . . . . 4-1
Battery Hazards . . . . . . . . . . . . . . . . . . . . . .1-10 Annual machine inspection . . . . . . . . . 4-1
Hydraulic Hazards . . . . . . . . . . . . . . . . . . . 1-11 Preventive maintenance . . . . . . . . . . . . 4-2
Welding and Polishing Requirements 1-11 Maintenance and Servicing
After Using the Machine. . . . . . . . . . . . . .1-12 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
2 Specifications .................... 2-1
Safety and workmanship . . . . . . . . . . . 4-3
Performance Parameters . . . . . . . . . . . . . 2-1
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Engine and Motor Specifications . . . . . . 2-6
Component removal and installation4-3
Function Speed . . . . . . . . . . . . . . . . . . . . . . . 2-6
Component disassembly and
Major Component Weights. . . . . . . . . . . . 2-7
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Power System Specifications . . . . . . . . . 2-8
Pressure-fit parts . . . . . . . . . . . . . . . . . . . 4-4
Hydraulic Hose and Fitting
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Hydraulic Hose Torque . . . . . . . . . . . . . 2-9
Bolt usage and torque application . . 4-4
Hydraulic Fitting Torque . . . . . . . . . . . . 2-9
Hydraulic lines and electrical wiring 4-4
Hydraulic Hose and Fitting Torque
Hydraulic system . . . . . . . . . . . . . . . . . . . 4-4
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fastener Torque Specifications . . . . . .2-12
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
3 System Descriptions............ 3-1 Pins and composite bearing. . . . . . . . . . . 4-5
Power system . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Application of Insulating Silicone
Hydraulic System . . . . . . . . . . . . . . . . . . . . . 3-1 Grease to Electrical Connections . . . . . 4-5
AB18EJ&18HJ Maintenance Manual i © Oct 2020

5 Maintenance Procedures ...... 5-1 B-5 Replace Fuel filter (AB18HJ
Conducting a Pre-delivery Inspection . 5-1 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
Following a Maintenance Schedule . . . 5-2 B-6 Inspect Air filter of Hydraulic
Repair & Inspection Report . . . . . . . . . . . 5-2 Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Checklist A Procedures . . . . . . . . . . . . . . . 5-6 B-7 Replace High-Pressure Filter
A-1 Inspect All Manuals. . . . . . . . . . . . . 5-6 Element . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
A-2 Inspect All Decals . . . . . . . . . . . . . . 5-6 B-8 Replace Air Filter of Engine (-
A-3 Inspect Damaged, Loose or AB18HJ only) . . . . . . . . . . . . . . . . . . . . . .5-18
Lost Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 B-9 Inspect Angle Sensor and
A-4 Inspect Hydraulic Oil Level . . . . . 5-6 Travel Switch . . . . . . . . . . . . . . . . . . . . . .5-19
A-5 Inspect Hydraulic Leakage . . . . . 5-7 B-10 Inspect Engine Exhaust
A-6 Inspect Fuel Level (AB18HJ System (AB18HJ only). . . . . . . . . . . . .5-19
only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 B-11 Inspect Drive Reducer Oil
A-7 Inspect Fuel Leakage (- Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
AB18HJ only) . . . . . . . . . . . . . . . . . . . . . . . 5-9 B-12 Inspect Slewing Reducer Oil
A-8 Inspect Engine Oil Level (- Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
AB18HJ only) . . . . . . . . . . . . . . . . . . . . . . . 5-9 B-13 Inspect Slewing Bearing
A-9 Inspect Coolant Level (- Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
AB18HJ only) . . . . . . . . . . . . . . . . . . . . . .5-10 B-14 Lubricate Slewing Bearing . . .5-22
A-10 Inspect Engine Belt (AB18HJ B-15 Inspect Platform Rotate
only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Cylinder Fasteners . . . . . . . . . . . . . . . .5-22
A-11 Inspect Fuel Filter (AB18HJ B-16 Test Cylinder Drift . . . . . . . . . . . .5-23
only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 B-17 Test Oscillate Cylinder
A-12 Inspect Cooling Fan (- Exhausting and Counterbalance
AB18HJ only) . . . . . . . . . . . . . . . . . . . . . .5-12 Valve Locking . . . . . . . . . . . . . . . . . . . . . .5-23
A-13 Inspect Engine Intake B-18 Inspect Electrical Wiring . . . . .5-24
System (AB18HJ only) . . . . . . . . . . . .5-12 B-19 Inspect the Battery . . . . . . . . . . .5-24
A-14 Functional Tests. . . . . . . . . . . . . .5-12 B-20 Test Oscillating Outriggers
A-15 Inspect Battery Level. . . . . . . . .5-15 and Inspect Oscillating Multi-way
A-16 Perform Maintenance after Valve Tie Rod . . . . . . . . . . . . . . . . . . . . . .5-25
30 Days . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 B-21 Test Drive Speed . . . . . . . . . . . . .5-25
Checklist B Procedures . . . . . . . . . . . . . .5-16 B-22 Test Emergency Lowering (-
B-1 Replace Hydraulic Oil Tank AB18EJ only) . . . . . . . . . . . . . . . . . . . . . .5-26
Return Filter Element . . . . . . . . . . . . . .5-16 B-23 Test Tilt Protection . . . . . . . . . . .5-27
B-2 Inspect Rim, Tire and Checklist C Procedures . . . . . . . . . . . . . .5-27
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . .5-16 C-1 Replace Fuel Filter Element (-
B-3 Inspect Hydraulic Oil . . . . . . . . . .5-17 AB18HJ only) . . . . . . . . . . . . . . . . . . . . . .5-27
B-4 Inspect Cooling System (- C-2 Replace Air Filter of Hydraulic
AB18HJ only) . . . . . . . . . . . . . . . . . . . . . .5-17 Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28
© Oct 2020 ii AB18EJ&18HJ Maintenance Manual

C-3 Replace Engine Oil (AB18HJ Hydraulic Schematic . . . . . . . . . . . . . . .6-15
only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28 Electrical System. . . . . . . . . . . . . . . . . . . . .6-17
C-4 Replace Engine Oil Filter (- Fault Code Desription . . . . . . . . . . . . .6-17
AB18HJ only) . . . . . . . . . . . . . . . . . . . . . .5-28 Use and Maintenance of Lead-
C-5 Test Weighing System. . . . . . . . .5-29 Acid Battery (requires
Checklist D Procedures . . . . . . . . . . . . . .5-30 maintenance) . . . . . . . . . . . . . . . . . . . . . .6-33
D-1 Replace Drive Reducer Gear Use and Care of Lead-acid Battery
Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30 (maintenance-free) . . . . . . . . . . . . . . . .6-37
D-2 Replace Slewing Reducer Use and Care of Lithium Battery . . .6-37
Gear Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30 Electrical Symbols . . . . . . . . . . . . . . . . .6-38
D-3 Replace Hydraulic Oil . . . . . . . . .5-30 Electrical Schematic . . . . . . . . . . . . . . .6-41
D-4 Replace Hydraulic Tank Appendix 1: Prepare the Word
Suction Filter. . . . . . . . . . . . . . . . . . . . . . .5-31
Record before Delivery........ A-1
D-5 Replace Coolant and Coolant
Hoses (AB18HJ only) . . . . . . . . . . . . . .5-31 Appendix 2: Repair & Inspection
D-6 Replace Fuel Hoses (AB18HJ Report ............................. A-3
only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32
D-7 Inpsect Boom Wear Pads . . . . .5-32
6 Repair Procedures .............. 6-1
Boom and Platform Components . . . . . 6-1
Boom and Platform Systems . . . . . . . 6-1
Platform Controller. . . . . . . . . . . . . . . . . . 6-1
Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Platform Swing Motor . . . . . . . . . . . . . . . 6-2
Jib Boom Assembly. . . . . . . . . . . . . . . . . 6-2
Platform Level Cylinder . . . . . . . . . . . . . 6-3
Cable Track Assembly . . . . . . . . . . . . . . 6-4
Main Boom Assembly . . . . . . . . . . . . . . 6-4
Telescopic Boom Assembly . . . . . . . . 6-5
Secondary Boom Assembly . . . . . . . . 6-6
Chassis and Turntable Components . . 6-7
Tires and Rims. . . . . . . . . . . . . . . . . . . . . . 6-7
Reducer and Drive Motor . . . . . . . . . . . 6-8
Turntable Slewing Mechanism. . . . . . 6-9
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
Hydraulic System . . . . . . . . . . . . . . . . . . . . 6-11
Layout of Hydraulic Elements. . . . . . 6-11
Boom Function Valves . . . . . . . . . . . . .6-12
Hydraulic Symbols . . . . . . . . . . . . . . . . .6-14
AB18EJ&18HJ Maintenance Manual iii © Oct 2020

© Oct 2020 iv AB18EJ&18HJ Maintenance Manual
INTRODUCTION
Thank you for choosing and using the machinery of
Hunan Sinoboom Intelligent Equipment Co., Ltd. Al-
ways read, understand and become familiar with the
operation requirements of the machine and its associ-
ated safety procedures before operating, maintaining
and repairing the machine. Operating the machine with-
out becoming familiar with its specific operation require-
ments and safety procedures poses serious risks.
Operators who follow safety rules and operate the ma-
chine carefully and effectively will prevent personal in-
jury, property loss and accidents.
Use this machine only to transport tools to work loca-
tions and for performing tasks on the work platform. Op-
erators must be competent and must obtain training to
carefully use the machine and follow safety procedures.
Only trained and authorized personnel may operate the
machine.
This manual guides the operator and authorized per-
sonnel in maintaining the machine. The operator is re-
sponsible for reading, understanding and implementing
the maintenance and safety procedures in this manual
and for following the manufacturer’s instructions before
beginning any work. Read, understand and follow all
safety rules and operating instructions. The operator
must also consider the machine’s uses and limitations
and the conditions at the jobsite before using this ma-
chine. Strictly following all safety requirements in this
manual is critical.
Consider this manual a part of the machine, along with
Operation Manual and Parts Manual, and always keep
the manuals with the machine. The owner or adminis-
trator of the machine shall offer all manuals and other
necessary information provided by the machine manu-
facturer regarding the daily inspection and maintenance
to each of the renters. If the machine is sold, the owner
or administrator must pass along the manuals and other
necessary information to the purchaser. The owner or
administrator of the machine shall also provide the
manufacturer’s maintenance information to the person
responsible for maintaining the machine.
If you have any questions, contact Hunan Sinoboom In-
telligent Equipment Co., Ltd..
AB18EJ&18HJ Maintenance Manual v © Oct 2020

© Oct 2020 vi AB18EJ&18HJ Maintenance Manual

1 SAFETY
Read, understand and comply with the safety rules and
regulations of your workplace and your government. NOTICE
Before using the machine, obtain proper training on Indicates a situation that can cause damage to the
safe machine operation and make sure you can safely engine, personal property and/or the environment, or
control and operate the machine. cause the equipment to operate improperly.
Understand that as the operator you have the NOTE: Indicates a procedure, practice or condition that
responsibility and right to shut down the machine in should be followed in order for the engine or
case of failure with the machine or other emergency at component to function in the manner intended.
your workplace.
NOTICE REPORTING ACCIDENTS

People suffering from heart disease, hypertension,
epilepsy and other diseases and people who fear
heights must never operate or use this machine. In case of any accident involving the machinery of
Also, people who have alcohol or drugs in their Hunan Sinoboom Intelligent Equipment Co., Ltd., notify
system, or experience excessive fatigue or Hunan Sinoboom Intelligent Equipment Co., Ltd.
depression, are prohibited from operating or using Immediately, even if no personal injury or property
this machine. damage occurs during the accident. Contact Hunan
Sinoboom Intelligent Equipment Co., Ltd. by telephone
and provide all necessary details. Failure to notify the
manufacturer within 48 hours of the incident involving
the machinery of Hunan Sinoboom Intelligent
SAFETY DEFINITIONS Equipment Co., Ltd. may void the product's warranty.
This safety alert symbol appears with NOTICE

most safety statements. It means
attention, become alert, your safety is Thoroughly inspect the machine and all its functions
involved! Please read and abide by the after any accident, being sure to test first from the
message that follows the safety alert ground controller and then from the platform
symbol. controller. Ensure the machine's lifting height does
not exceed 3 m(9.8 ft) until all damage has been
repaired and all controllers operate properly.
Indicates a hazardous situation that, if not

avoided, will result in death or serious injury. ELECTROCUTION
HAZARDS
NOTE: This machine is not insulated and does not
Indicates a hazardous situation that, if not have an electric shock protection function.
avoided, could result in death or serious injury. All operators and managers shall comply with national
or local regulations regarding the minimum safe
distance of live conductors above the ground. In the
absence of such requirements, operators and
managers should follow the minimum safety distance
Indicates a hazardous situation that, if not requirements in Table 1-1 , page 1-2.
avoided, could result in minor or moderate injury.
AB18EJ&18HJ Maintenance Manual 1-1 © Oct 2020

SAFETY
Imperial 507 lb (unrestricted/2 persons & tools)
AB18HJ
ELECTRICAL SHOCK HAZARDS
Metric 230kg (unrestricted/2 persons & tools)
• Always maintain a safe distance Imperial 507 lb (unrestricted/2 persons & tools)
from power lines and electrical
equipment in accordance with
applicable government
regulations and see Table 1-1 ,
page 1-2.
• Consider platform and boom
movement, wire swinging or
drooping, beware of strong winds
or gusts, and do not operate the
machine when there is lightning
or heavy rain.
• If the machine comes into contact
with live wires, keep away from
the machine. Personnel on the
ground or on the platform must
not touch or operate the machine
until the power is switched off.
• Do not use the machine as a
ground wire during welding and
polishing operations.
Table 1-1
Voltage Minimum Safe Distance

(Phase to Phase, kV) (m/ft)
0-50 3.05 (10)
50-200 4.60 (15)
200-350 6.10 (20)
350 -500 7.62 (25)
500 -750 10.67 (35)
750 -1000 13.725 (45)
TIPPING HAZARDS AND

RATED LOAD
Maximum rated load bearing capacity of the platform:
Table 1-2
AB18EJ
Metric 230kg (unrestricted/2 persons & tools)
© Oct 2020 1-2 AB18EJ&18HJ Maintenance Manual

SAFETY
TIPPING HAZARDS TIPPING HAZARDS

and steep slopes, maintain a
• Personnel, equipment and minimum distance of 0.6m (2ft)
materials on the platform must and reduce the speed.
not exceed the maximum load
capacity. • When on the platform do not push
and pull objects outside of it. The
• Only raise or extend the boom maximum lateral force allowed is:
when the machine is on solid, 400 N (90 lbf).
level ground.
• Tow the machine only from the
• Select only the low speed when tiedown/lifting points on the
driving the machine on a slope. chassis.
• Do not use the tilt alarm as a level • Never use the boom or platorm to
indicator. The tilt alarm on the stablize or support any objects
platform will sound only if the outside of the machine.
machine is heavily tilted.
• Do not change any machine parts
• If the tilt alarm sounds when the that may affect safety and
machine drives up a slope, please stability.
lower the boom per the following
procedure and move the machine • Do not replace key parts that
onto firm level ground. Be sure affect machine stability with
not to rotate the boom when different weights or
lowering. specifications.
1. Lower the main boom; • Do not modify or change moving
aerial platforms without the
2. Lower secondary boom; manufacturer’s prior written
3. Retract the telescopic boom. permission.
• If the tilt alarm sounds when the • On the platform, do not attach an
machine drives down a slope, additional device for placing tools
please lower the boom per the or other materials to the guardrail.
following procedure and move the This will increase the platform
machine onto firm level ground. weight, surface area and load.
Be sure not to rotate the boom • Do not place on, or fasten any
when lowering. overhanging load to any part of
1. Retract the telescopic boom; this machine.
2. Lower secondary boom; • Do not place ladders or

scaffolding on the platform or any
3. Lower the main boom. parts of the machine.
• Do not drive faster than 1.1 km/h • Do not use the machine on a
(0.68 mph) when the platform is moving or active surface or on a
raised. vehicle. Ensure all tires are in
good condition, the slotted nuts
• When the platform is raised, the
machine cannot travel on uneven tightened and the cotter pins
complete.
terrain, unstable surfaces or in
other dangerous conditions. • Do not use a battery that weighs
less than the original lead acid
• Do not operate the machine
battery (55kg[121 lb]) , and do not
during strong winds or gusts, and
do not increase the surface area remove or modify the
counterweight or other parts of
of the platform or load. Increasing
the battery box. The battery not
the area exposed to the wind will
only provides power, it also
reduce the stability of the
serves as a counterweight. The
machine.
battery is vital to maintaining the
• When the machine is on rough stability of the machine.
ground, with gravel or other
uneven surfaces, or near holes

SAFETY
WORK ENVIRONMENT
TIPPING HAZARDS
HAZARDS
• Do not use the platform or boom
assembly to push other machines
or objects.
• Do not let the platform or boom UNSAFE JOBSITE HAZARDS
assembly touch the nearby
structures. • Do not operate the machine on
surfaces, edges or potholes that
• Do not tie off the platform with cannot bear the weight of the
rope or other binding materials to machine. Raise or extend the
the nearby structures. boom only when the machine is
• Do not put a load outside the on firm, flat ground.
platform. • Never travel on uneven terrain or
• When the platform is caught or unstable surfaces or in other
stuck or when other objects in the dangerous conditions when
vicinity impede its normal raising the platform.
movement, do not use the • When the machine is on rough
platform controller to lower the ground, with gravel or other
platform. If you intend to lower the uneven surfaces, or near holes
platform with a ground controller, and steep slopes, maintain a
you must operate it only after all minimum distance of 0.6m(2ft)
personnel have left the platform. and reduce the speed.
• Do not use the tilt alarm as a
horizontal indicator. The tilt alarm
on the platform will sound only
when the machine is heavily tilted.
• If the tilt alarm sounds when the
machine drives up a slope, lower
the boom per the following
procedure and move the machine
onto firm level ground. Be sure
not to rotate the boom while
lowering.
1. Lower the main boom;
2. Lower secondary boom;
3. Retract the telescopic boom.
machine drives down a slope,
lowering.
1. Retract the telescopic boom;
3. Lower the main boom.
• Running speed should not exceed
1.1km/h (0.68 in./second) when
the platform rises.
• If the machine can be used
outdoors, never operate it during
strong winds or gusts. Do not lift

SAFETY
UNSAFE JOBSITE HAZARDS UNSAFE JOBSITE HAZARDS

the platform when the wind speed
exceeds 12.5 m/s (18 mph). If the • Do not operate the machine on
wind speed exceeds 12.5 m/s (18 surfaces, edges or potholes that
mph) after the platform is lifted, cannot bear the weight of the
fold the platform and do not machine. Raise or extend the
continue to operate the machine. boom only when the machine is
on firm, flat ground.
• Do not drive or lift the machine on
slopes, steps or vaulted surfaces • Never travel on uneven terrain or
that exceed the maximum unstable surfaces or in other
gradeability of the machine. dangerous conditions when
raising the platform.
• Do not lift the machine on slopes
of more than 5° and do not drive • When the machine is on rough
laterally on slopes of more than ground, with gravel or other
5°. uneven surfaces, or near holes
and steep slopes, maintain a
minimum distance of 0.6m(2ft)
and reduce the speed.
• Do not use the tilt alarm as a
horizontal indicator. The tilt alarm
on the platform will sound only
when the machine is heavily tilted.
machine drives up a slope, lower
the boom per the following
lowering.
1. Lower the main boom;
3. Retract the telescopic boom.
machine drives down a slope,
lowering.
1. Retract the telescopic boom;
3. Lower the main boom.
• Running speed should not exceed
0.8 km/h (0.5 in./second) when the
platform rises.
• If the machine can be used
outdoors, never operate it during
strong winds or gusts. Do not lift
the platform when the wind speed
exceeds 12.5 m/s (18 mph). If the
wind speed exceeds 12.5 m/s (18
mph) after the platform is lifted,

SAFETY
UNSAFE JOBSITE HAZARDS UNSAFE JOBSITE HAZARDS

fold the platform and do not laterally on slopes of more than
continue to operate the machine. 5°.
• Do not drive or lift the machine on
slopes, steps or vaulted surfaces Before or during machine operation, check the possible
that exceed the maximum hazards on the jobsite and beware of the restrictions
gradeability of the machine. within the environment, including flammable and
explosive gas/dust.
• Do not lift the machine on slopes
of more than 5° and do not drive
Table 1-3
BEAUFORT METERS/ MILE/ DESCRIPTI-

GROUND CONDITION
NUMBER SECOND HOUR ON
0 0～0.2 0～0.5 Calm Calm. Smoke rises vertically.
1 0.3～1.5 1～3 Light air Wind motion visible in smoke.
2 1.6～3.3 4～7 Light breeze Wind felt on exposed skin. Leaves rustle.
Gentle Leaves and smaller twigs in constant motion.

3 3.4～5.4 8～12
breeze
Moderate Dust and loose paper rise. Small branches begin
4 5.5～7.9 13～18
breeze to move.
5 8.0～10.7 19～24 Fresh breeze Smaller trees sway.
Strong Large branches in motion. Flags waving near

6 10.8～13.8 25～31
breeze horizontal. Umbrella use becomes difficult.
Near gale/
Whole trees in motion. Effort needed to walk
7 13.9～17.1 32～38 moderate
against the wind.
gale
8 17.2～20.7 39～46 Fresh gale Twigs broken from trees. Cars veer on road.
9 20.8～24.4 47～54 Strong gale Light structure damage.
NOTICE
Maximum gradeability is suitable for machines with Downhill: 25% / 14°
platform retracted. Gradeability: 40%/21°
Gradeability means the maximum allowable tilt angle
of the machine when it is on solid ground and the
platform is only capable of carrying one person. As
the weight of the machine’s platform increases, the
machine’s climbing capacity reduces.
Sideslope: 25% / 14°
Gradability:
Uphill: 40% / 21°

SAFETY
UNSAFE OPERATION
HAZARDS UNSAFE OPERATION HAZARDS
At a minimum, operators must operate and maintain the • Do not push any object outside
machine as stated in this manual and in the the platform. The maximum
Maintenance Manual in addition to following more lateral force allowed is 400N (90
stringent industry regulations and workplace rules. lbf).
Never engage in unsafe machine operation.
• Tow the machine only from the
tiedown/lifting points on the
chassis.
• Never use the boom or platform
to stablize or support any
objects outside of the machine.
• Do not modify any component
that may affect the machine
safety and stability.
• Do not replace key parts that
affect machine stability with the
ones of different weights or
specifications.
• Do not change or modify
moving aerial platforms without
the manufacturer’s written
permission.
• On the platform, do not attach
an additional device for placing
tools or other materials to the
guardrail. This will increase the
platform weight, surface area
and load.
• Do not put ladders or
scaffolding on the platform or
any part of this machine.
• Do not use the machine on any
mobile or movable surface or
vehicle. Ensure all tires are in
good condition, the slotted nuts
tightened and the cotter pins
complete.
• Do not use a battery that
weighs less than the original
lead acid battery (55kg[121 lb]),
and do not remove or modify
the counterweight or other
parts inside the battery box.
The battery not only provides
power, it also serves as a
counterweight. The battery is
vital to maintaining the stability
of the machine.
• Do not place or attach any
suspended load onto any part
of the machine.
crane.

SAFETY
UNSAFE OPERATION HAZARDS FALL HAZARDS

• Do not use the platform to push
the machine or other objects. • Each person on the platform must
wear harnesses or use safety
• Do not allow the platform or equipment consistent with
boom to touch structures. government regulations. Fasten
the cable to the fixed point of the
• Do not use rope or other
platform. Never fasten the cable of
binding materials to tie the
more than one person to a fixed
platform or boom onto nearby
structures. point on the platform.
• Do not sit, stand or crawl on the
• Do not put the load outside the
guardrails. When on the platform
platform.
always remain standing on the
• When the platform is caught or platform floor.
stuck or when other objects in
• Do not enter or exit the platform
the vicinity impede its normal
through the boom.
movement, do not use the
platform controller to lower the • Keep the platform floor free of
platform. If you intend to lower obstacles.
the platform with a ground
controller, you must operate it • Do not allow mud, oil stains,
only after all personnel have grease or other slippery
left the platform. substances reside on the
footwear or platform floor.
• When one or more of the
machine’s tires are off the • Do not enter or exit the platform
ground, evacuate all personnel unless the machine is fully in
before attempting to stabilize stowed position.
the equipment. Use a crane, • Close the platform entrance door
forklift or other suitable before operating the machine.
equipment to stabilize the
machine. • Do not operate the machine if the
handrails are not properly
installed and the platform entry
door is not closed.
FALL HAZARDS
At a minimum, operators must operate and maintain the COLLISION HAZARDS
machine as stated in this manual and in the
maintenance manual in addition to following more
stringent industry regulations and workplace rules. At a minimum, operators must operate and maintain the
machine as stated in this manual and in the
Maintenance Manual in addition to following more
stringent industry regulations and workplace rules.

SAFETY
COLLISION HAZARDS COLLISION HAZARDS

other factors that may cause
• Pay attention to the field of sight collisions.
and the presence of blind spots
when moving or operating the • Do not operate the machine on
machine. any crane or overhead traveling
device unless the crane control is
• The non-staff must maintain a locked or precautions have been
minimum of 1.8m (5.9ft) distance taken to prevent any potential
from the machine while it is collision.
travelling or swinging.
• Never operate a machine
• When the work platform of a dangerously or for fun.
moving machine is approx.2m
(6.6ft) away from the obstructions,
use the boom lifting/lowering
function (rather than the driving
function) to get close to the
obstructions.
CRUSH HAZARDS
• Switch to the low speed gear A potential crush hazard exists during movement of the
before parking the machine that machine. Always keep body parts and clothing a safe
drives at high speed. distance from the machine during machine operation.
• Do not use the high speed gear
when the machine is driving
reverse or in restricted or
enclosed work area.
CRUSH HAZARDS
• Check the work area to avoid
ground and overhead
obstructions or other possible • Do not place your hands and arms
risks. where they may become crushed
or trapped.
• Be sure to exercise caution when
using the platform controller and • Do not work under the platform or
ground controller. Color-marked the boom when the boom is not
directional arrows show the protected by a crane.
function of travel, lift and steering. • Maintain good judgment and
• Users must comply with user, planning when using the
workplace and government rules controller on the ground to
regarding the use of personal operate the machine. Maintain
protective equipment (hard hats, proper distance between operator,
safety belts and gloves, etc.). machine and fixed object.
• Place the machine on level
ground or in a secured position
before releasing the brakes.
• Only lower the platform when
there are no people or
obstructions in the area beneath
it.
• When the machine is conducting
aerial work, warn the staff/non-
staff not to work, stand or walk
under the raised boom or
platform.
• Limit the speed of travel
according to ground conditions,
crowding, gradients, the presence
and location of personnel and any

SAFETY
EXPLOSION AND FIRE BODILY INJURY HAZARDS

HAZARDS
Always follow all operation and maintenance
requirements in this manual and the Maintenance
Manual.
EXPLOSION AND FIRE HAZARDS
Do not use the machine or charge the BODILY INJURY HAZARDS

battery in hazardous or potentially
flammable or explosive atmospheres.
• Do not operate the machine when
there are oil spills/leaks. Oil spills
or leaks in hydraulic fluids may
penetrate and burn the skin.
• Always operate the machine in
well ventilated atmosphere to
prevent carbon monoxide
poisoning.
DAMAGED MACHINE NOTE: The operator must carry out maintenance

HAZARDS during the pre-operation inspection only. During
operation, keep the left and right doors of the chassis
closed and locked. Only trained service personnel can
open the left and right doors to repair the machine.
NOTICE
To avoid machine damage, follow all operation and
maintenance requirements in this manual and the
Maintenance Manual. BATTERY HAZARDS
DAMAGED MACHINE HAZARDS FIRE AND EXPLOSION HAZARD
• Do not use the machine if it is • Batteries contain sulfuric acid and

damaged or not in proper generate explosive mixtures of
operating condition. hydrogen and oxygen gases.
Keep any device that may cause
• Thoroughly inspect and test for sparks or flames (including
all functions of the machine cigarettes/smoking materials)
before use. Immediately mark and away from the battery to prevent
stop damaged or faulty machines. explosion.
• Ensure that all maintenance • Do not touch the battery terminals
operations have been performed or cable clips with tools that may
in accordance with this manual cause sparks.
and the corresponding
Maintenance Manual.
• Make sure all labels are in place
and are legible.
• Ensure that the Operation Manual
and Maintenance Manual are
sound, easy to read and stored in
the storage compartment on the
platform.

SAFETY
NOTICE
After charging the battery, be sure that:
BATTERY HAZARD
• The battery cable connections are free of
• Be sure to read and follow the corrosion.
rocomendations given by the • The battery hold-down and cable connections are
battery manufacturor regarding secured.
how to correctly use and maintain
the battery. Adding terminal protection and anti-corrosion
sealants will help reduce corrosion of the battery
• Always wear protective glasses or terminals and cables.
goggles and protective clothing
when working with batteries.
Remove all rings, watches and
other accessories.
HYDRAULIC HAZARDS
CHEMICAL BURN HAZARD

BURN AND SPRAY HAZARDS
Avoid spilling or contacting battery
acid with unprotected skin. Seek • When the hydraulic system is hot,
medical attention immediately if do not touch to avoid severe skin
battery acid contacts skin. burn.
• After the machine shutdown,
thoroughly clean the spilled
hydraulic oil. Do not throw the oil
on the ground. Once the
BATTERY HAZARD maintenance and repair is
complete, immediately clean any
oil on the skin, Dispose of the
• Only the properly trained
used oil as per the governing laws
personnel authorized by the
and regulations.
workplace are allowed to remove
the battery from the machine. • Do not use your hand to block the
hydraulic leaks. If the leakage
• Before replacing the battery, be
occurs, please first release the
sure to identify the appropriate
system pressure and maintain
number of personnel and the
only after the hydraulic oil cools
lifting method.
down. If any injury is caused by
• During the assembling or the spray of hydraulic oil, go to
disassembling process, never use the doctor immediately, otherwise
the battery in a forciable manner, severe complication may develop.
and never allow the battery to fall
off.
• Never directly short-circuit the
battery outputs with electrical
cords.
WELDING AND POLISHING
• Should the battery acid spill out, REQUIREMENTS
use bicarbonate (baking soda)
mixed with water to neutralize the Before welding, grinding and polishing operations,
acid. always ensure you read and understand all operation
• Never store the battery in water or and maintenance requirements in this manual and the
humid atomosphere. Maintenance Manual.
• Daily check the battery cable for

damage, and replace any
damaged parts before operating
the machine.

SAFETY
NOTICE
After using the machine, the main power switch must
WELDING HAZARDS
be disconnected.
• Comply with the welder
manufacturer’s recommendations
for procedures concerning proper
use of the welder.
• Welding leads or cables may only
be connected after turning off the
power unit.
• Carry out welding operations only
after the welding cable has been
correctly connected.
ground wire during welding
operation.
• At all times, make sure that the
power tools are completely stored
in the working platform. Do not
hang the power tools on the
railing of the working platform or
the work area outside the working
platform, or hang the power tools
directly by the wire.
Before performing welding, grinding and polishing work,

welders must seek permission of the responsible
department at the workplace.
AFTER USING THE

MACHINE
1. Choose a safe parking location that is on sturdy,
level ground and that is free of obstructions. Avoid
areas with heavy traffic.
2. Lower the boom to stowed position.
3. Take off all loads from the platform and run the
enghine at low speed for 3–5 minutes to reduce the
engine inside temperature.
4. Push in the emergency stop button at the platform
controls to the OFF position.
5. Close the cover of platform controls to protect the
control panel,handle and controller from hostile
weather conditions.
6. Push in the emergency stop button at ground
controls to the OFF position.
7. Turn the key switch at the ground controls to OFF
position and remove the key to avoid unauthorized
operation of the machine.
8. Turn off the main power switch.

2 SPECIFICATIONS
PERFORMANCE
PARAMETERS
Table 2-1 AB18EJ specifications
MEASURE AB18EJ (Metric) AB600EJ (Imperial)
DIMENSION PARAMETERS
Max platform height 18.2 m 59 ft 8.5 in
Max working height 20.2 m 66 ft 3 in
Max horizontal reach 11.5 m 37 ft 9 in
Overall length(stowed) 8.7 m 28 ft 6.5 in
Overall width(stowed) 2.49 m 8 ft 2 in
Overall height (stowed) 2.56 m 8 ft 4.8 in
Wheelbase 2.49 m 8 ft 2 in
Ground clearance 0.25 m 9.8 in
Tire size (spec / type) 355/55D625 (foam-filled)
Platform dimension (L×W×H) 1.83 × 0.85 × 1.1 m 72 × 33.5 × 43 in

PERFORMANCE PARAMETERS
230 kg (unrestricted / 2 persons & 507 lb (unrestricted / 2 persons &
Platform capacity
tools) tools)
Turntable rotation / continuous 355°/uncontinuous

Platform rotation 160°
Max drive speed (stowed) 6.5 km/h 4 mph
Max drive speed (raised) 1.1 km/h 0.68 mph
Drive mode (drive×steer) 4WD×2WS

Gradeability 40% / 21°
Turntable tailswing 0.8 m 2 ft 7.5 in
Max allowable inclination 5°

Turning radius (inside) 2.4 m 7 ft 10.5 in
Turning radius (outside) 5.55 m 18 ft 2.5 in
Max allowable side force 400 N 90 lbf
Max operating noise level 82 dB
IP grade IP54

SPECIFICATIONS
MEASURE AB18EJ (Metric) AB600EJ (Imperial)
POWER PARAMETERS
Electric motor (rated power, rated
9.5 kW, 2600 rpm
rpm)
Duplex gear pump displacement 8ml/r + 4ml/r

Hydraulic tank capacity 70 L 15.4gal (UK)/18.5gal (US)
Hydraulic system pressure 21 MPa 3046 Psi
Battery (number×voltage, capacity) 8×6 V, 390 Ah
System voltage 48 VDC
Control voltage 12 VDC

GROUND BEARING DATA
Max tire load 4920 kg 10846 lb
Tire contact pressure 556 KPa 81 Psi
ENVIRONMENT REQUIREMENT
Max allowable wind speed 12.5 m/s 28 mph
Max allowable altitude 1000 m 3280 ft

Allowable ambient temperature
(lead-acid battery) -10℃～40℃ 14℉～104℉
Allowable ambient temperature (-

lithium battery) -20℃～40℃ -4℉～104℉
Max allowable RH 90%

Stored at -20℃ to 50℃(-4℉ to 122℉) in a well-ventilated environment with
Storage environment 90% relative humidity (20℃ [68℉]), and away from rain, sun, corrosive
gas,inflammables and explosives.
WEIGHT
Gross weight (unladen) 8100 kg 17857 lb
Note：
a) The working height adds 2m(6ft7in) of human height to platform height。
b) The ground bearing data is approximate value, not factoring the different options,thus it serves only in
adequately safe conditions
c) In different areas, hydraulic oil, engine oil, coolant, fuel and lubrication should be added in accordance with the
environmental temperature.
d) In cold weather, auxiliary devices are needed to start the machines
Table 2-2 AB18HJ specification
MEASURE AB18HJ (Metric) AB600HJ (Imperial)
DIMENSION PARAMETERS
Max platform height 18.2 m 59 ft 8.5 in
Max working height 20.2 m 66 ft 3 in
Max horizontal reach 11.5 m 37 ft 9 in

SPECIFICATIONS
Overall length(stowed) 8.7 m 28 ft 6.5 in

Overall width(stowed) 2.49 m 8 ft 2 in
Overall height (stowed) 2.56 m 8 ft 4.8 in
Wheelbase 2.49 m 8 ft 2 in
Ground clearance 0.25 m 9.8 in
Tire size (spec / type) 355/55D625 (foam-filled)
Platform dimension (L×W×H) 1.83 × 0.85 × 1.1 m 72 × 33.5 × 43 in

PERFORMANCE PARAMETERS
230 kg (unrestricted / 2 persons & 507 lb (unrestricted / 2 persons &
Platform capacity
tools) tools)
Turntable rotation / continuous 355°/uncontinuous

Platform rotation 160°
Max drive speed (stowed) 6.5 km/h 4 mph
Max drive speed (raised) 1.1 km/h 0.68 mph
Drive mode (drive×steer) 4WD×2WS

Gradeability 40% / 21°
Turntable tailswing 0.8 m 2 ft 7.5 in
Max allowable inclination 5°

Turning radius (inside) 2.4 m 7 ft 10.5 in
Turning radius (outside) 5.55 m 18 ft 2.5 in
Max allowable side force 400 N 90 lbf
Max operating noise level 82 dB
IP grade IP54
POWER PARAMETERS
Engine (rated power, rated rpm) 18.5kW, 1500rpm
Electric motor (rated power, rated

9.5 kW, 2600 rpm
rpm)
Duplex gear pump displacement 8ml/r + 4ml/r

Hydraulic tank capacity 70 L 15.4gal (UK)/18.5gal (US)
Fuel tank capacity 60 L 13.2gal (UK)/15.9gal (US)
Hydraulic system pressure 21 MPa 3046 Psi
Battery (number×voltage, capacity) 8×6 V, 390 Ah
System voltage 48 VDC

Control voltage 12 VDC
GROUND BEARING DATA

SPECIFICATIONS
Max tire load 4920 kg 10846 lb

Tire contact pressure 556 KPa 81 Psi
ENVIRONMENT REQUIREMENT
Max allowable wind speed 12.5 m/s 28 mph
Max allowable altitude 1000 m 3280 ft

Allowable ambient temperature
(lead-acid battery) -10℃～40℃ 14℉～104℉
Allowable ambient temperature (-

lithium battery) -20℃～40℃ -4℉～104℉
Max allowable RH 90%

Stored at -20℃ to 50℃(-4℉ to 122℉) in a well-ventilated environment with
Storage environment 90% relative humidity (20℃ [68℉]), and away from rain, sun, corrosive
gas,inflammables and explosives.
WEIGHT
Gross weight (unladen) 8250 kg 18188 lb
Note：
a) The working height adds 2m(6ft7in) of human height to platform height。
b) The ground bearing data is approximate value, not factoring the different options,thus it serves only in
adequately safe conditions
c) In different areas, hydraulic oil, engine oil, coolant, fuel and lubrication should be added in accordance with the
environmental temperature.
d) In cold weather, auxiliary devices are needed to start the machines

SPECIFICATIONS
Figure 2-1 Range of motion chart

SPECIFICATIONS
ENGINE AND MOTOR ITEM AB18EJ AB18HJ
SPECIFICATIONS Secondary boom up 31～39s 31～39s

Secondary boom
31～39s 31～39s
Table 2-3 Kubota engine D1105-E4B-EU-X1 down
Turntable rotate
Type Water-cooled (355°)-retracted 80～105s 80～105s
Cylinder Turntable rotate

3 138～165s 138～165s
Nuumber (355°)-extended
Cylinder Bore 78mm (3.07 in) Main boom extend 40～50s 40～50s
Stroke 78.4mm (3.09 in) Main boom retract 31～39s 31～39s
1.123L Platform rotate (160°) 12～18s 12～18s
Displaecement 0.25 gal (UK)
0.30 gal (US) Platform level up 50～60s 50～60s
Comression Platform level down 40～50s 40～50s

24.0
Ratio Jib up 32～38s 32～38s
Firing
Sequence 1-2-3 Jib down 22～28s 22～28s
Max drive speed
Output 18.5kW@3000rpm (30m) 15～19s 15～19s
Torque 71.5Nm (52.78 ft-lb)@2200rpm a) The function speed depends on the start and end
5.1L point of the movement rather than the controls/
Oil capacity 1.12 gal (UK) switches.
1.35 gal (US) b) The test results of drive speed vary with tires of
different specifications.
Low RPM 1500rpm c) All the speed tests should be conducted from the
platform controller, The test results will differ if tested
High RPM 3000rpm from the ground controller.
d) All the tests should be conducted with the
hydraulic oil temperature higher than 40℃. If the
Table 2-4 Electric Motor hydraulic oil temerature is too low, the test results will
be affected.
Power 9.5kW Test requirements:
Voltage 29V Main boom up/down：With the secondary boom fully
Torque 34.9Nm (25.768 ft-lb) lowered and telescopic boom fully retracted, make the
up and dowm movement of the main boom twice,
RPM 2600rpm respectively.
Secondary boom up/down：Make the up and down
Frequency 90Hz
movement of the Secondary boom twice, respectively.
Current 265A Turntable rotate：With the boom centered, rotate a
turn of the turntable. Test twice.
Main boom extend/retract：With the main horizontal,
extend the main boom from the fully retracted to fully
FUNCTION SPEED extended position and retract the main boom from the
fully extended to fully retracted position twice,
respectively.
Table 2-5
Platform rotate：With the platform horizontal, rotate
ITEM AB18EJ AB18HJ the platform clockwise and anticlockwise twice,
respectively.
Main boom up 54～66s 54～66s
Main boom down 54～66s 54～66s

SPECIFICATIONS
Jib up/down：With the platform horizontal, raise/lower

the jib boom from the lowest/highest points twice, MAJOR COMPONENT
respectively. WEIGHTS
Drive：The test should be performed on a level
surface. Select the high idle speed and move the
handle to the maximum off-center position to drive
forward and reverse for a distance of 30m twice,
respectively. UNSAFE OPERATION HAZARD
• Do not move heavy

components without
machanical assistance.
• Do not place heavy component
upon instable surface.
Table 2-6
Component Metric (kg) Imperial (lb)
Chassis assembly 3115.0 6867.4

Turntable assembly (AB18EJ) 1510.8 3330.7
Turntable assembly (AB18HJ) 1680.1 3704.0
Boom assembly 2492.0 5493.9
Secondary boom, lower 260.7 574.7
Lower pivot 393.8 868.2
Secondary boom, upper 221.4 488.1
Upper pivot 179.4 395.5
Upper link 51.3 113.1
Lower link 42.6 93.9
link 11.9 26.2
Base boom 283.3 624.6
Telsscopic boom 185.7 409.4
Jib boom assembly 161.6 161.6
Platform 183.1 403.7
Slewing mechanism 249.1 549.2
Turntable cover assembly 249.1 549.2
Telescope cylinder 148.9 328.3
Main lift cylinder 117.9 259.9
Secondary lift cylinder 106.5 234.8
Slave cylinder (upper level cylinder) 29.9 65.9
Master cylinder (lower level cylinder) 28.6 63.1
Jib cylinder 28.5 62.8

SPECIFICATIONS
Component Metric (kg) Imperial (lb)
Electric motor 53.9 118.8

Tire assembly 150.9 332.7
Drive reducer 38.3 84.4
Drive motor 39.0 86.0
Engine (AB18HJ only) 95.0 209.4
POWER SYSTEM SPECIFICATIONS

Table 2-7
ITEM SPECIFICATION
Hydraulc Oil
Normal temperature region

(0℃~40℃ [32℉~104℉]) L-HM46
Cold temperature region

(-25℃~25℃ [-13℉~77℉]) L-HV32
High temperature region (＞40℃ [104℉]) L-HM68

Extremely cold temperature region
Special program to be determined
(＜-30℃ [-22℉])
Hydraulic Pump
Type Tandem gear pump
Flow (motor rated rpm=2600r/min) 31 L/min

Rated operating pressure 25 MPa (3626 Psi)
Function Manifold
Boom function manifold pressure, max 21 MPa (3046 Psi)
Return Filter
Return filter bypass pressure 0.4 MPa (58 Psi)
High-pressure Filter
High-pressure filter bypass pressure 0.7 MPa (101.5 Psi)
NOTICE
The factory-filled hydraulic oil can be selected to suit the customer’s demand. Do not intermix different types of
hydraulic oil.

SPECIFICATIONS
HYDRAULIC HOSE AND

FITTING SPECIFICATIONS
HYDRAULIC HOSE TORQUE
Hydraulic hoses must be torqued to the following specifications.
Table 2-8 Hydraulic Hose Torque
METRIC THREAD L (LIGHT-DUTY) S (HEAVY-DUTY)
M12 × 1.5 19 ± 1 Nm (14 ± 1 ft-lb)
M14 × 1.5 26 ± 2 Nm (19 ± 2 ft-lb)
M16 × 1.5 40 ± 3 Nm (30 ± 2 ft-lb)
M18 × 1.5 50 ± 4 Nm (37 ± 3 ft-lb)
M20 × 1.5 - 60 ± 4 Nm (44 ± 3 ft-lb)
M22 × 1.5 70 ± 5 Nm (52 ± 4 ft-lb) -
M24× 1.5 - 85 ± 6 Nm (63 ± 4 ft-lb)
M26 × 1.5 90 ± 6 Nm (66 ± 4 ft-lb) -
M30 × 2 120 ± 8 Nm (89 ± 6 ft-lb) 140 ± 10 Nm (103 ± 7 ft-lb)
M36 × 2 150 ± 12 Nm (111 ± 9 ft-lb) 180 ± 12 Nm (133 ± 9 ft-lb)
M42 × 2 - 260 ± 16 Nm (192 ± 12 ft-lb)
M45 × 2 240 ± 15 Nm (177 ± 11 ft-lb) -
M52 × 2 250 ± 16 Nm (184 ± 12 ft-lb) 280 ± 18 Nm(207 ± 13 ft-lb )
HYDRAULIC FITTING TORQUE

Hydraulic fittings with metric thread must be torqued to the following specifications.
Table 2-9 Hydraulic Fitting Torque – Metric
INSTALLED INTO
INSTALLED INTO STEEL
THREAD SIZE ALUMINUM
ED, O-RING + CIRCLIP ED, O-RING + CIRCLIP O-RING
L (LIGHT-DUTY)
M10×1 18 ± 1 Nm(13 ± 1 ft-lb ) 20 ± 2 Nm (15 ± 2 ft-lb) 18 ± 1 Nm (13 ± 1 ft-lb)
M12×1.5 30 ± 2 Nm (22 ± 2 ft-lb) 35 ± 2 Nm (26 ± 2 ft-lb) 30 ± 2 Nm (22 ± 2 ft-lb )
M14×1.5 42 ± 3 Nm (31 ± 2 ft-lb) 48 ± 4 Nm (35 ± 3 ft-lb ) 35 ± 2 Nm (26 ± 2 ft-lb)
M16×1.5 55 ± 4 Nm (41 ± 3 ft-lb) 60 ± 4 Nm (44 ± 3 ft-lb) 40 ± 3 Nm (30 ± 3 ft-lb)

SPECIFICATIONS
INSTALLED INTO
M22×1.5 90 ± 6 Nm (66 ± 4 ft-lb) 130 ± 8 Nm (96 ± 6 ft-lb) 60 ± 4 Nm(44 ± 3 ft-lb )
M27×2 120 ± 8 Nm (89 ± 6 ft-lb) 185 ± 12 Nm (136 ± 9 ft-lb) 100 ± 7 Nm (74 ± 5 ft-lb)
M33×2 180 ± 10 Nm (133 ± 7 ft-lb) 320 ± 20 Nm (236 ± 15 ft-lb) 160 ± 10 Nm(118 ± 7 ft-lb )
S (HEAVY-DUTY)
M22×1.5 90 ± 6 Nm (66 ± 4 ft-lb) 140 ± 8 Nm(103 ± 6 ft-lb ) 100 ± 10 Nm (74 ± 7 ft-lb)
Hydraulic fittings with inch thread (British Standard Pipe [BSP]) must be torqued to the following specifications.
Table 2-10 Hydraulic Fitting Torque – British Standard Pipe (BSP)
INSTALLED INTO
L (LIGHT-DUTY)
G1/8A 20 ± 1 Nm (15 ± 1 ft-lb) 20 ± 1 Nm (15 ± 1 ft-lb) -
G1/4A 35 ± 2 Nm (26 ± 2 ft-lb) 40 ± 2 Nm (30 ± 2 ft-lb) -
G3/8A 50 ± 3 Nm (37 ± 2 ft-lb) 75 ± 5 Nm (55 ± 2 ft-lb) -
G1/2A 75 ± 5 Nm (55 ± 2 ft-lb) 95 ± 6 Nm (70 ± 4 ft-lb) -
G3/4A 120 ± 8 Nm (89 ± 6 ft-lb) 185 ± 12 Nm (136 ± 9 ft-lb) -
G1A 180 ± 10 Nm (133 ± 7 ft-lb) 320 ± 20 Nm (236 ± 15 ft-lb) -
G1-1/4A 240 ± 15 Nm (177 ± 11 ft-lb) 450 ± 25 Nm (332 ± 18 ft-lb) -
G1-1/2A 280 ± 20 Nm (207 ± 15 ft-lb) 540 ± 30 Nm (398 ± 22 ft-lb) -

SPECIFICATIONS
INSTALLED INTO
S (HEAVY-DUTY)
G1/4A 40 ± 3 Nm (30 ± 2 ft-lb) 43 ± 3 Nm (32 ± 2 ft-lb) -
G3/8A 55 ± 3 Nm (41 ± 2 ft-lb) 85 ± 5 Nm (63 ± 4 ft-lb) -
G1/2A 80 ± 5 Nm (59 ± 4 ft-lb) 120 ± 8 Nm (89 ± 6 ft-lb) -
G3/4A 120 ± 8 Nm (89 ± 6 ft-lb) 185 ± 12 Nm (136 ± 9 ft-lb) -
G1A 180 ± 10 Nm (133 ± 7 ft-lb) 320 ± 20 Nm (236 ± 15 ft-lb) -
G1-1/4A 240 ± 15 Nm (177 ± 11 ft-lb) 450 ± 25 Nm (332 ± 18 ft-lb) -
G1-1/2A 280 ± 20 Nm (207 ± 15 ft-lb) 540 ± 30 Nm (398 ± 22 ft-lb) -
Hydraulic fittings with Unified Thread Standard (UNC/UNF) must be torqued to the following specifications.
Table 2-11 Hydraulic Fitting Torque – Unified Thread Standard (UNC/UNF)
INSTALLED INTO
O-RING O-RING
L (LIGHT-DUTY)
7/16-20 21 ± 2 Nm (15 ± 2 ft-lb) 21 ± 2 Nm (15 ± 2 ft-lb)
9/16-18 34 ± 2 Nm (25 ± 2 ft-lb) 35 ± 2 Nm (26 ± 2 ft-lb)
11/16-12 40 ± 3 Nm (30 ± 2 ft-lb) 50 ± 4 Nm (37 ± 3 ft-lb)
3/4-16 50 ± 3 Nm (37 ± 2 ft-lb) 65 ± 4 Nm (48 ± 3 ft-lb)
7/8-14 75 ± 5 Nm (55 ± 4 ft-lb) 110 ± 8 Nm (81 ± 6 ft-lb)
1-1/16-12 110 ± 8 Nm (81 ± 6 ft-lb) 140 ± 10 Nm (103 ± 7 ft-lb)
1-5/16-12 160 ± 10 Nm (118 ± 7 ft-lb) 210 ± 15 Nm (155 ± 11 ft-lb)
S (HEAVY-DUTY)
7/16-20 21 ± 2 Nm (15 ± 2 ft-lb) 23 ± 2 Nm (17 ± 2 ft-lb)
9/16-18 34 ± 2 Nm (25 ± 2 ft-lb) 40 ± 3 Nm (30 ± 2 ft-lb)
11/16-12 40 ± 3 Nm (30 ± 2 ft-lb) 65 ± 4 Nm (48 ± 3 ft-lb)
3/4-16 50 ± 3 Nm (37 ± 2 ft-lb) 80 ± 6 Nm (59 ± 4 ft-lb)
7/8-14 75 ± 5 Nm(55 ± 4 ft-lb ) 125 ± 10 Nm (92 ± 7 ft-lb)
1-1/16-12 110 ± 8 Nm (81 ± 6 ft-lb) 185 ± 15 Nm (136 ± 11 ft-lb)
1-5/16-12 160 ± 10 Nm (118 ± 7 ft-lb) 280 ± 20 Nm (207 ± 15 ft-lb)

SPECIFICATIONS
HYDRAULIC HOSE AND FITTING 4. Position the tube and nut squarely on the fitting.
Then tighten the nut as required.
TORQUE PROCEDURE
5. Tighten the nut or fitting to the torque specified in
The hydraulic hose and fitting must be torqued to the the appropriate table.
following requirements when they are installed. 6. Operate all machine functions and inspect the hose,
fittings and related components to confirm there are
1. Replace the O-ring if damaged. The O-ring cannot
no leaks.
be reused if the fitting or hose end has been tight-
ened beyond finger tight.
2. Lubricate the O-ring before installation.
3. Properly seat the O-ring. FASTENER TORQUE
SPECIFICATIONS
Unless special torque requirements are stated in this manual or other instructions, torque metric bolts to the values
listed in the table bellow.
Table 2-12 Fastener Torque Specifications – Metric
NOMINAL
DIAMETER PITCH (MM) CLASS 8.8 CLASS 10.9 CLASS 12.9
(MM)
5 0.8 7 Nm (5 ft-lb) 9 Nm (7 ft-lb) 10 Nm (7 ft-lb)
6 1 12 Nm (9 ft-lb) 15 Nm (11 ft-lb) 18 Nm (13 ft-lb)
1.25 30 Nm (22 ft-lb) 35 Nm (26 ft-lb) 42 Nm (31 ft-lb)

8
1 30 Nm (22 ft-lb) 37 Nm (27 ft-lb) 45 Nm (33 ft-lb)

14

16
18
20
1.5 500 Nm (369 ft-lb) 650 Nm(479 ft-lb ) 770 Nm (568 ft-lb)
22

SPECIFICATIONS
NOMINAL
DIAMETER PITCH (MM) CLASS 8.8 CLASS 10.9 CLASS 12.9
(MM)
Unless special torque requirements are listed in this manual or other instructions, torque Unified Thread Standard
bolts (label: UNC) to the values listed in the table bellow.
Table 2-13 Bolt Torque Specifications Unified – Thread Standard (UNC)
NOMINAL
OPPOSITE NUT SIZE (S) CLASS 5 CLASS 8
DIAMETER (IN)
1/4-20 7/16" 10 Nm (7 ft-lb) 14 Nm (10 ft-lb)
5/16-18 1/2" 21 Nm (15 ft-lb) 29 Nm (21 ft-lb)
3/8-16 9/16" 37 Nm (27 ft-lb) 51 Nm (38 ft-lb)
7/16-14 5/8" 60 Nm (44 ft-lb) 82 Nm (60 ft-lb)
1/2-13 3/4" 90 Nm (66 ft-lb) 130 Nm (96 ft-lb)
9/16-12 13/16" 130 Nm (96 ft-lb) 180 Nm (133 ft-lb)
5/8-11 15/16" 178 Nm (131 ft-lb) 250 Nm (184 ft-lb)
3/4-10 1-1/8" 315 Nm (232 ft-lb) 445 Nm (328 ft-lb)
7/8-9 - 509 Nm (375 ft-lb) 715 Nm (527 ft-lb)
Unless special torque requirements are listed in this manual or other instructions, torque Unified Thread Standard
bolts (label: UNF) to the values listed in the table bellow.
Table 2-14 Bolt Torque Specifications – Thread Standard (UNF)
NOMINAL
OPPOSITE NUT SIZE (S) CLASS 5 CLASS 8
DIAMETER (IN)
1/4-28 7/16" 11.5 Nm (8 ft-lb) 16 Nm (11 ft-lb)
5/16-24 1/2" 23 Nm (17 ft-lb) 32 Nm (24 ft-lb)
3/8-24 9/16" 41 Nm (30 ft-lb) 58 Nm (43 ft-lb)
7/16-20 5/8" 65 Nm (48 ft-lb) 92 Nm (68 ft-lb)
1/2-20 3/4" 100 Nm (74 ft-lb) 145 Nm (107 ft-lb)
9/16-18 13/16" 145 Nm (107 ft-lb) 200 Nm (148 ft-lb)
5/8-18 15/16" 200 Nm (148 ft-lb) 280 Nm (207 ft-lb)
3/4-16 1-1/8" 350 Nm (258 ft-lb) 495 Nm (365 ft-lb)
7/8-14 - 560 Nm (413 ft-lb) 780 Nm (575 ft-lb)

SPECIFICATIONS

3 SYSTEM DESCRIPTIONS
move. In response to the varying flow necessary for
POWER SYSTEM different boom functions, the electrical control system
regulates the opening size of the electric proportional
The model AB18EJ is powered by electric motor. flow valve and operation mode of the duplex gear pump
(oil supply by single or dumplex pump) to enable the
The model AB18HJ is powered by either of the delivery of pressure oil at varying flow.
following two options：
• Kubota engine D1105-E4B-EU-X1
• Electric motor ELECTRICAL SYSTEM
The auxiliary power consists of a 12V battery to drive a
12V DC motor. The gear pump is splined to the output AB18EJ：
shaft of the motor to provide auxiliary power for the
systems. The system adopts eight 6V lead acid batteries in
series or two 24V lithium battery in series to drive a 48V
DC motor for controlling boom functions and drive/steer
functions.
HYDRAULIC SYSTEM AB18HJ：
Diesel mode: the system adopts a 12V battery to start
AB18EJ： the engine, auxiliary pump as well as the three
controllers for engine control, platform control and
The machine is driven by electric motor. The entire
ground control. The battery is charged by the DC
hydraulic system can be divided into two sections: one
generator powered by the engine. The battery
for boom functions, the other for chassis steering and
separator is used for charging one of the two batteries
oscillation control.
first and the other thereafter. Two circuit breakers are
When the motor operates, the pressure oil at the duplex used to protect the control system.
gear pump outlet goes through the electric proportional
Electric mode：the system adopts eight 6V lead acid
flow valve and solenoid directional vavle on the
batteries in series or two 24V lithium battery in series to
mainfiold and drives the hydraulic actuator to move. In
drive a 48V DC motor for controlling boom functions
response to the varying flow necessary for different
and drive/steer functions.
boom functions, the electrical control system regulates
the motor rpm and operation mode of the duplex gear
pump (oil supply by single or dumplex pump) to enable
the delivery of pressure oil at varying flow.
AB18HJ：
ELECTRICAL SYSTEM
The machine is driven by electric motor or engine. The The machine functions are controlled by two
entire hydraulic system can be divided into two controllers, one installed on the left side of turntable to
sections: one for boom functions, the other for chassis control the boom functions, the other on the platform to
steering and oscillation control. control the machine drive and boom functions. The
When the motor operates, the pressure oil at the duplex controller communicates signals through a high-speed
gear pump outlet goes through the electric proportional data bus.
flow valve and solenoid directional vavle on the
mainfiold and drives the hydraulic actuator to move. In
response to the varying flow necessary for different
boom functions, the electrical control system regulates SAFETY MEASURES
the motor rpm and operation mode of the duplex gear
pump (oil supply by single or dumplex pump) to enable
A series of proximity switches and limit switches are
the delivery of pressure oil at varying flow. used to provide signals for the controller.
When the engine operates, the pressure oil at the
• The level sensor measures the inclinations in X axis
duplex gear pump outlet goes through the electric
and Y axis of the chassis. When the inclined angle
proportional flow valve and solenoid directional vavle
in X or Y axis exceeds 5°, the alarm will go off and
on the mainfiold and drives the hydraulic actuator to
restrict such functions as lift, drive and steer.

SYSTEM DESCRIPTIONS
• The travel switch measures whether the main boom

is restracted in place. When the main boom is
retracted in place, the boom is restricted from
further retraction.
• The angle sensor which measures the relative angle
between the main boom and secondary boom is
used for identifying the operating/drive positions of
the machine and the buffer control of boom in place.
• The weight sensor measures the weight on the
platform. When the weight on the platform exceeds
the rated load, the buzzer will sound continuously,
the overload indicator will flash, the display will
indicate platform overload, the associated functions
will be restricted.

4 SERVICE AND GUIDELINES
MACHINE PREPARATION, PRE-OPERATION INSPECTION
INSPECTION AND Prior to daily use or work shift of operators, the user or
operator shoud perform a pre-operation inspection.
MAINTENANCE Refer to the Operation Manual for the complete
procedure for the pre-operation inspection. The
Operation Manual must be entirely read and
GENERAL understood before performing the pre-operation
inspection.
This section provides safety and necessary information
for the machine operators. For maximum service life
and safe operation, ensure that all necessary PRE-DELIVERY INSPECTION AND
inspections and maintenance have been completed
before placing the machine into service FREQUENT INSPECTION
About machine positions The pre=delivery inspection shall be performed by
Stowed position： qualified Sinoboom equipment mechanic. The pre-
delivery inspection and the frequent inspection are
The boom is fully lowered and retracted. performed in the same manner, but at different times.
Non-operating position： The pre-delivery inspection shall be performed before
each sale, lease or rental delivery. The frequent
The boom lifts within 15°above the horizontal,and the inspection shall be accomplished for each machine in
boom extends not exceeding 1.2m. service for 3 months or 150 hours (whichever comes
first); out of service for a period of more than 3 months;
Operating/raised position or when purchased used. The frequency of this
The boom lifts beyond 15°above the horizontal,or the inspection must be increased as environment, severity
boom extends exceeding 1.2m. and frequency of usage requires.
Reference the Prepare the Word Record before
Delivery and Repair & Inspection Report for items
PREPARATION, INSPECTION AND requiring inspection. Reference the Inspection
MAINTENANCE Procedures in appropriate areas of this manual to
perform the inspection and maintenance procedures.
It is important to establish and conform to a
comprehensive inspection and preventive maintenance
program. This mamual outlines the scheduled machine ANNUAL MACHINE INSPECTION
inspections and maintenance recommended by Hunan
Sinoboom Intelligent Co., Ltd., Consult your national, The annual machine inspection must be performed on
regional or local regulations for aerial work platforms. an annual basis, no later than 13 months from the date
The frequency of inspections and maintenance must be of the prior annual machine inspection. Hunan
increased as environment, severity and frequency of Sinoboom Intelligent Equipment Co.,Ltd. recommends
usage requires. this task be performed by a factory-trained service
technician, a person recognized by Sinoboom as one
who, by possession of a recognized degree, certificate,
QUALIFIED SINOBOOM EQUIPMENT training, has successfully demonstrated the ability and
proficiency to service, repair and maintain the subject
MECHANIC Sinoboom product model.
Qualified Sinoboom equipment mechanic is a person Reference the Repair & Inspection Report for items
recognized by Sinoboom as one who, by possession of requiring inspection. Reference the Inspection
a recognized degree, certificate, training, has Procedures in appropriate areas of this manual to
successfully demonstrated the ability and proficiency to perform the inspection and maintenance procedures.
service, repair and maintain the subject Sinoboom For the purpose of receiving the safety-related
product model. bulletins, it is important that Hunan Sinoboom
Intelligent Equipment Co., Ltd. has updated ownership
information for each machine. When performing each

SERVICE AND GUIDELINES
annual machine inspection, notify Hunan Sinoboom

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

Table 4-1
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre- Prior to use each day;
operation or at cach operator User or operator User or operator Operation Manual
Inspection change.
Maintenance Manual, Pre-

Pre-delivery Prior to each sale, Owner, dealer or Qualified Sinoboom delivery Preparation Form,
Inspection lease or rental delivery. user mechanic and Maintenance Inspection
Report
In service for 3 months

or 150 hours,
whichever comes first; Maintenance Manual and
Frequent Owner, dealer or Qualified Sinoboom
or out of service for a Maintenance Inspection
Inspection user mechanic
period of more than 3 Report
months; or purchased
used.
Annually, no later than Maintenance Manual, Pre-
Annual
13 months from the Owner, dealer or Factory-trained delivery Preparation Form,
Machine
date of the prior annual user service technician and Maintenance Inspection
Inspection
inspection. Report
Maintenance Manual,
At inervals as specified
Preventive Owner, dealer or Qualified Sinoboom Maintenance Inspection
in the Maintenance
Maintenance user mechanic Report, and Maintenance
Manual.
Schedule
covers, seals and filters are provided to keep air,

MAINTENANCE AND fuel and oil supplies clean; however, these items
SERVICING PRECAUTIONS must be maintained on a scheduled basis to
function properly.
2. When air, fuel or oil lines are disconnected, clean
GENERAL the adjacent areas as well as the openings and
fittings. As soon as a component or line is
This section assists you in the use and application of disconnected, cap or cover all openings to prevent
the maintenance and servicing procedures contained in entry of foreign matter.
this manual. 3. Clean and inspect all parts during servicing and
maintenance, and assure that all passages and
openings are unobstructed. Cover all parts to keep
SAFETY AND WORKMANSHIP them clean. Be sure all parts are clean before they
are installed. New parts should remain in their
Your safety, and that of others, is the first consideration containers until they are ready to be used.
when engaging in the maintanance of equipment.
Never attempt to move heavy parts without the aid of a
mechanical device. Do not allow heavy objects to rest COMPONENT REMOVAL AND
in an unstable position. When raising a portion of the
equipment, ensure that adequate support is provided.
INSTALLATION
1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (-
CLEANLINESS chains, cables, etc.) should be parallel to each
other and as near perpendicular as possible to top
1. The most important single item in preserving the of part being lifted.
service life of a machine is to keep dirt and foreign
materials out of the vital components. Precautions 2. Should it be necessary to remove a component on
have been taken to safeguard against this. Shields, an angle, keep in mind that the capacity of an
eyebolt or similar bracket lessens, as the angle

between the supporting structure and the BOLT USAGE AND TORQUE
component becomes less than 90 degrees.
APPLICATION
3. If a part resists removal, check to see whether all
nuts, bolts, cables, brackets, wiring, etc, have been
removed and that no adjacent parts are interfacing. NOTICE
Self-locking fasteners, such as nylon insert and
thread deforming locknuts, are not intended to be
COMPONENT DISASSEMBLY AND reinstalled after removal.
ASSEMBLY
1. Always use new replacement hardware when
When disassembling or reassembling a component, installing locking fasteners. Use bolts of proper
complete the procedural steps in sequence. Do not length. A bolt which is too long will bottom before
partially disassemble or assemble one part, then start the head is tight against its related part. If a bolt is
on another. Always recheck your work to assure that too short, there will not be enough thread area to
nothing has been overlooked. Do not make any engage and hold the part properly. When replacing
adjustments, other than those recommended, without parts, use only those having the same
obtaining proper approval. specifications of the original, or one which is
equivalent.
2. Unless specific torque requirements are given
PRESSURE-FIT PARTS within the text, standard torque values should be
used on heat-treated bolts, studs, and steel nuts, in
When assembling pressure-fit part, use a molybdenum accordance with recommended shop practices.
disulfide base compound or equivalent to lubricate the (See Fastener Torque Specifications, page 2-12)
mating surface.
HYDRAULIC LINES AND

BEARINGS ELECTRICAL WIRING
1. When a bearing is removed, cover it to keep out dirt Clearly mark or tag hydraulic lines and electrical wiring,
and abrasives. Clean bearings in nonflammable as well as as their receptacles, when disconnecting or
cleaning solvent and allow to drip dry. Compressed removing them from the unit. This will assure that they
air can be used but do not spin the bearing. are correctly reinstalled.
2. Discard bearings if the races and balls (or rollers)
are pitted, scored, or burned.
HYDRAULIC SYSTEM
3. If bearing is found to be serviceable, apply a light
coat of oil and wrap it in clean (waxed) paper. Do
not unwrap reusable or new bearings until they are 1. The primary enermy of a hydraulic system is
ready to install. contamination. Contaminants enter the system by
various means, e.g., using inadequate hydraulic oil,
4. Lubricate new or used serviceable bearings before allowing moisture, grease, filings, sealing
installation. When pressing a bearing into a retainer components, sand, etc., to enter when performing
or bore, apply pressure to the outer race. If the maintenance.
bearing is to be installed on a shaft, apply pressure
to the inner race. 2. Keep the system clean. If evidence of metal or
rubber particles are found in the hydraulic system,
drain and flush the entire system.
GASKETS 3. Disassemble or reassemble parts on clean work
surface. Clean all metal parts with non-flammable
Check that holes in gaskets align with openings in the cleaning solvent. Lubricate components, as
mating parts. If it becomes necessary to hand-fabrictae required, to aid assembly.
a gasket, use gasket material or stock of equivalent
material and thickness. Be sure to cut holes in the right
location, as blank gaskets can cause serious system LUBRICATION
damage.
Service applicable components with the amount, type,
and grade of lubricant recommended in this manual, at
the specified intervals. When recommended lubricants
are not available, consult your local supplier for an

equivalent that meets or exceeds the specifications

listed. APPLICATION OF
INSULATING SILICONE
BATTERY GREASE TO ELECTRICAL
Clean battery, using a non-metallic brush and a solution
CONNECTIONS
of baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry battery and coat terminals with Insulating silicone grease should be applied to all
an anti-corrosion compound. electrical connections for the purpose of：
• Avoiding oxidization of the mechanical joints
between the male pins and femaile pins.
PINS AND COMPOSITE • Avoiding electrical failure due to low conductivity
between the pins in humid environment.
BEARING The following procedure should be observed to apply
the insulating silicone grease to the electrical
1. Pinned joints should be disassembled and connections. The procedure applies to all plugged
inspected if the following occurs： connections outside of the power distribution box. The
silicone grease is not suitable for the connectors with
• Excessive sloppiness in joints.
enclosed outer surface.
• Noise originating from the joint during operation.
1. Prior to the machine assembling, apply silicone
2. The composite bearing should be replaced if the grease around the male pins and female pins inside
following occurs： the connectors to prevent oxidization. An injector
may be used for the convenience of operation.
• Frayed or separated fibers on the liner surface.
• Cracked or damaged liner backing.
• Bearing that have moved or spun in their
NOTICE
housing. The oxidization exceeding a certain period will
• Debris embedded in liner surface. increase the resistance of the connector and
eventually lead to electrical failure.
3. Pins should be replaced if any of the following is
observed (pin should be properly cleaned prior to 2. Silicone grease should be applied to each electrical
inspection： cord that is exposed at the outside of the connector
• Detectable wear in the bearing area. to prevent short circuit. Besides, the joint between
the male and female connectors should also been
• Flaking, pealing, scoring, or scratches on the pin applied with silicone grease. Other joints that may
surface. allow entry of water into the connectors, like the
area around the anti-pull buckle, should be properly
• Rusting of the pin in the bearing area.
sealed as well.
4. Reassembly of pins and composite bearing:
• Housing should be blown out to remove all dirt NOTICE
and debris. Bearings and bearing housings must
be free of all contamination. Since the electrical conductivity of cleaning
solvent is superior to that of water, it is mostly
• Bearing/pins should be cleaned with a solvent to likely that this will occur when using pressure
remove all grease and oil. The composite cleaning method to clean the machine.
bearing is a dry joint and needs no lubricating.
• Pins should be inspected to ensure it is free of 3. Silicone grease should be applied to each contact
burrs, nicks, and scratches which wound of the connectors for battery case and charger.
damage the bearing during installation and
operation.
NOTICE
The setting type sealant can be used to avoid
short circuit and keep the connections tidy, but it
will make the future removal of pins more difficult.


5 MAINTENANCE PROCEDURES
This section provides specific procedures for scheduled • Unless otherwise specified, perform the
maintenance inspection. maintenance procedures according the following
terms and conditions:
– Park the machine on flat, level and solid ground.
– Place the machine in non-operating position.
UNSAFE OPERATION HAZARD
– Turn the key switch on ground controller to OFF
position and remove the key to prevent
Improper maintenance may result in unauthorized use of the machine.
death, severe injury or machine
damage. – Pull out the red emergency stop buttons on
ground and platform controls to OFF position to
avoid unintended start-up of the operating
system.
– Turn off the main power switch.
HIGH PRESSURE HAZARD – Disconnect all DC power supply.
Before releasing or removing the – Lock all wheels to prevent movement of the
hydraulic components, release the machine.
hydraulic oil pressure in the
hydraulic circuit, particularly with the
counterweight valve.
CONDUCTING A PRE-
Observe the following rules：
DELIVERY INSPECTION
• Maintenance inspections shall be completed only by
a person trained and qualified on the maintenance
of this machine. When the machine owner/company changes, in
addition to conducting a pre-delivery inspection, the
• Routine maintenance inspection contains the corresponding inspection shall be carried out according
inspection items to be performed daily for normal to the maintenance schedule requirement and repair &
machine operation. The service technician must inspection report. When conducting a pre-delivery
perform the routine maintenance inspection and inspection, comply with the following requirements:
complete the report in details.
1. It is the responsibility of the machine owner/
• Scheduled maintenance inspection shall be company to perform a pre-delivery inspection.
completed quarterly, half-yearly, and annually. The
service technician must perform the scheduled 2. Follow this procedure each time before delivery.
maintenance inspection and complete the report in Performing a pre-delivery inspection could reveal
details. potential problems with the machine before you
begin putting the machine into service.
• Timely tag and remove from service a damaged or
malfunctioning machine. 3. Never use a damaged or malfunctioning machine.
Tag the machine and do not use it.
• Repair any machine damage or malfunction before
operating machine. 4. Only professionally trained, qualified personnel may
repair the machine and must follow the procedures
• Keep all inspection records for at least 10 years or as stated in operation manual and maintenance
until the machine has been removed from service or manual.
as required by the machine owner/company/keeper.
5. A competent operator must conduct daily
• Machines that have been out of service for a period maintenance on this machine as stated in operation
longer than 3 months must complete the quarterly manual and maintenance manual.
inspection.
Before delivering the machine, complete the following
• The replacement parts used in the maintenance record using these instructions:
should be identical or equivalent to the original
parts. 1. Prepare the machine before delivery, which
includes performing a pre-delivery inspection,

MAINTENANCE PROCEDURES
following maintenance procedures and performing 3. Record the inspection results. If any inspection
functional inspections. results are "NO", the machine must be stopped and
re-inspected after repair is completed and marked
2. Use the following table to note the results. After
in the box marked "inspection".
each section is complete, mark the appropriate box.
Table 5-1
PREPARE THE WORK RECORD BEFORE DELIVERY

Model
Serial No.
YES/Machine is in NO/Machine Has Damage REPAIRED/Machine
Inspection Item
Good Condition or Malfunction Has Been Repaired
Pre-operational Inspection
Maintenance Procedure
Functional Inspection
Machine Buyer/ Renter
Inspector Signature
Inspector Title
Inspector Company
FOLLOWING A REPAIR & INSPECTION

MAINTENANCE SCHEDULE REPORT
Regular maintenance inspections must occur daily, 1. Divide the Repair & Inspection Report into four
quarterly, biannually (every 6 months) and annually. sections (A, B, C and D) according to the time
Use the table to help you adhere to a routine requirements of the maintenance schedule and the
maintenance schedule. maintenance procedure requirements.
2. The Repair & Inspection Report shall include the
Table 5-2 inspection table of each regular inspection.
3. Duplicate the Repair & Inspection Report for each
INSPECTION inspection. Store the completed tables for 10 years
INSPECTION INTERVAL
PROCEDURES or until the machine is no longer in use or as
Every day or every 8 hours required by machine owner/company/custodian.
A
4. Use the following table to note the results. After
Every quarter or every 250 hours A+B each section is complete, mark the appropriate box.
Every half a year or every 500 5. Record the inspection results. If any inspection
A+B+C
hours results are "NO", the machine must be stopped and
re-inspected after repair is completed and marked
Every year or every 1000 hours A+B+C+D in the box marked "inspection". Select the
appropriate inspection procedure based on the
inspection type.

Table 5-3
REPAIR & INSPECTION REPORT

Model
Serial No.
Checklist A Procedures
YES/Machine is NO/Machine Has REPAIRED/
Problem
Items in Good Damage or Machine Has
Description
Condition Malfunction Been Repaired
A-1 Inspect All Manuals
A-2 Inspect All Decals
A-3 Inspect Damaged, Loose

or Lost Parts
A-4 Inspect Hydraulic Oil
Level
Leakage
A-6 Inspect Fuel Level (AB18

HJ only)
A-7 Inspect Fuel Leakage

(AB18 HJ only)
A-8 Inspect Engine Oil Level

(AB18 HJ only)
A-9 Inspect Coolant Level

(AB18 HJ only)
A-10 Inspect Engine Belt (AB

18HJ only)
A-11 Inspect Fuel Filter (AB

18HJ only)
A-12 Inspect Cooling Fan

(AB18 HJ only)
A-13 Inspect Engine Intake

System (AB18HJ only)
A-14 Functional Tests

A-15 Inspect Battery Level
A-16 Perform Maintenance

after 30 Days
Checklist B Procedures
Problem
Description


B-1 Replace Hydraulic Oil
Tank Return Filter Element
B-2 Inspect Rim ,Tire and
Fasteners
B-3 Inspect Hydraulic Oil
B-4 Inspect Cooling System

(AB18 HJ only)
B-5 Replace Fuel Filter and

High-Pressure Filter (AB18HJ
only)
B-6 Inspect Air Filter of

Hydraulic Tank
B-7 Replace High-Pressure

Filter Element
B-8 Replace Air Filter of
Engine (AB18HJ only)
B-9 Inspect Angle Sensors

and Travel Switch
B-10 Inspect Engine Exhaust
B-11 Inspect Drive Reducer

Oil Level
B-12 Inspect Slewing
Reducer Oil Level
B-13 Inspect Slewing Bearing
Bolts
B-14 Lubricate Slewing
Bearing
B-15 Inspect Platform Rotate

Cylinder Fasteners
B-16 Test Cylinder Drift
B-17 Test Oscillate Cylinder

Exhausting and
Counterbalance Valve
Locking
B-18 Inspect Electrical Wiring
B-19 Inspect the Battery
B-20 Test Oscillating

Outriggers and Inspect
Oscillating Multi-way Valve
Tie Rod
B-21 Test Drive Speed
B-22 Test Emergency

Lowering (AB18EJ only)


B-23 Test Tilt Protection
Checklist C Procedures
Problem
Description
C-1 Replace Fuel Filter

Element (AB18HJ only)
C-2 Replace Air Filter of

Hydraulic Tank
C-3 Replace Engine Oil

(AB18 HJ only)
C-4 Replace Engine Oil Filter

(AB18HJ only)
C-5 Test Weighing System
Checklist D Procedures
Problem
Description
D-1 Replace Drive Reducer

Gear Oil
D-2 Replace Slewing
Reducer Gear Oil
D-3 Replace Hydraulic Oil
D-4 Replace Hydraulic Tank

Suction Filter
D-5 Replace Coolant and
Coolant Hoses (AB18HJ
only)
D-6 Replace Fuel Hoses (-

AB18HJ only)
D-7 Inpsect Boom Wear Pads
User
Inspector Signature
Inspector Date


Inspector Title
Inspector Company
CHECKLIST A A-3 Inspect Damaged, Loose or Lost

Parts
PROCEDURES
Check the machine for any damaged, improperly
installed, loose or lost parts and unauthorized changes:
• Electrical components, wirings and cables
Keeping the Operation Manual and Maintenance • Hydraulic hoses & fittings, hydraulic cylinders and
Manual in appropriate place is vital to safe machine valves
operation. The manuals should be kept at all times in
the manual storage container on the platform. If the • Hydraulic tank
manual is missing or illegible, it will fail to provide the
• Fuel tank (AB18HJ only)
information necessary for safe machine operation.
• Engine and associated parts (AB18HJ only)
• Verify the manual storage container is properly
intalled on the platform. • Battery pack and its connection
• Verify the Operation Manual and Maintenance • Drive motor & reducer, slewing motor & reducer
Manual are in good condition and placed inside the
• Boom wear pads and telescopic axle wear pads
storage container.
• Limit switch and horn
• Verify each page of the manuals is legible and
intact. • Tire and rim
• Return the manual to the storage container after • Alarms and lighting (if equipped)
each use.
• Guardrail and entry gate
Note: If the manuals need to be replaced, please
• Structure and welding cracks
contact Hunan Sinoboom Intelligent Equipment Co.,
Ltd.. • Nuts, bolts and other fasteners
A-2 Inspect All Decals NOTICE

If damaged parts, incorrect installation or missing
Ensuring all decals in good condition is vital to safe parts are discovered, please replace immediately
machine operation. Decals serve not only to alert the and install correctly; if the fasteners are found
operator to potential hazards but also to provide the detached or loose, please secure immediately.
user with information regarding operation and
maintenance. An illegible decal will fail to provide
correct instructions for the operator, which may lead to
the occurence of unsafe operation. A-4 Inspect Hydraulic Oil Level
• Refer to the Decals/Nameplate Inspection in
Operation Manual and use the list and chart of Ensuring appropriate hydraulic oil level is vital to proper
decals to determine the correct location of a decal. operation of the machine. If too high, the oil will spill out
from the oil tank during machine operation, if too low,
• Verify all decals are legible and free of damage, and the oil pump will suction air and damage hydraulic
replace in time if necessary. components. Performing daily inspection of the
Note: If the decals on the machine need to be replaced, hydraulic oil level will help you determine if a problem
please contact Hunan Sinoboom Intelligent Equipment exists in the hydraulic system.
Co., Ltd.. Perform the following procedures with the boom in
stowed position:
1. Open the left turntable cover to make visual
inspection of the sides of hydraulic tank, the

hydraulic oil level should be within the marking • Hydraulic tank, filters, hoses, fittings, and
range of oil level indicator. emergency power unit
• All hydraulic cylinders,manifolds and pumps
• Engine(AB18HJ only)
• Boom system
• Slewing bearing
• Drive chassis
• Areas around the machine
A-6 Inspect Fuel Level (AB18HJ only)
NOTICE
Figure 5-1
Be sure to shut down the engine before inspection.
2. Ensure the hydraulic tank body and its connections
are free of leaks. Keeping the diesel fuel at an appropriate level is vital to
maintaining the engine performance and extending
3. Add oil as needed. Never overfill the tank. service life. An inappropriate fuel level will bring
damage to the engine parts and lead to improper
Table 5-4 functioning of the machine.
Perform the following procedures with the boom in
CUSTOMER HYDRAULIC OIL stowed position:
REQUIREMENTS MARK
1. Turn the Ground/Platform select switch at the
Normal-temperature region ground controller to the “Ground” position, and turn
0°C to 40°C (32°F to 104°F) L-HM46
the Diesel/Electric drive mode select swith to the
“Diesel” position,the indicator panel of the ground
Cold region control will show the fuel level percentage.
-25°C to 25°C (-13°F to 77° L-HV32
F)
High-temperature region 4 6
greater than 40°C (104°F) L-HM68
2 8
Extremely cold region Special programmes
less than -30°C (-22°F) need to be identified. E F
11%
NOTICE
Different hydraulic oils can be added according to
customer requirements upon factory delivery, but Figure 5-2
cannot be mixed.
2. Or turn the Ground/Platform select switch at the
ground controller to the “Ground” position, and turn
A-5 Inspect Hydraulic Leakage the Diesel/Electric drive mode select swith to the
“Diesel” position,the indicator panel of the platform
controller will show the fuel level percentage.
Preventing the hyrdraulic oil from leaking is vital to safe
and normal machine operation. If the hydraulic leaks
fail to be discovered, it will lead to hazardous situations,
reduce the machine performance and damage
components.
Inspect the area on or around the following components
for hydraulic spill, dripping or residues:

NOTICE
• The diesel has been drained off before delievery,
so the customer should add diesel of appropriate
grade to suit the operating ambient temperature
and the governing emission regulations.
• Do not add mixed diesel of different grades.
• The light fuel may affect the fuel economy or
damage the combustion components.
Figure 5-3 • It is recommended to use the diesel with sulphur
content less than 5000ppm.
3. When the fuel level is less than or equal to 10%, the
alarm will sound, be sure to add fuel to continue • It is recommended to use the diesel with min.
working. cetane number of 45 in operating temperatures
below 0℃ and min.cetane number of 40 in
4. Ensure the fuel tank and its connections are free of operating temperatures over 0℃. When the
leaks. cetane number of the diesel in use is less than the
recommended number,it may lead to startup
5. Add fuel with the engine off only.
failure, instable running or large amount of white
6. Open the cap of feul tank, add fuel as need. Never smoke.
overfill the tank, it is recommended to add 50%–
• The max cloud point and pour point of the diesel
100% of the tank capacity.
must be 6℃ less than the lowest operating
ambient temperature.
Table 5-5
DIESEL
RECOMMENDED AMBIENT TEMP
GRADE
5# Lowest temperature 8℃ or higher EXPLOSION ADN FIRE HAZARD
0# Lowest temperature 4℃ or higher • Do not mix the diesel with

gasoline, alcohol or their mixture.
-10# Lowest temperature -5℃ or higher
• Do not add diesel when the
-20# Lowest temperature -14℃ or higher engine is running.
-35# Lowest temperature –29℃ or higher
-50# Lowest temperature -44℃ or higher
DAMAGED MACHINE HAZARD

Due to the extremely accurate
tolerance match of the diesel
injection system, it is critical to keep
the fuel clean and free of dirts or
water. The dirts or water entering the
combustion system can cause
severe damage to the fuel pump and
injectors.

A-7 Inspect Fuel Leakage (AB18HJ on engine oil level which may indicate a system
distress with the engine.
only)
1. Turn the ground/platform select switch to ground
Inspecting fuel leakage is vital to safe and normal control.
machine operation. If a fuel leak is not discovered and 2. Pull out the emergency stop button at ground
corrected in a timely manner, it will pose hazardous controller to ON position.
situations.
3. Turn the Diesel/Electric drive mode select switch at
the ground controller to Diesel position.
NOTICE 4. Move the engine start switch and idle for 2 minutes.
Shut off the engine before inspection. 5. Switch off the engine, and 5 minutes later open the
turntable cover on the right side.
6. Remove the engine dipstick to inpsect the engine
oil level.
EXPLOSION AND FIRE HAZARD 7. The engine oil level should be between the FULL
and ADD marks.
• Diesel is an inflammable material. 8. Add engine oil as needed. Do not overfill. It is
This procedure must be recommended to use engine oil equivalent to or
performed outdoors in well- higher than CH-4 with viscosity grade of 15W-40.
vented area and far away from
flames.
Table 5-6
• Ensure that a conforming fire
extinguisher is readily accessible VISCOSITY RECOMMENDED AMBIENT TEMP
when performing this inspection
procedure. 0W-30 -35℃～0℃
5W-40 -25℃～30℃
Inspect for diesel spills, drippings or residues in the
following areas： 15W-40 -15℃～40℃
• Fuel tank, piping and fittings 20W-50 0℃～50℃
• Fuel pump and fuel filter
• Fuel injection system
EXPLOSION AND FIRE HAZARD

If fuel leakage is discovered,
immediately forbid any other
personnel from entering the area or
operating the machine, and repair the
leakage as soon as possible.
A-8 Inspect Engine Oil Level (AB18HJ

only)
NOTICE
Turn off the engine before inspection.
The appropriate engine oil level is vital to maintaining

the engine performance and extending its service life,
otherwise it will damage the engine parts. Through the
daily check the inspector can know about the changes

NOTICE NOTICE
Turn off the engine before inspection.
• The engine oil filled by the factory is generally
CH-4 with viscosity 15W-40, suitable for regions
with ambient temperature range of 15℃～40℃. If 1. Turn off the engine, and open the right turntable
the operating ambient temperature is outside of cover.
the range, please change the engine oil as 2. Open the cover of coolant box over the radiator to
appropriate. inspect the coolant level.
• The muti-grade engine oil can provide excellent
lubrication under high-temperature operating
condition, reduce the sediments, and improve the
engine low-temperature start performance and
durability.Also, the multi-grade engine oil plays an
important role in fullfilling the machine with the
emission standards.
• Do not mix the engine oils of different grades.
• It is recommended that the sulphated ash content
not exceed 1%, otherwise it will damage the air
valve or piston, and lead to excessive
consumption of engine oil.
• The use of high-quality engine oil in conjunction
with suitable oil filter and change interval is very
critical to maintaining engine performance and
extending service life. If the oil or oil filter is not
changed as recommended, there will be
sediments, contaminants or wear incurred which
will shorten the engine service life.
Figure 5-4
3. The coolant level should be at the fill inlet of the

A-9 Inspect Coolant Level (AB18HJ coolant box.
only) 4. Add coolant as needed. Do not overfill. It is
recommended to choose the -18℃ ready-mix
The appropriate coolant level is vital to maintaining the coolant or the ethylene glycol(ethylene and
engine performance and extending its service life, propene) in ratio mix with water. The water quality
otherwise it will damage the engine parts. Through the must meet the requirements as listed in the table
daily check the inspector can know about the changes below.
on coolant level which may indicate a system distress
with the engine.
Table 5-7
RECOMMENDED
COOLANT TYPE
AMBIENT TEMP
HIGH TEMPERATURE AND
PRESSURE HAZARDS -18℃ ready-mix coolant -18℃ or higher
Before inspecting the coolant level, -37℃ ready-mix coolant -37℃ or higher
allow the coolant to cool down to
room temperature, and slowly open 50% ethylene glycol and
-32℃～0℃
the cover to release the pressure. 50% water mixed coolant
650% ethylene glycol and
-54℃～-32℃
40% water mixed coolant

NOTICE NOTICE
The engine manufacturor recommends the drive belt
• Do not apply sealing additive to the cooling not be applied with belt oil or anti-slipping agent.
system, otherwise it will cause blockage to the
low-fludity area, radiator and engine oil cooler, or
damage the water pump sealing.
• Do not apply soluable engine oil to the cooling A-11 Inspect Fuel Filter (AB18HJ only)
system, otherwise it will corrode the brass and
copper, damage the surface of heat exchanger,
sealings and hose. NOTICE
• The water added into the coolant must meet the Shut off the engine before inspection.
requirements of calcium and magnesium less
than 170ppm and sulphur less than 100ppm. Inspecting the fuel filter is vital to proper functioning of
Excessive calcium and magnesium can lead to engine. Failure to perform this inspection procedure will
scale formation, and excessive chloride and result in engine working improperly or component
sulfate can corrode the cooling system. damage.
A-10 Inspect Engine Belt (AB18HJ

only) EXPLOSION AND FIRE HAZARD
Maintaining the engine belt in good condition is vital to • Diesel is an inflammable material.
good machine performance and service life. The This procedure must be
machine should not continue operation with the engine performed outdoors in well-
belt being loose or deficient, or it will result in vented area and far away from
component damage. flames.
NOTICE extinguisher is readily accessible
Shut off the engine before inspection. procedure.
Inspect the engine belt for： 1. Open the right turntable cover.
• Crack or breakage 2. Locate the fuel filter.
• Wear or misalignment 3. Loosen the plug of drain valve at the bottom, and
drain the water into a suitable vessel until the fuel
• Peeling-off flows out.
• Glazing or hardening
• Improper tensioning (press at the middle position of
the mostly extended belt between the pulleys to
check the tensioning condition, the press-down of
belt should not exceed 13mm [0.5 in.].)
Figure 5-6
4. Tighten the valve plug.

5. Clean up the fuel spill.
Figure 5-5
6. Start the engine from the ground controller and
Replace the engine belt immediately if the above inspect the fuel filter for leakage.
conditions occur.

A-12 Inspect Cooling Fan (AB18HJ 2. Tighten or replace parts, if needed, to assure the
intake system free from leakage.
only)
Inspecting cooling fan is vital to normal functioning of NOTICE
engine and extending service life.
Even if a tiny amount of dust or debris gets inside the
engine, it will result in severe wear of piston ring and
NOTICE increased exhaust. Be sure to keep the intake
system clean and free of leakage.
Shut off the engine before inspection.
1. Open the cover on the right side of engine.

2. Locate the cooling fan in the radiator of engine.
3. Inspect the cooling fan for： Testing each machine function is vital to safe machine
operation. If any function operates improperly, it will
• Cracks pose dangers to safe operation. Ensure any function
• Tilting or loosening operates smoothly and reliably, without shaking, sharp
or unusual noise.
• Abrasion
4. Please replace immediately if any of the above
conditions occurs.
A-13 Inspect Engine Intake System
Be sure to observe the instructions
(AB18HJ only) and safety rules noted in this manual
and Operation Manual, otherwise it
Inspecting the engine intake system is vital to good may lead to death or severe injury.
engine performance and extending service life.
For the specific procedure for fuction tests, please
reference the Pre-operation Function Test section in
NOTICE Operation Manual. Before performing the function test,
ensure that the safety rules in the operation manual are
fully read and understood.
1. Inspect whether the engine intake tube is damaged
or extruded flat, or getting loose. If such conditions
occur, the dust or debris may enter the engine.

1 2 3 4 5 6 7
DC FE
8
20
19
9
18
10
17
11
CAUTION
21
16 15 14 13 12
Figure 5-7 Ground controller
Table 5-8
1. Display screen (See the Fig and

8. Main boom telescope switch 15. Turntable slewing switch
Table below)
2. Ground position 9. Jib up/down switch 16. Secondary boom up/down

switch
17. Emergency power (AB18EJ) /
3. OFF position (Neutral position) 10. Platform level switch Engine start switch (AB18HJ)
4. Platform position 11. Platform rotate switch 18. Enable switch

12. Engine preheat switch (AB18HJ
5. Emergency stop button 19. Main boom up/down switch
only)
20. Ground/Platform select switch

6. Electric mode 13. Horn (key switch)
21. Engine high/low speed select

7. Diesel mode (AB18HJ only) 14. Buzzer switch (AB18HJ only)

1 2 3
4 6 2 3
2 8 1 4
RPM
X1000
E F 0 5
11% 0
11.5 H 0011.5 H
4 5
Figure 5-8 Ground controller display screen
Table 5-9
1. Fuel/battery level gauge 3. Tachometer 5. Platform load

2. Accumulated work hours 4. Current work hours
1 2 3 4 28 5 6 7
CAUTION
DC FE
27
Scope
DC FE
26 9
10
25
24
23 22 21 20 19 18 17 16 15 14 13 12 11
Figure 5-9 Platform controller

Table 5-10
1. Buzzer 11. Drive/Steer joystick 21. Platform rotate switch

22. Secondary boom up/down
2. Horn 12. Steer direction
switch
13. Engine preheat switch (AB18HJ
3. Power indicator only) 23. Main boom lift direction
24. Main Lift/Turntable Slewing

4. Fault panel indicator 14. Reverse drive switch joystick
5. Emergency stop button 15. Rear detection indicator 25. Turntable slewing direction
6. Electric drive 16. Inverter switch (if equipped) 26. Platform level switch
17. Jib rotate direction 27. Diesel/Electric mode select
7. Diesel drive (AB18HJ only)
(if equipped) switch
8. Engine start switch (AB18HJ 28. Emergency power switch (-
18. Main boom telescope direction
only) AB18EJ only)
9. Drive High/Low Speed select 19. Main Telescope/Jib Rotate

switch joystick
10. Drive direction 20. Jib Up/Down switch

1. Turn the Ground/Platform select switch at the
ground controller to Ground (and turn the Diesel/
Electric mode select switch to Electric[AB18HJ
only]), the indicator panel at the ground controller
will display the battery power percentage.
4 6
2 8 Figure 5-11
E F NOTICE
11% The battery must be charged when the residual
battery level is around 20%. Never use the battery
until fully depleted.
Figure 5-10
2. Or turn the Ground/Platform select switch at the A-16 Perform Maintenance after 30
ground controller to Platform (and turn the Diesel/ Days
Electric mode select switch to Electric[AB18HJ
only]), the indicator panel at the platform controller Perform maintenance on a new machine after the
will display the battery power percentage. machine is operated for 30 days or 50 hours. After
performing the 30-day maintenance, continue
performing maintenance as scheduled.
Perform the following procedure：
• B-1 Inspect and replace the return filter of hydraulic
oil tank.

• B-2 Inspect rims, tires and fasteners

• B-13 Inspect slewing bearing bolts
• B-14 Inspect platform rotate cylinder fasteners HIGH PRESSURE HAZARD
Slowly remove the hydraulic

components to reduce hydraulic
CHECKLIST B oil pressure. High hydraulic oil
pressure could penetrate the skin.
PROCEDURES Seek medical attention
immediately.
B-1 Replace Hydraulic Oil Tank Return 4. Loosen the cap on the filter top, and remove the
Filter Element filter element.
5. Apply a thin coat of oil film over the gasket of the
Replaceing the hydraulic tank return filter element on a new return fitler element.
regular basis is vital to proper machine opration and
extending service life. Repeated use of a dirty or 6. Clean the housing of return filter, install the new
blocked filter could cause damage to the machine filter element, and re-install the return filter.
components. Replace the return filter element more 7. Clean all oil spills during the replacement process.
frequently in very dirty environments.
8. Start the engine from the ground controller.
9. Inspect the filter and hydraulic components to
ensure no leakage exists.
BURN HAZARD
Allow the hydraulic oil to cool to B-2 Inspect Rim, Tire and Fasteners
room temperature before servicing
the hydraulic system. Good maintenance of rims and tires is vital to safe
machine operation. The machine might tip over if the
rim or the tire has problems. Repair any problems with
the rims and tires before operating the machine.
NOTICE The machine is equipped with solid tires that do not
Shut off the engine before inspection. need to be inflated.
1. Inspect the tires on a daily basis for damage or
1. Open the left side cover of the turntable. excessive wear. If any of the following condition
occurs, immediately remove the machine from
2. Locate the return filter of hydraulic oil tank. service and replace tires or tire assembly (including
rims). For the requirements and procedure for the
replacement, please reference Tires and Rims,
page 6-7.
• Play separation of tires, i.e., circumferential rips
or lamination occurring to in between the
rubbers.
• Detachment from rims: the rubber comes off
from the steel rims.
• Rubber surface locally peeling off in lumps.
• Rubber cracks in radial direction.
• Rubber worn to the wear mark.
2. Inspect the lug nuts are torqued to specificion
(800Nm[590ft-lb]).
Figure 5-12
3. Use a wrench to remove the return filter.

NOTICE NOTICE
Tighten the lug nuts prior to the first use or after each Shut off the engine before inspection.
tire removal, inspect and retorque every 3 months or
150 hours of operation. • Inspect the cooling system for leakage or loose
connections.
• Inspect all hoses of radiator for crack, abrasion, free
B-3 Inspect Hydraulic Oil of getting flattened, and clamps secured.
• Ensure the cooling fins of radiator are not blocked
Inspecting and replacing the hydraulic oil is vital to by debris.
proper machine operation and extending service life.
The machine may be unable to operate properly if the
hydraulic oil becomes dirty, and the hydraulic parts may
be damaged if using contaminated oil. Replace the
B-5 Replace Fuel filter (AB18HJ only)
hydraulic oil often, especially when the service
environment is very dirty. Replacing fuel filter on a regular basis is vital to proper
operation of engine and extending service life. A dirty or
Note:Due to wear and tear on the mesh components, blocked filter may cause the machine to work
metal particles may appear in the hydraulic fluid or filter improperly. and continued operation may result in
of the new machine. component damage. The fuel fiter should be replaced
at increased frequency if the machine uses fuel of
inferior quality or operates in humid environment.
BURN HAZARD NOTICE

Before maintaining the hydraulic sys- Shut off the engine before inspection.
tem, allow the hydraulic fluid to cool
to room temperature.
Replace the hydraulic oil if any of the following

conditions exist： EXPLOSION AND FIRE HAZARD
• The hydraulic oil is milky white and cloudy. • Diesel is an inflammable material.
• The hydraulic oil is blackened. This procedure must be performed
outdoors in well-vented area and far
• Obtain a sample of the hydraulic oil and inspect it in away from flames.
sunlight. Rub the oil between two fingers to
determine if it contains metal particles. • Ensure that a conforming fire
extinguisher is readily accessible
• The hydraulic oil has an abnormal smell. when performing this inspection
See D-3 Replace Hydraulic Oil, page 5-30for the procedure.
replacement steps.
1. Open the right side cover of turntable.
2. Locate the fuel filter.
B-4 Inspect Cooling System (AB18HJ
3. Disconnect the fuel flow from the fuel tank to the
only) fuel filter.
Inspecting cooling system on a regular basis is vital to 4. Loosen the valve plug over the fuel filter.
proper operation of engine and extending service life. 5. Place a suitable vessel under the fuel filter.
6. Remove the drain plug at the bottom to drain the
water and the remaining fuel into the vessel.
7. Remove the fuel filter, replace with a new one and
BURN HAZARD install.
Be cautious of the heated parts of 8. Tighten the plug.
engine. Bodily contact with them may 9. Clean up the fuel spills.
result in severe burn.

10. Start the engine from the ground controller and B-7 Replace High-Pressure Filter
inspect the fuel filter for leakage.
Element
B-6 Inspect Air filter of Hydraulic Tank Replacing high-pressure filter element on a regular
basis is vital to proper machine operation and
extending service life. A dirty or blocked filter could
Keeping the breather cap of hydraulic tank in well- cause the machine to work improperly, and continued
ventilated condition is vital to normal operation of operation may result in component damage. The high-
hydraulic system and extending service life of hydraulic pressure filter element should be replaced more often
elements. Dirty or blocked air filter of hydraulic tank in hostile operating environment.
may cause the hydraulic pump to suction improperly,
and continued operation may result in component
damage. The air filter of hydraulic tank should be
inspected more often in hostile operating environment.
BURN HAZARD
NOTICE Be cautious of hot hydraulic oil.
Bodily contact with hot hydraulic oil
may result in severe burn.
1. Remove the air filter of hdraulic tank.
NOTICE
1. Open the right side cover of turntable, and locate

the high-pressure filter.
2. Place a suitable vessel under the filter.
3. Remove the filter from the mounting bracket.
4. Replace the filter element as needed.
5. Clean up the hydraulic oil spills.
6. Start the engine from the ground controller.
7. Inspect the high-pressure filter and relevant
components for leakage.
B-8 Replace Air Filter of Engine

(AB18HJ only)
Figure 5-13
NOTICE
2. Check the air filter of hydraulic tank.
3. The air should pass through the air filter smoothly.
4. If the air has difficulty in passing through the air Inspecting the engine air filter is vital to proper engine
filter, observe the following steps to clean the air operation. Failure to perform this inspection procedure
filter. will result in engine malfunction and component
damage.
5. Use neutral solvent to clean the air filter, then blow
dry and repeat the Step 2. 1. Open the right side cover of turntable.
6. Install the air filter back to the hydraulic tank. 2. Locate the engine air filter, as shown in the below
figure：

6. Stop lowering the secondary boom and main boom

once fully lowered.
Inspecting travel switch
1. Turn the Ground/Platform select switch to ground
control position.
2. Pull out the emergency stop button on ground
controller to ON position.
3. Move the the main boom telescope switch to extend
the boom.
4. The boom stops extending further when reaching
the limit.
5. Move the main boom telescope switch to retract the
boom.
6. The main boom can be fully retracted.
B-10 Inspect Engine Exhaust System

(AB18HJ only)
Figure 5-14
Inspecting engine exhaust system is vital to proper
3. Loosen the clip at the end cap of air filter, and engine operation and extending service life.
remove the end cap.
4. Remove the air filter element.
5. Use a wet cloth to scrub the inside of filter housing
and end cap. BURN HAZARD
6. Inspect the filter element for contamination or Be cautious of the heated parts of
blockage. Replace the filter element if needed. engine. Bodily contact with them may
7. Install the filter element. result in severe burn.
8. Install the end cap back to the filter and secure the
clip.
NOTICE
B-9 Inspect Angle Sensor and Travel Shut off the engine before inspection.
Switch
1. Inspect whether the engine exhaust pipe is
Regularly inspecting angle sensor and travel switch is damaged or crushed flat.
vital to safe machine operation. If the sensor and travel 2. Inspect whether the exhaust pipe is tightly
switch can’t function properly, it will pose dangers to connected.
machine operation.
3. Inpsect whether the muffler shows signs of heating
Inspecting angle sensor fatigue or possiblity of interal malfunction.
1. Turn the Ground/Platform select switch to ground 4. Inspect the catalytic converter for blockage.
control position.
5. Tighten or replace parts, if needed, to ensure the
2. Pull out the emergency stop button on ground exhaust system is free of leakage.
controller to ON position.
3. Fully raise the boom through the secondary boom
up/down and main boom up/down switches. B-11 Inspect Drive Reducer Oil Level
4. Stop raising the secondary boom and main boom at
the max lift angle. Inappropriate gear oil level of drive reducers will reduce
the machine performance, and continued use could
5. Lower the boom through the secondary boom up/ result in component damage.
down and main boom up/down switches.

1. Drive the machine to rotate the reducer until one

bolt at top and the other one at 90 degrees, as
Figure 5-16
shown in the figure below.
1. Open the left side cover of turntable, and locate the
slewing reducer.
2. Remove the plug of fill port to check the oil level.
3. The oil level should be even with the bottom of the
plug hole.
4. If the oil level is lower than the bottom of the plug
hole, add oil.
5. Add gear oil from the fill port until the oil level is
even with the bottom of the plug hole.
6. Install the plug back.
7. Clean up the gear oil spills during the inpection.
Figure 5-15 B-13 Inspect Slewing Bearing Bolts

2. Remove the bolt #2, and check the oil level. Regularly inspecting the slewing bearing bolts is vital to
3. The oil level should be even with the bolt hole. proper machine operation. This inspection should be
performed after the first 50 hours of operation and
4. If necessary, add oil to the bolt hole. every 600 hours thereafter. If the bolts come off or get
5. Remove the bolt #1, add gear oil to the bolt hole #1 loose, replace with new ones. Apply threadlocker
until the oil level is even with that of the bolt hole #2. Loctite 272 to the new bolts and torque to specification.
After the bolts are replaced and torqued, re-inspect the
6. Install the bolts back. bolts for tightness.
7. Clean up the gear oil spills during the inpection.
8. Perform this inspection procedure to all drive
reducers of the machine.
B-12 Inspect Slewing Reducer Oil

Level
Inappropriate gear oil level of slewing reducers will
reduce the machine performance, and continued use
could result in component damage.
Figure 5-17
Inspecting the connecting bolts between

chassis and slewing bearing

Figure 5-18
1. Fully raise the secondary boom and keep the main

boom horizontal and fully extended.
2. Locate the connecting bolts between chassis and
slewing bearing.
3. As indicated by the arrowFig 5-16 , page 5-20,
insert 0.04mm feeler gauge in between the bolt and
washer.
4. Ensure the feeler gauge won’t go through the
outside of bolt head to the bolt shank.
5. Rotate the turntable to inspect all the bolts.
Inspecting the connecting bolts between
turntable and slewing bearing


B-14 Lubricate Slewing Bearing

Regulary lubricating the slewing bearing from a long
distance is vital to proper machine operation. The
Lubricating frequency and the amount of lubricant used
should be increased if the machine is operated on
successive work shifts or in hostile environment.
• Lube point：1 grease nipple (see the following
figure)
Figure 5-20
• Amount：as needed
• Lubricant：ZL-3 lithium based grease
B-15 Inspect Platform Rotate Cylinder

Fasteners
Figure 5-19
Regularly inspecting the platform rotate cylinder
1. Fully raise the boom and keep the main boom fully fasteners is vital to proper and safe machine operation.
retracted.
2. Locate the connecting bolts between turntable and
slewing bearing.
washer.
5. Lower the main boom to horizontal position, and
fully extend the main boom.
washer.

Cylinder Bore Maximum Allowable Drift in

Diameter 10 Minutes
（mm/in）（mm/in）
180/7.09 0.13/0.005
200/7.87 0.10/0.0038
220/8.66 0.08/0.0030
• Measure drift at cylinder rod with a calibrated dial

indicator.
• The oil in cylinder must be at ambient temperature
and consistent.
• The cylinder must be applied with normal load from
the platform.
Figure 5-21 • The cylinder is acceptable if it passes this test.
NOTE：This information is based on 6 drops per
1. Place the machine in stowed position. minute cylinder leakage. Since the hydraulic oil
2. Locate the platform rotate motor. expands or contracts due to thermal effect, thus the test
value of cylinder drift may have a tolerance of 7/10000.
3. Inspect whether the bolt #1 as indicated in the
above figure is properly torqued to specification
(70Nm[52ft-lb]). B-17 Test Oscillate Cylinder Exhausting
4. If necessary, replace the bolt, torque to specified and Counterbalance Valve Locking
value, and apply threadlocker Loctite 272.
5. Inspect whether the bolt #2 as indicated in the Testing oscillate cylinder exhausting
above figure is properly torqued to specification
(630Nm[465ft-lb]).
6. If the bolt needs to be replaced, be sure to toruqe to NOTICE
specifiation. Ensure the platform remains in stowed position while
performing the oscillate cylinder exhuasting test.
B-16 Test Cylinder Drift 1. Loosen the hose fitting to the oscillate
counterbalance valve on the left side of machine
Platform drift until fluid flows out.
Measuring the drift from platfrom to ground: with rated 2. Place a 120mm (4.7 in)wooden block with bevel
load on platform and power off, fully extend the main side in front of the front left wheel of the machine.
boom. The maximum allowable drift in 10 minutes is 3. Drive the machine to rest the front left wheel on the
50mm (1.97 in). If the test result exceeds this value, wooden block.
please proceed as below.
4. During the process, there should be hydraulic oil
Cylinder drift and air mixture flowing out of the loosened hose
fitting.
Table 5-11 5. Repeatedly drive the machine on and off the
wooden block until there are only hydraulic oil
Cylinder Bore Maximum Allowable Drift in flowing out of the loosened hose fitting, and then
Diameter 10 Minutes tighten the hose fitting.
（mm/in）（mm/in）
6. Now the left oscillate cylinder exhausts
63/2.48 0.96/0.037 successfully.
80/3.15 0.63/0.025 7. Drive the machine off the wooden block.
100/3.94 0.39/0.015 8. Perform the same procedure to test the exhausting

of oscillate cylinder on the right side.
125/4.92 0.23/0.009
9. Proceed to test the counterbalance valve locking.
160/6.30 0.14/0.006
Testing counterbalance valve locking

NOTICE
Be sure to test the oscillate system quarterly, or after
ELECTROCUTION HAZARD
replacing any system component, or when any
system malfuction is discovered.
Before inspecting the electrical
wires, be sure to disconnect the
1. Place a 120mm (4.7 in)wooden block with bevel
battery and the charger on the AC
side in front of the front left wheel of the machine.
outlet. Contact with hot or live
2. Extend the boom by at least 1.2m to place the circuits could result in death or
machine in operating position. serious injury.
3. Drive the machine to rest the front left wheel on the
wooden block. 1. Inspect the following areas for damage or
corrosion：
4. Slowly rotate the turntable to the right by 90
degrees. • Engine wiring harness (AB18HJ only)
5. The rear detection indicator light will illuminates, • Turntable manifold wiring harness
move the function switches to keep the boom • Junction box at ground controller
horizontal and fully extended.
• Junction box at platform controller
6. Inspect the oscillate cylinder, ensure the oscillate
cylinder on the side with load applied is without any • Cable track system wiring harness
evidence of retracting, and then retract the boom. 2. Inspect the flexile joints, and confirm that the joints
7. Move the reverse drive switch to drive the machine are tight and the sensor lines are not damaged.
off the wooden block.
8. The assistant on the ground should inspect whether
the wheel on the front left or rear right still remains B-19 Inspect the Battery
off the ground, and keep it elevated.
Good battery condition is important for the proper and
9. Slowly rotate the turntable to allow the turntable safe operation of the equipment. The equipment
back to the center position (at the center between components may be damaged and it might lead to
the two drive wheels) hazardous conditions if the electrolyte level is
10. Drive the machine forward or reverse, the float inappropriate and the battery cable is damaged or is
cylinder on the front left wheel should be released not connected firmly.
to lower the wheel to come in close contact with the
ground.
11. Perform the same procedure to test the oscillate
cylinder on the front right side.
ELECTRICAL SHOCK HAZARD
12. If the oscillate cylinder malfunctions, the malfuction
must be cleared by qualified service technician Touching battery charger conductor
before proceeding to next step. might lead to death or serious
injuries. Remove all earrings,
wristwatches and other jewelry.
Maintaining electrical wiring in good condition is vital to
safe operation and good machine performance.
Continued use of the machine with damaged electrical BODILY INJURY HAZARD
wiring or in corrosive environment will cause severe
injury. Before operating the machine, be sure to replace
or repair the damaged or corroded electrical wires. Lead-acid batteries and lead-acid
maintenance-free batteries contain
acid. Avoid acid overflow or contact
with acid in lead-acid batteries and
lead-acid maintenance-free batteries.
If battery acid spills, use water mixed
with bicarbonate (baking soda) to
neutralize the acid.

Result: The battery should be recharged normally,

NOTICE and the charge indicator should illuminate
After the battery is fully charged, wear protective

gloves for inspection. B-20 Test Oscillating Outriggers and
Ensure the connection of the battery cable is not Inspect Oscillating Multi-way Valve Tie
corroded. Rod
Ensure the battery is firmly in place and the cable
wiring is fastened.
NOTE: Add wiring end protectors and antiseptic TIPPING HAZARD

sealants to help eliminate corrosion of the battery
terminals and cables. To perform this test, the machine
must be in stowed position.
NOTE: Be sure to fully charge the battery before
testing.
There are three types of batteries: lead-acid battery,
lead-acid maintenance-free battery and lithium battery. 1. Inspect the tie rod of multi-way valve is properly
Lithium battery and lead-acid maintenance-free secured before machine startup.
batteryare maintenance-free batteries. 2. Start the machine at the platform controller.
INSPECT THE LEAD-ACID BATTERIES 3. Drive the machine to allow the right steer wheel
• Wear protective clothing and goggles properly. upon the kerb or a block with thickness of 12cm (4.7
in).
• Ensure that the connections of battery cable are not
corroded. 4. The other 3 wheels of the machine should come in
close contact with the ground.
• Ensure that the battery is installed properly and the
cable connections are tight. 5. Drive the machine to allow the left steer wheel upon
the kerb or a block with thickness of 12cm (4.7 in).
• Open the vent caps and test the density of the
electrolyte of individual battery cells with a liquid 6. The other 3 wheels of the machine should come in
density tester. close contact with the ground.
Result: Replace the battery if the electrolyte density 7. Drive the machine to allow the both steer wheels
of any battery cell is below 1.026. upon the kerb or a block with thickness of 12cm (4.7
in).
• Inspect the electrolyte level. Add distilled water if the
level is low. Do not overflow. 8. The non-steer wheels of the machine should come
in close contact with the ground.
• Install the vent caps
• Connect the battery charger cable to the correct
post on the battery (red to positive, black to B-21 Test Drive Speed
negative).
• Connect the charging plug to 220V socket. Diesel mode (AB18HJ only)
Result: The battery should be recharged normally, 1. Turn the Ground/Platform select switch on the
and the charge indicator should illuminate. ground controller to the platform position.
INSPECT THE MAINTENANCE-FREE 2. Pull out the emergency stop buttons on both the
BATTERIES ground and platform controllers to the ON position.
• Wear protective clothing and goggles properly. 3. Select the diesel drive mode.
• Ensure that the connections of the battery cable are 4. Move the engine start switch on the platform
not corroded. controller.
• Ensure that the battery is installed properly and the 5. Move the drive high/low speed select switch on the
cable is connected tightly. platform controller to select the drive high speed.
• Connect the battery charger cable to the correct 6. Depress the footswitch.
post on the battery (red to positive, black to 7. Slowly push forward the drive/steer joystick to the
negative). full drive speed.
• Connect the charging plug to 220V socket. 8. The test results are shown in Table 5-12 , page 5-
26.

9. Move the drive high/low speed select switch on the Table 5-13
platform controller to select the drive low speed.
10. Depress the footswitch. MODELS TEST RESULTS
11. Slowly push forward the drive/steer joystick to the Boom in non-operating position: the
full drive speed. max drive speed is 6.5 km/h (4 mph).
AB18EJ Boom in operating position: the max
12. The test results are shown inTable 5-13 , page 5- drive speed is 1.1 km/h (0.7 mph).
26
Boom in non-operating position: the
Electric mode
max drive speed is 6.5 km/h (4 mph).
AB18HJ Boom in operating position: the max
1. Turn the Ground/Platform select switch on the
ground controller to the platform position. drive speed is 1.1 km/h (0.7 mph).
2. Pull out the emergency stop buttons on both the
ground and platform controllers to the ON position.
NOTICE
3. Select the electric drive mode.
If the drive speed exceeds the test results as shown
4. Move the drive high/low speed select switch on the above, please immediately remove the machine from
platform controller to select the drive high speed. service and have it tagged.
5. Depress the footswitch.
6. Slowly push forward the drive/steer joystick to the
full drive speed. B-22 Test Emergency Lowering
7. The test results are shown in Table 5-12 , page 5- (AB18EJ only)
26:
8. Move the drive high/low speed select switch on the When the engine/motor fails, depending on the actual
platform controller to select the drive low speed. conditions, move the emergency power switch on the
ground or platform controller to start the emergency
9. Depress the footswitch. power unit, and meanwhile move the boom function
switch to actuate the corresponding function.
10. Slowly push forward the drive/steer joystick to the
full drive speed.
11. The test results are shown in Table 5-13 , page 5- NOTCIE
26
• Emergency power switch is only for temporary
use (with platform stowed) when the engine fails.
Table 5-12
• When the emergency power unit is in use, never
MODELS TEST RESULTS operate two or more functions at the meantime,
otherwise it may overload the auxiliary motor and
Boom in non-operating position: the pump.
AB18EJ Boom in operating position: the max Operating from the ground controller:
drive speed is 1.1 km/h (0.7 mph).
Boom in non-operating position: the ground controller to the ground control position.
AB18HJ Boom in operating position: the max 2. Pull out the emergency stop button on the ground
drive speed is 1.1 km/h (0.7 mph). controller to the ON position.
3. Move and hold the emergency power switch on the
ground controller.
4. Move the corresponding boom function switch on
the ground controller to lower the platform.
Operating from the platfrom controller:
ground controller to the platform control position.
2. Pull out the emergency stop buttons on both the
ground and platform controllers to the ON position.

3. Move and hold the emergency power switch on the 10. With the machine in operating position, place two
ground controller. wooden blocks under the two wheels on the front or
back side of the machine, and then drive the
4. Move the corresponding boom function switch on
machine onto the two wooden blocks. The wooden
the platform controller to lower the platform.
block should measure 750×250×262mm (29.5
in.×9.8 in.×10.3 in.).
B-23 Test Tilt Protection 11. The tilt alarm sounds and the chassis tilt indicator
light flashes, some functions are restricted, but the
boom retracting, lowering and turntable rotating are
allowed.
12. Retract and lower the boom, drive off the machine
in non-operating position and remove the wooden
blocks.
CHECKLIST C
PROCEDURES
C-1 Replace Fuel Filter Element
(AB18HJ only)
Regularly replacing fuel filter element is vital to good
engine performance and extending service life. A dirty
or blocked filter may fail the engine and continued use
may result in component damage. The flter element
should be replaced more often if operating the mahine
Figure 5-22 in hostile environment.
1. Turn the Ground/Platform select switch to the

ground control position.
2. Pull out the emergency stop button on the ground
controller to the ON position. EXPLSION AND FIRE HAZARD
3. With the machine in non-operating position, flip the • Diesel is an inflammable material.
level switch to exceed 5°in X (left-to-right)/Y (front- This procedure must be performed
to-back) direction. outdoors in well-vented area and far
4. The tilt alarm sounds and the chassis tilt indicator away from flames.
light flashes, no fuctions are restricted. • Ensure that a conforming fire
5. With the machine in operating position, flip the level extinguisher is readily accessible
switch to exceed 5°in X (left-to-right)/Y (front-to- when performing this inspection
back) direction. procedure.
6. The tilt alarm sounds and the chassis tilt indicator
light flashes, some functions are restricted, but the
boom retracting, lowering and turntable rotating are NOTICE
allowed.
7. With the machine in non-operating position, place
two wooden blocks under the two wheels on the left 1. Open the right side cover of turntable and locate the
or right side of the machine, and then drive the fuel filter.
machine onto the two wooden blocks. The wooden
block should measure 750×250×218mm (29.5 2. Disconnect and cap the line between fuel tank and
in.×9.8 in.×8.6 in.). fuel filter.
8. The tilt alarm sounds and the the chassis tilt 3. Remove the fuel fiter element.
indicator light flashes, no functions are restricted. 4. Clean the inside of flter head.
9. Drive the machine off, and remove the wooden
blocks.

5. Add clean fuel to the new filter element, and

lubricate the seal ring with the clean fuel and install
it to the filter head.
6. Clean up the fuel spills in performing the procedure.
C-2 Replace Air Filter of Hydraulic Tank

Keeping the breather cap of hydraulic tank in well-
ventilated condition is vital to normal operation of
hydraulic system and extending service life of hydraulic
elements. Unqualified cleanliness or blocked air filter of
hydraulic tank may cause the hydraulic pump to suction
improperly, and continued operation may result in
component damage. The air filter of hydraulic tank
should be replaced more often in harsh operating
environment.
1. Use a wrench to remove the air filter from the
hydraulic tank. (The location of the air filter is shown
inFig 5-12 , page 5-18)
2. Install new air filter and tighten.
Figure 5-23
C-3 Replace Engine Oil (AB18HJ only)
NOTICE BURN HAZARD

The engine oil filter must also be replaced after Do not come in contact with the hot
replacing the engine oil. Replace the oil with engine engine oil when draining to avoid
started to circulate the oil more smoothly and avoid burns.
contamination.
1. Turn the Ground/Platform select switch to Ground.

2. Pull out the emergency stop button on the ground NOTICE
controller to ON. The waste engine oil should collected in a
3. Turn the Engine/Motor select switch on the ground suitable vessel for disposal or reclying. The waste
controller to Engine position. engine oil should be treated in compliance with
the environment laws or regulations.
4. Move the engine preheat switch to idle for 2
minutes. 7. Close the drain valve.
5. Shut off the engine. 8. Add the new engine oil. For the recommended
6. Open the drain valve to drain the engine oil. viscosity grade of the engine oil, please reference
A-8 Inspect Engine Oil Level (AB18HJ only),
page 5-9。
C-4 Replace Engine Oil Filter (AB18HJ

only)
NOTICE
Replace the engine oil filter each time the engine oil
is replaced.

3. Thoroughly clean the residues on the seal surface

of the filter support.
4. Apply clean engine oil to the rubber washer of the
new engine filter.
5. Mount the new filter.
6. For the engine oil level inspection procedure,
please reference A-8 Inspect Engine Oil Level (-
AB18HJ only), page 5-9.
7. Inspect the engine oil filter element to make sure no
leakage occurs.

Before the test, move the boom fully up and down and
telescope in and out for at least twice to ensure the
Figure 5-24 pulley and track are adequately lubricated. Fully retract
the boom and place the boom in the two positions of
15°above/below the horizontal, and then apply load to
1. Clean the areas around the filter. the platform, the test results are shown in the Table
2. Remove and discard the seal ring of the engine oil below.
filter.
Table 5-14
MODELS TEST RESULTS

When the load does not exceed 230kg (507 lb), the platform can be raised to the max height.
Boom in non-operating position: when the load exceeds 230kg (507 lb), the buzzer will sound
continuously, the overload indicator light will flash, the display screen will indicate platform
overload, such functions as machine driving , boom raising and extending will be restricted and
will not resume until the excessive load is removed.
Boom in operating position (for GB models): when the load exceeds 230kg (507 lb), the buzzer
will sound continuously, the overload indicator light will flash, the display screen will indicate
AB18EJ
platform overload, some functions will be restricted but boom retracting, lowering and turntable
rotating is allowed. The machine will not resume all the functions until the excessive load is
removed.
Boom in operating position (for models except GB): when the load exceeds 230kg (507 lb), the
buzzer will sound continuously, the overload indicator light will flash, the display screen will
indicate platform overload, all the functions will be restricted and will not resume until the
excessive load is removed.
When the load does not exceed 230kg (507 lb), the platform can be raised to the max height.
Boom in non-operating position: when the load exceeds 230kg (507 lb), the buzzer will sound
continuously, the overload indicator light will flash, the display screen will indicate platform
overload, such functions as machine driving , boom raising and extending will be restricted and
will not resume until the excessive load is removed.
Boom in operating position (for GB models): when the load exceeds 230kg (507 lb), the buzzer
will sound continuously, the overload indicator light will flash, the display screen will indicate
AB18HJ
platform overload, some functions will be restricted but boom retracting, lowering and turntable
rotating is allowed. The machine will not resume all the functions until the excessive load is
removed.
Boom in operating position (for models except GB): when the load exceeds 230kg (507 lb), the
buzzer will sound continuously, the overload indicator light will flash, the display screen will
indicate platform overload, all the functions will be restricted and will not resume until the
excessive load is removed.

8. Add new gear oil to the port #1 until the oil level is
CHECKLIST D even with that of the port #2.
PROCEDURES 9. Mount back the bolts.
10. Clean up the oil spills in performing the inspection
D-1 Replace Drive Reducer Gear Oil procedure.
11. Perform the same procedure on all drive reducers
Regularly replacing drive reducer gear oil is vital to of the machine.
good machine performance and extending service life
of the reducer.
1. Drive the machine to rotate the reducer to the D-2 Replace Slewing Reducer Gear Oil
position with one bolt at the bottom, as shown in the
figure below. Regularly replacing slewing reducer gear oil is vital to
good machine performance and extending reducer
service life.
slewing reducer.
2. Place a suitable vessel under the drain plug of the
slewing reducer.
3. Remove the drain plug.
4. Fully drain the slewing reducer gear oil to the
vessel.
5. Mount back the drain plug.
6. Remove the fill plug (for the location, reference B-
12 Inspect Slewing Reducer Oil Level, page 5-
20), add new gear oil to the fill port until the oil level
Figure 5-25 is even with the bottom of the fill plug.
7. Mount back the fill plug.
2. Place a suitable vessel under the bolt as indicated
by the arrow in the figure. 8. Clean up the gear oil spills in performing the
inspection procedure.
3. Remove the bolt as indicated.
4. Fully drain the drive reducer gear oil to the vessel.
5. Mount back the loosened bolt. D-3 Replace Hydraulic Oil
6. Drive the machine to rotate the reducer until one Regularly replacing hydraulic oil is vital to good
bolt is at top and the other is at 90 degrees.
machine performance and extending service life. Dirty
oil may cause the machine to perform poorly and
continued use may result in hydraulic component
damage. Extremely dirty condition requires the oil
changes to be performed more frequently.
BURN HAZARD
Before servicing the hydraulic
system, allow the hydraulic oil to
cool down to room temperature.
Figure 5-26
7. Remove the #1 and #2 bolts as indicated.

NOTICE
The inspection must be performed with the engine in
off position.
When removing the hose and fittings, the O-rings on
the hose and fittings must be replaced.

hydraulic tank.
2. Close the hydraulic shutoff valve located on the
side of hydraulic tank.
3. Remove the drain plug at the bottom of the tank,
and completely drain the oil into a suitable vessel.
For the capacity of hydraulic tank, please reference
Performance Parameters, page 2-1。
HIGH PRESSURE HAZARD Figure 5-27
Slowly remove the hydraulic

elements to reduce the oil
pressure. High oil pressure may D-5 Replace Coolant and Coolant
penetrate the skin. Should any Hoses (AB18HJ only)
injury occur, go to a doctor at
once. Regularly replacing the coolant and coolant hoses is
vital to good engine performance and extending service
4. Disconnect and plug the suction hoses. life. Dirty coolant may cause the machine to function
5. Disconnect and plug the return hoses. improperly and continued use could result in hydraulic
component damage. Extremely dirty condition requires
6. Remove the retaining fasteners from the hydraulic the coolant changes to be performed more frequently.
tank, and remove the hydraulic tank.
7. Rinse out the inside of the tank using a mild solvent,
and dry it up.
8. Install the hydraulic tank onto the machine. BURN AND HIGH PRESSURE
9. Attach the sunction hoses and return hoses to the HAZARD
hydraulic tank. Before replacing the coolant, allow
the fluid in the coolant tank to cool
down to room temperature.
D-4 Replace Hydraulic Tank Suction
Filter
Regularly replacing hydraulic tank suction filter is vital
to good machine performance and extending service
life. Dirty hydraulic oil may cause the machine to
function improperly and continued use may result in
hydraulic component damage. Extremely dirty condition
requires the oil changes to be performed more NOTICE
frequently.
When performing the procedure D-3 Replace
Hydraulic Oil, page 5-30, the hydraulic tank suction 1. Open the right side cover of turntable, and locate
filter must also be replaced. the coolant tank.
2. Disconnect the the coolant return hose, and drain
the coolant inside the return hsoe into a suitable
vessel.

3. Open the coolant tank cover. 4. Remove the clamps from the hoses, and remove
the hoses.
4. Open the coolant tank drain valve to completely
drain the coolant into a suitable vessel. 5. Install the clamps onto the new hsoes, and attach
the hoses to the respective fittings.
5. After the coolant is fully drained, close the drain
valve. 6. Adjust the clamp to secure each hose.
6. Remove the coolant hose clamp, and remove the 7. Clean up the fuel spills during performing the
coolant hoses from each connector. procedure.
7. Install the clamp onto the new coolant hose, and 8. Connect the fuel hoses between the fuel tank and
attach the hose to the corresponding connector. the fuel filter.
8. Secure the hose clamp in place.
9. Add new coolant into the tank until the coolant level D-7 Inpsect Boom Wear Pads
reaches the fill port of the tank.
10. Clean up the coolant spills in performing the Regularly inspecting the boom wear pads is vital to safe
procedure. machine operation. Friction pair develops between
each wear pad and the telescope boom surface.
11. Start the engine from the ground controller to Improperly shimmed wear pads or continued use of
circulate the coolant in the cooling system. extremely worn wear pads may result in component
12. Shut off the engine. damage and unsafe operating conditions.
D-6 Replace Fuel Hoses (AB18HJ

only)
Regularly replacing the fuel hoses is vital to safe engine
operation and extending service life. Long-time use of
old, frayed or broken fuel hoses may pose dangers to
machine operation.
EXPLOSION AND FIRE HAZARD
• Diesel is an inflammable material.

This procedure must be performed
outdoors in well-vented area and far
away from flames.
extinguisher is readily accessible
procedure.
NOTICE
1. Open the right side cover of turntable.

2. Disconnect and plug the fuel hoses between fuel
tank and fuel filter.
3. Locate the following fuel hoses:
• Hoses between fuel tank and fuel filter. Figure 5-28
• Hoses between fuel filter and fuel pump. 1. Remove the both boom end covers or nylon brush.
• Hoses between injector and fuel tank.

2. Measure the thickness of each wear pad as

indicated in the above figure. The wear pad
thickness specifications are listed in the table
below.
Table 5-15
NO. Thickness Specifications
1 16mm (0.63in)
2 13mm (0.51in)
3 11mm (0.43in)
4 11mm (0.43in)
3. When the wear extent of the wear pad is greater or

equal to 3mm, the wear pad assembly should be
timely replaced.
NOTICE
The wear pad disassembled from the boom should
never be reused. Be sure to replace with a new wear
pad asssembly.


6 REPAIR PROCEDURES
are “live”, the enabled light will be illuminated in the
platform display panel. When the time limit has been
reached, the enabled light will turn off and the controls
will be “dead” or disabled. To continue use of the
Repair procedures shall be machine the controls must be re-enabled to start the
completed by a person trained and timer system over again. This is done by releasing all
qualified on the repair of this functions, then releasing and re-depressing the
machine. footswitch.
Immediately tag and remove from Boom Position Sensing System
service a damaged or malfunctioning
machine. The boom position sensing system uses 2 angle
sensors mounted in the upper pivot and travel switch
Repair any machine damage or mounted in the main boom to indicate the boom
malfuction before operating the position. The boom operating position is recognized
machine. when the angle sensor reads more than 0°of main
Before machine startup： boom up , or more than –10°of upper secondary boom
up, relative to the horiztonal, or when the travel switch
• Read, understand and obey the detects the telescopic boom is not fully retracted,
safety rules and operating otherwise it indicates that the boom is in the non-
instructions contained in operating position. The jib boom position is excluded
operation manual. from consideration.
• Read all procedures and rules. This system is used to control the following systems：
• Unless otherwise specified, • Drive speed cutback system
perform each repair procedure
with the machine in the following Drive Speed Cutback System
configuration:
When boom is in operating position, the drive motors
– Machine parked on a firm, level are automatically restricted to the low speed mode.
surface.
– Platform in the stowed
position. Platform Controller
– Key switch in the OFF position
with the key removed.
– All wheels choked.
ELECTROCUTION HAZARD
Before performing this procedure, be

sure to disconnect the battery and
BOOM AND PLATFORM the charger on AC outlet. Contact
with live conductors may result in
COMPONENTS death or serious injury.
Boom and Platform Systems

NOTICE
Platform Control Enable System Perform this procedure with the machine in stowed
position.
The platform controls make use of a time dependent
enable circuit to limit the time availability of “live” or
enabled controls. When the footswitch is depressed, 1. Disconnect external power supply, and push in the
the controls are enabled and the operator has 7 emergency stop buttons on the platform and ground
seconds to operate any function. The controls will controllers to OFF position.
remain enabled as long as the operator continues to 2. Locate the cable connected to the bottom of the
use any function and will remain enabled 7 seconds platform controller.
after the last function has been used. While the controls

REPAIR PROCEDURES
3. Disconnect and tag the cable from the bottom of the 1. Remove the platform.
pltaform controller.
2. Tag, disconnect and plug the 2 hydraulic lines to the
4. Remove the retaining bolts from the platform platform swing motor, and plug the fittings on the
controller. manifold.
5. Remove the platfrom controller from the machine. 3. Use appropriate supporting equipment to stablize
the swing motor bracket.
4. Remove the retaining screws and pins to detach the
Platform bracket from the swing motor.
5. Use appropriate equipment to stablize the swing
1. Remove the platform controller from the platform.
motor.
For the specific procedure, please reference
Platform Controller, page 6-1. 6. Remove the retaining screws and nuts at the pin
connecting the motor and the jib boom.
2. Remove the footswitch.
7. Remove the swing motor.
3. Support and secure the platform to an appropriate
lifting device.
4. Remove the platform mounting bolts. Jib Boom Assembly
MOVING OBJECT HAZARD
Wear eye protection when tapping

the brass drift with wooden hammer.
Figure 6-1
5. Use a brass drift or wooden hammer to tap the

connecting pin out.
6. Slowly move the platform away with a lifting device.
Platform Swing Motor
NOTICE
Perform this procedure with the machine in stowed Figure 6-2
position.
Removal
NOTICE NOTICE
When removing a hose or fitting, the O-ring on the When removing the hose and fitting, the O-ring on
fitting or hose end must be replaced. the fitting and hose end must also be removed and
tagged.
Note:
The swing cylinder serves for the platform swing within 1. Place the main boom horizontal, and use suitable
the range of 160°. lifting equipment to support the jib boom assembly.

REPAIR PROCEDURES
2. Remove the pin keeper at the pin #1 of the slave strike the pins #3 and #4 into the jib boom, then
cylinder, tap the pin out using a brass drift and secure the pins with pin keepers.
wooden hammer.
4. Align the connecting hole of main boom with that of
3. Remove the pin keeper at the pin #2, and tap the connector, use a soft head wooden hammer to
pin out using a brass drift and wooden hammer. strike the pin #2 into the jib boom, then secure the
pin with a pin keeper.
4. Use suitable lifting equipment to detach the jib
boom assembly from the main boom. 5. Align the connecting hole of connector with that of
slave cylinder, use a soft head wooden hammer to
5. Remove the pin keepers at the pins #3 and #4, and
strike the pin #1 of slave cylinder into the connector,
tap the pins #3 and #4 out using a brass drift and
then secure the pin with a pin keeper.
wooden hammer.
6. Remove the pin keepers at the pins #5 and #6, and
tap the pins #5 and #6 out using a brass drift and Platform Level Cylinder
wooden hammer.
7. Remove the pin keeper at the pin #7 of jib lift
cylinder, and tap the pins #7 and #4 out using a
brass drift and wooden hammer.
MOVING OBJECT HAZARD
Inspection
Wear eye protection when tapping
NOTICE the brass drift with wooden hammer.
When inspecting the pins and bearings, please

reference Pins and composite bearing, page 4-5.
• Inspect the pins of jib boom for wear, abrasion, NOTICE

tapering, ovality or other damages, and replace the When removing the cylinder, special care should be
pins if necessary. taken to avoid the fall of the cylinder and component
• Inspect the inner ring of the bearing at jib boom pin damage.
for scratch, deformation, wear or other damages,
and replace the bearing if necessary. The machine is configured with 2 platform level
• Inspect the jib lift cylinder connnecting pin for wear, cylinders located at the boom upper end (slave
scratch, tapering, ovality or other damages, ensure cylinder) and lower end (master cylinder).
the pin surface has been properly treated, if The platform level cylinder ensures the platform is
necessary, replace the pin. always kept horizontal relative to the turntable within
• Inspect the inner ring of the bearing at the swing the whole range of boom motion.
motor pin for scratch, deformation, wear or other 1. Extend the boom until the platform level cylinder
damages, and replace the bearing if necessary. rod-end pin is accessible.
• Inspect all threaded parts for damages like 2. Slightly raise the boom and place a support under
elongation, thread deformation or torsion, and the platform.
replace if necessary.
3. Lower the boom until the platform sits on the
• Inspect the structures of of jib boom assembly for support. Take special care not to press the total
bending, cracks, weld separation or other damages, weight of boom over the support.
if necessary, replace the jib boom.
4. Tag, disconnect and plug the hydraulic lines to the
Assembly platform level cylinder, and cap the fittings.
1. Align the connecting hole of jib boom with that of jib 5. Remove the retaining screw from the rod-end pin
lift cylinder,use a soft head wooden hammer to #1 of the platform level cylinder. And do not move
strike the pin #7 of jib lift cylinder into the jib boom, the pin.
then secure the pin with a pin keeper.
2. Align the connecting hole of jib boom with that of
platform swing cylinder,use a soft head wooden
hammer to strike the pins #5 and #6 into the jib
boom, then secure the pins with pin keepers.
3. Align the connecting hole of the connector with that
of jib boom,use a soft head wooden hammer to

REPAIR PROCEDURES
7. Support the platform level cylinder with an

appropriate supporting device to protect the piston
rod from damage.
8. Use brass drift and wooden hammer to tap the pin
#1 out.
9. Use brass drift and wooden hammer to tap the pin
#2 out.
10. Carefully remove the cylinder from the boom.
Cable Track Assembly
NOTICE
Figure 6-3
When removing a hose or fitting, the O-ring on the
fitting or hose end must also be removed.
6. Remove the retaining ring from the pin #2. And do
not move the pivot pin.
Figure 6-4
1. Tag, disconnect and plug all hydraulic hoses and Main Boom Assembly
cables from cable track guide to the platform.
2. Remove the hydraulic hoses and cables from the
cable track guide.
3. Using suitable lifting device, fully support the cable MOVING OBJECT HAZARD
track along the entire length.
4. Remove the bolts as indicated by the arrows in the Wear eye protection when tapping
above figure. the brass drift with wooden hammer.
5. Using lifting device, slowly move the cable track
away from the boom.

REPAIR PROCEDURES
11. Using a lifting device, slowly move the boom

NOTICE assembly away from the turntable.
When removing a hose or fitting, the O-ring on the
fitting or hose end must also be removed and tagged.
Telescopic Boom Assembly
NOTICE
When removing the hose and fittings, the O-ring at
the fittings or hose end must also be removed and
tagged.
Figure 6-5
1. Place the machine on a solid, level surface.

2. Slightly raise the boom until the main lift cylinder
and master cylinder are accessible.
3. Tag, disconnect and plug the hydraulic hoses and
cables to the chassis/turntable.
4. Using a suitable lifting device (capacity not less
than 2t), secure the lifting straps to the bottom end
of the main boom.
5. Remove the Bolts and nuts at the pin #1 connecting
the rod end of main lift cylinder with the main boom.
Figure 6-6
1. Remove the bolts and shims at the stop block #1 at
Throughout the process, be sure the rod end of main boom telescopic cylinder, and
to use a suitable supporting device remove the stop block.
to stablize the main lift cylinder to
prevent injury or damage due to 2. Remove the screws and shims at the position #2
the unintended movement of and the wear pads and shims at the position #3 on
cylinder. the upper surface and both sides of the boom tail.
3. Pull the telescopic boom with the telescopic cylinder
6. Using brass drift and wooden hammer, tap the pin out of the main boom tail, and place them on a
#1 out. suitable support.
7. Remove the bolts and nuts at the pin #3 connecting
the rod end of master cylinder with the main boom.
8. Using a suitable lifting device (capacity not less
than 2t), secure the lifting straps to the lower end of UNSAFE OPERATION HAZARD
the main boom.
9. Remove the bolts and nuts at the pin #2 connecting Take care to prevent the cylinder
the main boom with the upper upright.. from rotating.
10. Using brass drift and wooden hammer, tap the pins
#2 and #3 out.

REPAIR PROCEDURES
4. Remove the bolts at the barrel end of the telescope 3. Remove the bolts and nuts at the pin #1 connecting
cylinder, and pull the cylinder out of the telescopic the barrel end of main lift cylinder with the upper
boom head. upright, and remove the pin #2 connecting the
barrel end of the master cylinder with the upper
5. Place the telescopic cylinder upon a suitable
upright.
support.
#1 and #2 out.
Secondary Boom Assembly 5. Using lifting device, lift away the main lift cylinder
and master cylinder.
6. Use an appropriate lifting device to support the
upper upright.
MOVING OBJECT HAZARD 7. Remove the bolts and nuts at the pin #3 connecting
the upper upright with the upper secondary boom.
Wear eye protection when tapping 8. Using brass drift and wooden hammer, tap the pin
the brass drift with wooden hammer. #3 out.
9. Using lifting device, lift away the upper upright.
10. Remove the bolts and shims at pin #4 connecting
the upper link with the lower upright, and remove
NOTICE the pin #4,
When removing a hose or fitting, the O-ring on the 11. Using lifting device, lift away the upper link.
fitting or hose end must also be removed and tagged.
12. Use appropriate lifting device to support the lower
link.
13. Remove the bolts, shims and snap plate at the pin
#5 connecting the lower link with the lower upright.
14. Remove the bolts and nuts at the pin #12
connecting the lower link with the turntable.
#5 and #12 out.
16. Using lifting device, lift away the lower link.
17. Use appropriate lifting device to support the upper
secondary boom, secondary lift cylinder, lower
upright and lower secondary boom.
18. Remove the bolts and nuts at the pin #6 connecting
the upper secondary boom with the secondary lift
cylinder.
19. Using brass drift and wooden hammer, tap the pin
#6 out.
20. Remove the bolts and shims at the pin #7
connecting the upper secondary boom and the
lower upright, and remove the pin #7.
21. Using lifting device, lift away the upper secondary
boom.
22. Remove the bolts and pin keeper at the pin #10
connecting the lower secondary boom and the
lower upright.
Figure 6-7
1. Remove the main boom assembly. #10 out.
2. Use a suitable lifting device to support the 24. Using lifting device, lift away the secondary lift
secondary boom head, master cylinder, main lift cylinder.
cylinder and upper link.

REPAIR PROCEDURES
25. Remove the bolts, shims and snap plate at the pin
#8 connecting the lower upright with the lower
secondary boom.
#8 out. The tires and rims installed on each
product model have been designed
27. Using lifting device, lift away the the lower upright.
for stability requirements. Size
28. Remove the bolts, shims, and snap plate at the pin changes such as rim width, center
#9 connecting the lower link with the lower piece location, diameter, etc., without
secondary boom. written factory recommendations,
may result in an unsafe condition
29. Using brass drift and wooden hammer, tap the pin regarding stability.
#9 out.
30. Using lifting device, lift away the the lower link. Installing tires and rims
31. Remove the bolts and nuts at the pin #11 It is extremely important to apply and maintain proper
connecting the lower secondary boom with the wheel mounting torque.
turntable.
#11 out.
33. Using lifting device, lift away the the lower UNSAFE OPERATION HAZARD
secondary boom.
• Use the wheel nuts that suit the
rim bolts. The wheel nuts must be
installed and maintained at the
CHASSIS AND TURNTABLE proper torque to prevent loose
COMPONENTS wheels, broken studsand possible
dangerous separation of wheels
from the axle, Be sure to only use
the nuts matched to the cone
Tires and Rims angle of the wheel.
Replacing tires and rims • Tighten the lug nuts to the proper
torque to prevent wheels from
Hunan Sinoboom Intelligent Equipment Co., Ltd. coming loose, Use a torque
recommends the replacement tires be of the same size, wrench to tighten the fasteners. If
ply rating and brand as the original tires. For the part you do not have a torque wrench,
number of a specific machine model, please reference tighten the fasteners with a socket
the Part Manual.If the replacement tires are not wrench, then immediately have a
asHunan Sinoboom Intelligent Equipment Co., Ltd. service garage or dealer tighten
recommends, the following requirememts of tires the lug muts to the proper torque.
should be met： Over-tightening will result in
breaking the studs or
1. Ply rating/rated load and dimension equal or permanently deforming the
greater than original. mounting stud holes in the
2. Tire tread contact width equal or greater than wheels.
original.
3. Wheel diameter, width and offset dimensions equal The proper procedure for attaching wheels is as
to the original. follows:
4. Approved for the application by the tire 1. First apply the threadlocker Loctite 272 to the nuts,
manufacturer (including intended purposes, then hand tighten all nuts to prevent cross-
maximum drive speed and maximum tire load, etc.). threading. Do not use a lubricant on threads or
nuts.
5. Due to size variations between different tire brands,
both tires on the same axle should be the same. 2. Tighten the nuts in the sequence as shown below.

REPAIR PROCEDURES
Figure 6-8
3. The tightening of the nuts should be done in stages.

Following the recommended sequence, tighten nuts
per wheel torque as listed in the table below.
Figure 6-9
Table 6-1
No. Description
1st Stage 2nd Stage 3rd Stage
1 Reducer
150Nm 250Nm 280Nm
(110ft-lb) (185ft-lb) (207ft-lb) 2 Drive motor
Removal of reducer and drive motor

NOTICE 1. Place the machine on a solid, level surface.
Wheel nuts should be torqued prior to first use of 2. Place a jack of sufficient capacity under the side of
machine and after each wheel removal. Check chassis to be removed. Lift the jack to make the
torque every 3 months or 150 hours of operation. wheel off the ground.
3. Remove the bolts and washers securing the wheel
to the reducer. Use a suitable lifting device to
Reducer and Drive Motor remove the wheel.
4. Tag, disconnect and plug the hyrdaulic hoses to the
The reducer and drive motor act not only the role of drive motor.
driving the machine but also the role of securing the 5. Remove the flange to secure the reducer and the
rear wheel. Before removing the reducer and motor, fasteners to secure the outrigger, and lift the flange
secure the machine on a suitable structure or support and reduce that are removed clear of the base
the machine by a jack of ample capacity. frame.
6. Remove the flange for motor installation from the
reducer. Take care not to damage the O-ring.
7. Remove the bolts securing the flange to the
reducer.
8. Remove the bolts securing the flange to the drive
motor.
Installation of reducer and drive motor
1. Use a lifting device with sufficient capacity to
support the outrigger.
2. Install the drive motor, and use torque wrench to
secure the bolts in diagonal sequence.
3. Align the reducer brake oil port with the nick of
support.

REPAIR PROCEDURES
4. Fit the washer with the mounting surface, apply 1. Tag, disconnect and plug the hydraulic hoses of
threadlocker Loctite 272 to the bolts,and intall in slewing buffer valve and slewing reducer brake.
turns.
2. Remove the bolt and washer from the slewing
5. Tighten the bolts with a torque wrench. buffer valve, and then remove the slewing buffer
valve from the slewing motor.
6. After all installed, add a suitable level of gear oil.
3. Remove the bolts securing the slewing reducer to
7. Clean the mount surface, lift the motor and align it
the turntable, and then remove the slewing reducer.
with the reducer: the motor spline shaft in mesh with
the inner gear of reducer, the motor mounting slot Installation of slewing drive device
aligned with the reducer mounting screw by slowly
rotating the motor housing. 1. Clear the foreign matters and burrs on the mounting
surface and gears of slewing reducer.
8. Apply the threadlocker Loctite 272 to the bolts and
torque the bolts after pretightening. 2. Place the slewing reducer on the turntable
mounting surface, use a feeler gauge to measure
9. Attach the hrdraulic hoses. the gear backlash relative to the slewing bearing,
10. Install the wheel. be sure the gear backlash falls within 0.15—
0.25mm (0.006–0.01in).
Turntable Slewing Mechanism
Figure 6-11
4 3. If the gear backlash exceeds the specification,

adjust the nut to specification.
4. With washer on the bolt, apply threadlocker Loctite
Figure 6-10 272. Install the mounting bolts to secure the slewing
reducer to the turntable, after installation pre-tighten
in diagonal order.
Table 6-2
5. Ensure the slewing reducer fits in well with the
turntable.
No. DESCRIPTION
6. Use a wrench to tighten the bolts in diagonal order.
1 Slewing buffer valve
7. Add gear oil to the slewing reducer until the gear
2 Slewing motor surface is covered.
3 Slewing reducer 8. Clean the mounting surface of slewing reducer, and
mate the axis pin of slewing motor with the reducer
4 Slewing bearing pin hole.
9. Rotate the motor housing to align the slewing motor
Removal of slewing drive device bolt hole with the reducer bolt hole. Apply
threadlocker Loctite 272 to the bolt with washer on,
install the bolt and tighten.

REPAIR PROCEDURES
Installation of slewing bearing 6. Hand turn the inner ring of the slewing bearing,
ensure it moves smoothly.
1. Use a lifing device with sufficient capacity to lift the
slewing bearing over the mounting surface of 7. Detach the lifting device from the slewing bearing.
chassis. 8. Rotate the inner ring of the slewing bearing until the
2. Use a feeler gauge to measure the clearance soft strap area on the inner ring and that on the
between the mounting surface of the slewing outer ring are symetrically arranged around the
bearing and that of the chassis, ensure the center of the slewing bearing.
clearance≤0.2mm (0.008in). 9. Using a lifting device, lift the turntable to the
3. Using the special washer for the high-strength bolt, mounting surface of the slewing bearing.
mate the washer surface with the mounting surface, 10. Using the special washer for the high-strength bolt,
apply threadlocker Loctite 272 to the bolt, and intall mate the washer surface with the mounting surface,
the bolts one by one. apply threadlocker Loctite 272 to the bolt, and intall
4. Tighten the bolts in the sequence as shown in the the bolts one by one.
figure below. 11. Refer to Fig 6-11 , page 6-10，and tighten the
1 23
retaining bolts in the sequence as indicated.
5
9 19 12. Refer to Table 6-3 , page 6-10, and tighten the
13 bolts per the recommended torques and sequence.
15
17 11
21 7 Battery
4 3
22
NOTICE
8
Before removing the battery, be sure to cut off the
12 18 charger power source and the total power source.
16 14
20 10 The batteries are located on both sides of the turntable.
24 2 6
1. Open the turntable cover and locate the battery.
2. Tag and disconnect the battery cables.
Figure 6-12
3. Remove the battery with lifting assistance.
5. The tightening of bolts should be done in stages,
Follow the stages and the recommended torques as
listed in the table below to tighten the bolts.
Table 6-3
1st Stage 2nd Stage 3rd Stage
90Nm 180Nm 300Nm

(66ft-lb) (133ft-lb) (221ft-lb)

REPAIR PROCEDURES
HYDRAULIC SYSTEM
Layout of Hydraulic Elements
1 2
3 4 9
5 8
6 7
Figure 6-13
Table 6-4
1. Oscillating counterbalance valve 4. Boom function valve 7. High-pressure filter
2. Oscillating mult-way valve 5. Slewing buffer vavle 8. Emergency power unit
3. Hydraulic tank 6. Slewing motor 9. Duplex gear pump

REPAIR PROCEDURES
Boom Function Valves
Figure 6-14

REPAIR PROCEDURES
Table 6-5
No. Name Spec. Function

2–way hydraulc Lock the hydraulic oil in master cylinder
1 DC08-40-0-N-25
lock
Solenoid Select directions for manual leveling function
2 SV08-47D-0-N-12ER
directional valve
Pressure Ensure the flow for leveling function remains constantly
3 compensating FR08-20F-0-N-M5.0 at 5Lpm, not affected by the the load pressure variation
valve at the downstream
Solenoid
4 directional valve, DS3-TA/11N-SD12K7 Control the main boom retraction
plate type
Solenoid
5 directional valve, DS3-TA/11N-SD12K7 Control the main boom extension in conjuction with #4.
plate type
Solenoid
6 SV10-47D-0-N-12ER Control the steer direction
directional valve
Solenoid Control the up and down movement of secondary boom
7 SV10-47D-0-N-12ER
directional valve
Solenoid Control the up and down movement of main boom
8 SV10-47D-0-N-12ER
directional valve
Solenoid Control turntable rotary dirction
9 SV10-47D-0-N-12ER
directional valve
Solenoid Control front pump discharing
10 SV08-21-0-N-12ER
directional valve
Solenoid Control rear pump discharging
11 SV08-21-0-N-12ER
directional valve
12 Check valve CV08-20-0-N-4 Prevent oil entering auxiliary power unit
13 Check valve CV08-20-0-N-4 Prevent oil entering rear pump
Proportional flow Make turntable rotary speed adjustable

14 PV72-30A-0-N-12ER
valve
Proportional Control the max allowable pressure for each action
15 TS08-27A-0-N-12ER
relief valve
Proportional flow Make main boom lifting speed adjustable
16 PV72-30A-0-N-12ER
valve
Restrict the secondary relief pressure of secondary
17 Relief valve RV08-22A-0-N-26/M100
boom down movement at 100bar
Proportional flow Common proportional valve
18 PV72-30B-0-N-12ER
valve
Restrict the secondary relief pressure of main boom
19 Relief valve RV08-22A-0-N-26/M145
extension at 145bar
Pressure
20 PR10-36A-0-N-15/M38 Restrict the operating pressure for oscillation at 38bar
reducing valve
Pressure Ensure the flow for oscillating function remains

21 compensating FR10-39A-0-N constantly at 5Lpm, not affected by the the load
valve pressure variation at the downstream

REPAIR PROCEDURES
No. Name Spec. Function
22 Relief valve RV08-22A-0-N-26/M240 Restrict the pressure for leveling at 240bar 28.5682
46.7096
23 Relief valve RV08-22A-0-N-26/M240 Restrict the pressure for leveling at 240bar 28.5682
28.5682
28.5682
28.5682
46.7096
24 Damper φ1.3 Restrict the flow for jib and swing cylinders. 28.5682
46.7096
28.5682
28.5682
28.5682
46.7096
25 Check valve CV10-20-0-N-5 Prevent oil entering the front pump 28.5682
46.7096
28.5682
28.5682
棕兰
黑
Hydraulic Symbols 棕兰
MP 黑
Table 6-6
+
棕兰
QF -
+
8.4982
CHARGE
MP 黑 28.5682
17.4787
Symbol Description 46.7096
8.498219.9977
28.5682
QF -
+
MP CHARGE
28.5682
28.5682
46.7096
17.4787
19.9977
46.7096
QF
14.7538
+
8.4982
CHARGE
Filter 34.4087 17.4787
14.7538
19.9977
46.7096
14.7538
34.4087 棕兰
34.3393
14.7538
32.0000 46.7096
黑
-
14.7538
+
30.0000
Brake 34.4087
28.5682
14.7538
34.3393
32.0000
16.0000
MP
28.5682
30.0000
QF + -
8.4982
34.3393
CHARGE 28.5682 46.7096
32.0000 28.5682 28.5682
16.0000
16.0000 17.4787 46.7096

19.9977
28.5682
30.0000
28.5682
28.5682
28.5682
Power unit
28.5682
28.5682
14.7538 16.0000
16.0000
46.7096 28.5682
28.5682
46.7096
28.5682
46.7096
16.0000
34.4087 28.5682
14.7538
+ Li
28.5682
28.5682
46.7096
棕兰
28.5682
28.5682
棕黑
兰
Hydraulic motor
34.3393
32.0000
黑 -
MP
30.0000
28.5682
16.0000
MP 棕兰
QF -
+
8.4982
棕兰
CHARGE
黑
17.4787
QF -
+
黑
8.4982
CHARGE
19.9977
Overflow valve
16.0000
17.4787
MP
19.9977
MP
46.7096
QF -
+
8.49828.4982
14.7538
CHARGE
28.5682
46.7096
QF -
+
CHARGE
3–position 4–way 34.4087 17.4787
14.7538
46.7096
19.9977
14.7538
17.4787 28.5682
solenoid directional
19.9977
34.4087
14.7538
28.5682
28.5682
46.7096
vavle 46.7096
34.3393
32.0000
14.7538
46.7096
34.3393
14.7538
32.0000
30.0000
34.4087
2–position 4–way
14.7538
34.4087 28.5682
30.0000
solenoid directional
14.7538
16.0000
28.5682
棕兰
valve
34.3393
16.0000
32.0000
黑
-
34.3393
16.0000
32.0000
+
30.0000
16.0000
28.5682
30.0000
MP
Pressure gradient 16.0000
16.0000
28.5682
control valve QF -
+
8.4982
CHARGE
16.000016.0000
17.4787
19.9977
Check valve
46.7096
14.7538
34.4087
14.7538
+ Li
34.3393
32.0000
-
30.0000
28.5682
© Oct 2020 16.0000
6-14 AB18EJ&18HJ Maintenance Manual
.0000
REPAIR PROCEDURES
Hydraulic Schematic
Figure 6-15 AB18EJ hydraulic schematic

REPAIR PROCEDURES
Figure 6-16 AB18HJ hydraulic schematic

REPAIR PROCEDURES
ELECTRICAL SYSTEM
Fault Code Desription
In case of machine malfunctions, please enter the fault display interface at the ground controller to check the fault
codes.
Table 6-7 Machine fault code description
Fault Description Cause Check

Code
Communication between Check the signal lines between platform and
Platform ground controllers, and ensure normal power
01 platform and ground
communication fault supply.
controllers abnormal
Communication between Check the signal lines between ground and drive
Drive controller
02 driver and ground controllers controllers, and ensure normal power supply.
communication fault
abnormal
Check whether the machine tilts exceeding 5°or
03 Turntable tilt alarm Turntable tilt alarm
the level switch becomes disconnected
Check whether the platform load exceeds the
04 Overload alarm Overload alarm rating.
Check whether the weight sensor functions

05 Weight sensor fault Weight sensor fault
properly
06 Drive joystick error Drive joystick data error Check the drive joystick data
07 Steer joystick error Steer joystick data error Check the steer joystick data
Main lift joystick Main lift joystick data error Check the main lift joystick data
08
error
Slewing joystick Slewing joystick data error Check the slewing joystick data
09
error
Telescope joystick Telescope joystick data error Check the telescope joystick data
10
error
Jib rotate joystick Jib rotate joystick data error Check the jib rotate joystick data
11
error
Hydraulic system Check whether the hydraulic system pressure
Hydraulic system pressure
12 pressure sensor sensor functions properly
sensor error
error
13 Level switch fault Level swtich fault Check whether the level switch functions properly
Check the signal lines between platform and

Lift controller Lift controller communication drive controllers, and ensure normal power
14
communication fault fault supply.
Footswitch or Check whether the footswitch or enable switch

Footswitch or Enable switch
15 Enable switch 7– function properly
7–second limit alarm
second limit alarm
Obstacle detection Check whether the obstacle detection switch
16 Obstacle detection alarm functions properly
alarm
Drive controller
17 Drive controller error alarm Check the associated error of drive controller
error alarm

REPAIR PROCEDURES

Code
Lift controller error
18 Lift controller error alarm Check the associated error of lift controller
alarm
Heavy load alarm Heavy load alarm Check the platform load and the actual
19
measurement of sensor AD value
Envelope alarm Envelope alarm Check the boom position and the actual
20
measurement of sensor AD value
Check the steel cables of boom and the wiring of
21 Broken cable alarm Broken cable alarm proximity switch
Weight sensor Weight sensor comparison Check the weight sensor actual values and AD
22 comparison error value, and check the wiring
error
23 Platform tilt alarm Platform tilt alarm Check whether the platform tilt angle out of range
Check whether the solenoid clutch fuctions

24 Solenoid clutch fault Solenoid clutch fault properly or the wiring harness is disconnected
Turntable slewing
Turntable slewing left Check the wiring of turntable slewing left solenoid
25 left solenoid valve
solenoid valve error valve
error
Turntable slewing
Turntable slewing right Check the wiring of turntable slewing right
26 right solenoid valve
solenoid valve fault solenoid valve
fault
Main boom extend Main boom extend solenoid Check the wiring of main boom extend solenoid
27
solenoid valve fault valve fault valve
Main boom retract Main boom retract solenoid Check the wiring of main boom retract solenoid
28
Main boom up Main boom up solenoid valve Check the wiring of main boom up solenoid valve
29
solenoid valve fault fault
Main boom down Main boom down solenoid Check the wiring of main boom down solenoid
30
solenoid valve error valve error valve
Secondary boom up Secondary boom up solenoid Check the wiring of secondary boom up solenoid
31
Secondary boom
Secondary boom down Check the wiring of secondary boom down
32 down solenoid valve
solenoid valve fault solenoid valve
fault
Steer left solenoid Check the wiring of steer left solenoid valve
33 Steer left solenoid valve fault
valve fault
Steer right solenoid Steer right solenoid valve Check the wiring of steer right solenoid valve
34
valve fault fault
Platform swing left Platform swing left solenoid Check the wiring of platform swing left solenoid
35
Platform swing right Platform swing right solenoid Check the wiring of platform swing right solenoid
36
Platform level up Platform level up solenoid Check the wiring of platform level up solonoid
37
Platform level down Platform level down solenoid Check the wiring of platform level down solonoid
38

REPAIR PROCEDURES

Code
Jib up solenoid Jib up solenoid valve fault Check the wiring of jib up solonoid valve
39
valve fault
Jib down solenoid Check the wiring of jib down solonoid valve
40 Jib down solenoid valve fault
valve fault
Function enable Check the wiring of function enable valve
41 Function enable valve fault
valve fault
Main boom anti-fall Check the wiring of main boom anti-fall valve
42 Main boom anti-fall valve fault
valve fault
Drive enable valve Check the wiring of drive enable valve
43 Drive enable valve fault
fault
44 Brake valve fault Brake valve fault Check the wiring of drive enable valve
Slewing enable Slewing enable valve fault Check the wiring of slewing enable valve
45
valve fault
Front pump
Front pump discharge valve Check the wiring of front pump discharge valve
46 discharge valve
fault
fault
Rear pump
Rear pump discharge valve Check the wiring of rear pump discharge valve
47 discharge valve
fault
fault
Electrically
Electrically proportional relief Check the wiring of electrically proportional relief
48 proportional relief
valve fault valve
valve fault
Secondary boom
Secondary boom angle Check whether the secondary boom angle
49 angle sensor
sensor comparison error sensor is correctly installed
comparison error
Secondary boom Secondary boom angle Check the wiring of secondary boom angle
50 angle sensor fault sensor fault sensor
Main boom angle Main boom angle sensor Check whether the main boom angle sensor is
51 sensor comparison comparison error correctly installed
error
Main boom angle Main boom angle sensor fault Check the wiring of main boom angle sensor
52
sensor fault
Secondary boom
Secondary boom relative Check whether the secondary boom relatvie
relative angle
53 angle sensor comparison angle sensor is correctly installed
sensor comparison
error
error
Secondary boom Secondary boom relative Check the wiring of secondary boom relatvie
54 relative angle angle sensor fault angle sensor
sensor fault
Main boom relative
Main boom relative angle Check whether the main boom relative angle
55 angle sensor
sensor comparison error sensor is correctly installed
comparison error
Main boom relative Main boom relative angle Check the wiring of main boom relative angle
56 angle sensor fault sensor fault sensor
Low battery level Low battery level alarm Check whether the battery voltage is too low
57
alarm

REPAIR PROCEDURES

Code
Front right steer Front right steer sensor fault Check the wiring of front right steer sensor
58
sensor fault
Check whether the clutch can be properly
59 Clutch fault Clutch fault enagaged or the sensor correctly wired.
Check whether the fuel level is too low or the

60 Low fuel level fault Low fuel level fault sensor correctly wired.
Table 6-8 General fault code description for electric motor controller

code
0012 Overcurrent of pump motor
1. Check the encoder surface for stains,
Overcurrent of FL motor replace if necessary;
0112 1. Encoder fault or circuit
controller interference; 2. Check whether the 3–phase of motor
Overcurrent of FR motor UVW is shorted or damaged, check the
0212 2. There is a short to
controller controller UVW 3–phase for damage using
Motor UVW;
a multimeter;
Overcurrent of RL motor 3. Mismatch of motor
0312 3. Monitor the controller current when fully
controller parameters;
loaded, re-match the motor if necessary;
Overcurrent of RR motor 4. Controller fault
0412 4. If the above checks fail, replace the
controller controller.
Current sensor fault of
0013 pump motor controller
Current sensor fault of FL

0113
motor controller
1. Motor UVW short- 1. Check the 3–phase cable of UVW for short
Current sensor fault of FR circuited; circuit or current leakage;
0213
motor controller
2. Current sensor of the 2. If the above check fails, replace the
Current sensor fault of RL controller faulted controller.
0313
motor controller
Current sensor fault of RR
0413
motor controller
Pre-charging fault of pump
0014
motor controller
Pre-charging fault of FL 1. Check whether the controller B+ circuit is
0114 linked to high-power load;
motor controller
1. The voltage reduces
Pre-charging fault of FR due to loaded B+ 2. Check the KSI wiring, and measure the
0214 voltage using a multimeter to check if it is
motor controller circuit;
normal;
Pre-charging fault of RL 2. Controller damage.
motor controller
controller.
Pre-charging fault of RR
0414
motor controller
Low temperature of pump
0015 1. 1. Raise the ambient temperature above–
motor controller
The controller operates at 40 ℃, restart the key switch and interlock
ambient temperatures switch;
Low temperature of FL below –40 ℃.
motor controller
controller.

REPAIR PROCEDURES

code
Low temperature of FR
0215
motor controller
Low temperature of RL
0315
motor controller
Low temperature of RR
0415
motor controller
High temperature of pump
0016
motor controller
High temperature of FL 1. Check the cooling measures of controller;
0116 1. Controller temperature
motor controller
over 95℃; 2. Monitor the operating current of controller,
High temperature of FR re-match the motor if too large, reset the
0216 2. Machine overload and turning point and slip value，properly
motor controller
motor mismatch; restrict the current if needed.
High temperature of RL
0316 3. Controller damage. 3. If the above checks fail, replace the
motor controller
controller.
High temperature of RR
0416
motor controller
Severe undervoltage of
0017 pump motor controller 1. Measure the battery voltage with a
1. Battery data setup multimeter to check proper voltage with
Severe undervoltage of FL
0117 error; KSI and B+ circuits;
motor controller
2. Excessive battery 2. Check the fuse and contactor;
Severe undervoltage of FR
0217 resistance;
motor controller 3. Check the battery setup, system voltage
3. Damaged fuse; and undervoltage setting.
Severe undervoltage of RL
0317 4. Damaged main 4. If the drive controller fails, main contactor
motor controller
contactor. not engaged, the pump controller will
Severe undervoltage of RR report the fault.
0417
motor controller
Severe overvoltage of
Severe overvoltage of FL 1. Check the battery with a multimeter for

0118 1. Battery setup error; proper voltage;
motor controller
2. Excessive battery 2. Check the fuse and contactor;
Severe overvoltage of FR resistance;
0218
motor controller 3. Check the battery setup, system voltage
3. Battery is disconected and undervoltage setting.
Severe overvoltage of RL when regenerative
0318 4. Check the regenerative brake setup and
motor controller brake enagages.
current limit.
Severe overvoltage of RR
0418
motor controller
Reduced low-temperature
0021 performance of pump
motor controller
Reduced low-temperature The machine operates at
Use the machine under normal operating
0121 performance of FL motor ambient temperatures
conditions.
controller below -25℃
0221 performance of FR motor
controller

REPAIR PROCEDURES

code
0321 performance of RL motor
controller
0421 performance of RR motor
controller
Reduced high-temperature
motor controller
0122 performance of FL motor
controller 1. Use the machine under normal operating
The controller operates at
conditions to increase the cooling effect of
Reduced high-temperature hostile environment with
controller.
0222 performance of FR motor the radiator blade
controller temperature higher than 2. If the ambient temperatue is normal, check
85℃ the controller current which may cause an
Reduced high-temperature abrupt rise in temperature if too large.
controller
controller
Reduced undervoltage
motor controller
0123 performance of FL motor
controller 1. Check the battery with a multimeter for
Reduced undervoltage 1. Low battery level; proper voltage;
0223 performance of FR motor 2. Battery setup error; 2. Check the fuse and contactor;
controller
3. Battery aging 3. Check the battery setup, system voltage
Reduced undervoltage and undervoltage setting.
controller
controller
Reduced overvoltage
motor controller
1. Check the battery with a multimeter for
Reduced overvoltage proper voltage;
0124 performance of FL motor 1. Battery setup error;
controller 2. Check the fuse and contactor;
2. Regenerative brake
Reduced overvoltage current results in 3. Check the battery setup, system voltage
0224 performance of FR motor voltage increase. and undervoltage setting.
controller 4. Check the regenerative brake setup and
Reduced overvoltage current limit.
controller

REPAIR PROCEDURES

code
Reduced overvoltage
controller
Invalid 5V internal power
0025 supply of pump motor
controller
Invalid 5V internal power 1. Check the externally connected device for
0125 supply of FL motor damage;
controller
2. Using handhold unit check monitor/outputs
Invalid 5V internal power menu/5 Volts;
Exterally connected
0225 supply of FR motor
device fault 3. Disconnect externally connected 5V
controller
devices, if the fault still exists, replace the
Invalid 5V internal power external devices.
0325 supply of RL motor Note：The pin #26 of the 35–pin controller
controller connector is for 5V output.
Invalid 5V internal power
0425 supply of RR motor
controller
Driver 6 output error of
1. Using handhold unit check monitor/digital
Driver 6 output error of FL out6 ，to inspect the driver 6 signal output
0126
motor controller percentage;
Driver 6 output error of FR Externally connected 2. Check the drive device of driver 6 for
0226 device fault
motor controller malfunctions, correct wiring,and current
not exceeding 1A.
Driver 6 output error of RL
0326
motor controller Note：The pin #19 of the 35–pin controller
connector is for drive 6 output.
Driver 6 output error of RR
0426
motor controller
Driver 7 output overcurrent
0027 of pump motor controller
1. Using handhold unit check monitor/digital
Driver 7 output overcurrent out7 ，to inspect the driver 7 signal output
0127
of FL motor controller percentage;
Driver 7 output overcurrent Externally connected 2. Check the drive device of driver 7 for
0227 device fault
of FR motor controller malfunctions, correct wiring,and current
not exceeding 1A.
0327
of RL motor controller Note：The pin #20 of the 35–pin controller
connector is for driver 7 output.
0427
of RR motor controller
Reduced overheat
0028 performance of pump 1. Check the motor temperature sensor for
motor controller damage;
1. Motor temperature 2. Check the motor temperature setup of
Reduced overheat reaching the preset controller for error; and check programme/
0128 performance of FL motor limit; motor menu/temperature control
controller
2. Improper set up motor temperature hot for overheat performance
Reduced overheat temperature. deceleration value setup;
0228 performance of FR motor 3. Monitor the machine operating current to
controller determine whether the overheat results

REPAIR PROCEDURES

code
Reduced overheat from an excessively large current, re-
0328 performance of RL motor match the motor if necessary.
controller
Note：The pins #7 and #8 of the 35–pin
Reduced overheat controller connector are for motor temperature
0428 performance of RR motor sensor.
controller
Temperature sensor fault
0029 of pump motor controller 1. Check the wiring of motor temperature
Temperature sensor fault sensor;
0129
of FL motor controller 1. Motor temperature 2. Check the setup of motor temperature
sensor fault; sensor via programme/motor menu/
Temperature sensor fault
0229 temperature control sensor type.
of FR motor controller 2. Setup error of motor
temperature sensor 3. Replace the motor temperature sensor.
Temperature sensor fault type
0329 Note：The pins #7 and #8 of the 35–pin
of RL motor controller
controller connector are for motor temperature
Temperature sensor fault sensor.
0429
Open/short-circuited drive
0031 1 output/main contactor of
pump motor controller
Open/short-circuited driver 1. Ensure the correct wiring and the pins free
0131 1 output/main contactor of of stains or damage;
FL motor controller 2. Monitor output signal via monitor menu/
Open/short-circuited driver 1. Driver 1 wiring fault; outputs menu/Driver 1 PWM to check
0231 1 output/main contactor of whether there is output control signal;
2. Loading device fault;
FR motor controller 3. Check the coil of contactor;
3. Contactor fault.
Open/short-circuited driver 4. Replace the contactor.
RL motor controller Note：The pins #6 of the 35–pin controller
connector is for driver 1 output.
Open/short-circuited driver
RR motor controller
0032 2 of pump motor controller 1. Ensure the correct wiring and the pins free
of stains or damage;
0132 2. Monitor output signal via monitor menu/
2 of FL motor controller
1. Drive 2 wiring fault; outputs menu/Driver 2PWM to check
Open/short-circuited driver whether there is output control signal;
0232 2. Loading device fault;
2 of FR motor controller
3. Check the coil of contactor;
Open/short-circuited driver 3. Contactor fault.
0332 4. Replace the contactor.
2 of RL motor controller
Note：The pins #5 of the 35–pin controller
Open/short-circuited driver connector is for driver 2 output.
0432
2 of RR motor controller
Open/short-circuited
solenoid brake/coil 3 1. Ensure the correct wiring and the pins free
0033 1. Open/short circuited of stains or damage;
output of pump motor
controller coil of solenoid brake; 2. Monitor output signal via monitor menu/
2. Stained/damaged/ outputs menu/Driver 3 PWM to check
Open/short-circuited broken wiring whether there is output control signal;
0133
solenoid brake/coil 3
3. Check the coil of contactor;

REPAIR PROCEDURES

code
output of FL motor 4. Replace the contactor.
controller
0233
output of FR motor
controller
Open/short-circuited Note：The pins #4 of the 35–pin controller
solenoid brake/coil 3 connector is for driver 3 output.
0333
output of RL motor
controller
0433
output of RR motor
controller
Open/short-circuited coil 4
0034 output of pump motor
controller
0134 output of FL motor
controller 1. Ensure the correct wiring and the pins free
1. Open/short-circuited of stains or damage;
coil 4; 2. Monitor output signal via monitor menu/
0234 output of FR motor
controller 2. Stained/damaged/ outputs menu/Driver 4PWM to check
broken wiring whether there is output control signal;
0334 output of RL motor 3. Check the driver coil.
controller
0434 output of RR motor
controller
Proportional drive error of
Proportional drive error of 1. Ensure the correct wiring and the pins free
0135 1. Open/short-circuited of stains or damage;
FL motor controller
loading device;
Proportional drive error of 2. Monitor output signal via monitor menu/
0235 2. Stained/damaged/ outputs menu/PD PWM to check whether
FR motor controller
broken wiring; there is output control signal;
0335 3. Improper wiring 3. Check the loading devices, such as the
RL motor controller
driver coil, for damage.
0435
RR motor controller
Encoder error of pump
0036 1. Check the encoder power supply;
motor controller
2. Check the encoder setup via programme/
Encoder error of FL motor 1. Failed power supply of
0136 motor menu/ encoder steps for the pulse
controller encoder; count;
Encoder error of FR motor 2. Damaged encoder; 3. Check the encoder feedback speed signals
0236
controller via monitor/motor menu/motor speed A/B;
3. Improper wiring.
Encoder error of RL motor 4. If the checks above fail to discover the
0336
controller problem, replace the encoder.

REPAIR PROCEDURES

code
Encoder error of RR motor Note: The pins #31 and #32 of the 35–pin controller
0436 connector are for encoder AB phase output signals.
controller
Open-circuited pump motor
0037
controller
Open-circuited FL motor
0137 1. Ensure the 3–phase wiring of UVW free of
controller
1. Incomplete motor; open circuit;
Open-circuited FR motor
0237 2. Improper wiring; 2. Use a multimeter to check the UVW power
controller
module works properly;
Open-circuited RL motor 3. Damaged controller.
0337 3. If the steps above fail, replace the motor.
controller
Open-circuited RR motor
0437
controller
Fused main contactor of
1. Check the main contactor for fused
Fused main contactor of FL
0138 contact;
motor controller
1. Fused contact of main 2. Measure the coil voltage to ensure it is
Fused main contactor of contactor; normal;
0238
FR motor controller
2. Improper wiring. 3. Ensure the correct wiring;
0338 4. If the motor lacks in phase, check the UV
RL motor controller
phase for unlinked cable.
0438
RR motor controller
Main contactor engaging
0039 failure of pump motor con
troller
1. Use a handhold to monitor the KSI, ensure
Main contactor engaging 1. Voltage drop between the difference between the capacitor
0139 failure of FL motor KSI voltage and voltage (monitor/outputs menu capacitor
controller battery voltage too big; Voltage) and the keyswitch voltage is less
Main contactor engaging than the threshold(programme/main
2. The KSI circuit is
0239 failure of FR motor contactor/main DNC).
series connected to a
controller large-power unit which 2. Check whether the KSI circuit is
Main contactor engaging brings the voltage connected to a large-power unit which
0339 failure of RL motor down; leads to the reduced KSI voltage;
controller 3. Contactor damage. 3. Use interchange method to determine
whether the contactor is damaged.
Main contactor engaging
0439 failure of RR motor
controller
High voltage at slider end
0041 of accelerator of pump
motor controller
1. Accelerator wiring Measure the output voltage at the slider end
High voltage at slider end interupted; of accelerator to check if it is too high, replace
0141 of accelerator of FL motor the accelerator if necessary.
controller 2. Excessively high Note：The pins #16 of the 35–pin controller
output voltage at slider connector is for accelerator slider end input.
High voltage at slider end end of accelerator.
0241 of accelerator of FR motor
controller

REPAIR PROCEDURES

code
0341 of accelerator of RL motor
controller
0441 of accelerator of RR motor
controller
Low voltage at slide end of
0042 accelerator of pump motor
controller
Low voltage at slider end of
0142 accelerator of FL motor
controller
Measure the output voltage at the slider end
Low voltage at slider end of Excessively low output of accelerator to check if it is too low, replace
0242 accelerator of FR motor voltage at slider end of the accelerator if necessary.
controller accelerator. Note：The pins #16 of the 35–pin controller
connector is for accelerator slider end input.
0342 accelerator of RL motor
controller
0442 accelerator of RR motor
controller
0043 of pot2 of pump motor
controller
0143 of pot2 of FL motor
controller
Measure the voltage at the slider end of pot2,
High voltage at slider end Excessively high output
replace if necessary.
0243 of pot2 of FR motor voltage at slider end of
Note：The pins #17 of the 35–pin controller
controller pot2.
connector is for pot2 slider end input.
0343 of pot2 of RL motor
controller
0443 of pot2 of RR motor
controller
0044 pot2 of pump motor
controller
0144 pot2 of FL motor controller Measure the voltage at the slider end of pot2,
Excessively low output
Low voltage at slider end of replace if necessary.
voltage at slider end of
0244 pot2 of FR motor controller Note：The pins #17 of the 35–pin controller
pot2.
connector is for pot2 slider end input.
0344 pot2 of RL motor controller

0444 pot2 of RR motor controller

REPAIR PROCEDURES

code
Pot-low overcurrent of
Pot-low overcurrent of FL
0145
motor controller
Pot-low overcurrent of FR Excessively low resistance Overcurrent at potentiometer low end, replace
0245 of potentiometer. if necessary
motor controller
Pot-low overcurrent of RL
0345
motor controller
Pot-low overcurrent of RR
0445
motor controller
Invalid EEPROM of pump
0046
motor controller
Invalid EEPROM of FL
0146
motor controller
Invalid EEPROM of FR 1. Software error; 1. Download the correct software version;
0246
motor controller
2. Controller failure. 2. Replace the controller.
Invalid EEPROM of RL
0346
motor controller
Invalid EEPROM of RR
0446
motor controller
Operation sequence error
0047 of pump motor controller
1. Input sequence error of
keyswitch, interlock 1. Check the input sequence of switches to
Operation sequence error
0147 switch, directional exclude the operation-induced cause;
of FL motor controller
switch and accelerator; 2. Use a handhold unit to check each switch
Operation sequence error condition;
0247 2. Failure of keyswitch,
of FR motor controller
interlock switch, 3. Use a handhold unit ot check the
Operation sequence error directional switch and accelerator signal;
0347
of RL motor controller accelerator;
4. Replace the failed switches.
Operation sequence error 3. Improper wiring.
0447
Setup change of pump
0049
motor controller
Setup change of FL motor
0149
controller
The key switch must be
Setup change of FR motor restarted after setup
0249 Restart the key switch to eliminate the fault.
controller change of some
parameters.
Setup change of RL motor
0349
controller
Setup change of RR motor
0449
controller
VCL run error of pump
0068
motor controller 1. Update the software to the correct version;
Software problem
VCL run error of FL motor 2. Replace the controller.
0168
controller

REPAIR PROCEDURES

code
VCL run error of FR motor
0268
controller
VCL run error of RL motor
0368
controller
VCL run error of RR motor
0468
controller
Power supply of pump
0069 motor controller exceeding
the range
Power supply of FL motor

0169 controller exceeding the
range 1. Check the external loads of 5V and 10V
1. Excessively high/low loading devices for short circuit or
Power supply of FR motor damage;
controller exceeding the current of external
0269
range loads; 2. Check the setup (external supply max and
2. Check the setup. external supply min);
Power supply of RL motor
3. Replace the failed devices.
range
Power supply of RR motor

range
Operation software fault of


0171
FL motor controller
Operation software fault of 1. Software problem; 1. Update the software to the correct version;
0271
FR motor controller 2. Replace the controller.
2. Controller failure.
0371
RL motor controller
0471
RR motor controller
PDO timeout of pump
0072 1. Update the software to the correct version,
motor controller
and ensure the bus free of interference;
PDO timeout of FL motor
0172 2. Ensure the the bus terminal resistance is
controller
60 ohm, the bus voltage approx. 2.5V;
PDO timeout of FR motor 1. Software problem;
0272 3. Ensure the devices on the bus are
controller 2. CAN bus correctly connected;
commnication error.
PDO timeout of RL motor 4. Check the on-bus devices are correctly
0372
controller programmed;
PDO timeout of RR motor 5. Use the exlusion method to replace the
0472
controller failed devices.
Motor rotary choke of
0073 pump motor controller 1. Motor rotary choke; 1. Check the power supply and wiring of
2. Encoder fault; motor encoder to ensure the speed signal
can be properly delivered;
Motor rotary choke of FL 3. Improper wiring or
0173
motor controller motor damage 2. Ensure the brake is fully disengaged;

REPAIR PROCEDURES

code
Motor rotary choke of FR 3. Check the motor and controller.
0273
motor controller
Motor rotary choke of RL
0373
motor controller
Motor rotary choke of RR
0473
motor controller
System distress of pump
0077 1. The processor
motor controller
discovers illegal and
System distress of FL reduntant data;
0177
motor controller
2. The processor inside
System distress of FR the controller fails; 1. Check the internal micro-processor for
0277 damage;
motor controller 3. The processor
discovers the switching 2. Check input signals of all switches, and
System distress of RL ensure the switches free of wetting or
0377 signal exceeds the
motor controller damage.
threshold by 100ms (if
the fault occurs
System distress of RR repeatedly, please
0477 check if the switch gets
motor controller
wet or damaged).
Motor matching failure of Description of motor matching

0087 pump motor controller failure codes:
0=Normal;
1=Encoder signal received,
Motor matching failure of pseudo not identified, manul
0187
FL motor controller setup of the encoder pulse
required;
Motor matching failure of 2=Motor temp sensor failure;
0287 3=Motor high-temp response
FR motor controller
failure; Check the encoder and motor and ensure
Motor matching failure of 4=Motor overheat response correct wiring
0387 failure;
RL motor controller 5=Motor low-temmp response
failure;
6=Low-volts response failure;
7=High-volts response failure;
Motor matching failure of 8=Controller fails to detect the
0487
RR motor controller encoder signal;
9=Motor setup exceeding the
range
Motor type error of pump

0089
motor controller
Motor type error of FL
0189
motor controller
Motor type error of FR Motor type data setup out
0289 Modify the motor type data
motor controller of range
Motor type error of RL
0389
motor controller
Motor type error of RR
0489
motor controller
VCL/OS mismatch of pump
0091
motor controller
Controller program error Update the program to the correct version.
VCL/OS mismatch of FL
0191
motor controller

REPAIR PROCEDURES

code
VCL/OS mismatch of FR
0291
motor controller
VCL/OS mismatch of RL
0391
motor controller
VCL/OS mismatch of RR
0491
motor controller
Invalid solenoid brake
0092 setup of pump motor
controller
0192 setup of FL motor
controller 1. The machine moves
freely after solenoid 1. Ensure the correct setup of solenoid brake
brake is triggered; and accelerator;
0292 setup of FR motor
controller 2. The holding force of 2. Check the brake disc of solenoid brake to
solenoid brake too determine whether it needs adjusting.
Invalid solenoid brake weak
0392 setup of RL motor
controller
0492 setup of RR motor
controller
Restricted encoder
0093 operation of pump motor
controller
Restricted encoder
0193 operation of FL motor 1. Motor rotary choke or 1. Check the encoder power supply and
controller encoder fault causes ensure correct wiring;
the restricted 2. Check the encoder setup for pulse count
Restricted encoder operational position of (programme/motor menu/ encoder steps);
0293 operation of FR motor encoder to be
controller activated; 3. Check the encoder feedback speed
signals via monitor/motor menu/motor
Restricted encoder 2. Improper wiring; speed A/B;
0393 operation of RL motor
controller 3. Machine rotary choke. 4. Replace the encoder
Restricted encoder
0493 operation of RR motor
controller
Emergency reverse
0094 response timeout of pump
motor controller
1. Emergency reverse 1. Use handhold unit to monitor (monitor /-
Emergency reverse switch in cosed inputs menu/emer Rev), if it keeps in the
0194 response timeout of FL position; ON position, check the emergency reverse
motor controller switch;
2. EmerTimer expires，
Emergency reverse which leads to the 2. Check the wiring of emergency reverse
0294 response timeout of FR activation of switch;
motor controller emergency reverse 3. Check the programming of emergency
Emergency reverse timeout. reverse.
0394 response timeout of RL
motor controller

REPAIR PROCEDURES

code
Emergency reverse
0494 response timeout of RR
motor controller
Model error of pump motor
0098
controller
Model error of FL motor
0198 1. Controller model
controller
unidentifiable; 1. Check the controller model;
Model error of FR motor
0298 2. Controller software 2. Check the software version;
controller
error;
Model error of RL motor 3. Replace the controller.
0398 3. Controller damage.
controller
Model error of RR motor
0498
controller
2WD machine motor setup
0098 mismatch of pump motor
controller
0198 mismatch of FL motor
controller
2WD machine motor setup When the dual-motor is
When the dual-motor is on, set the control
0298 mismatch of FR motor on, the control mode is not
mode as 0 or 1.
controller set as 0 or 1
0398 mismatch of RL motor
controller
0498 mismatch of RR motor
controller
Table 6-9 Special fault code description for electric motor controller

Code
CAN
Communication timeout 1s
communication Check CAN3 signal lines between pump motor
0052 between motor controller and
timeout of pump controller and machine main controller.
machine main controller
motor controller
Charging voltage Pump motor controller Check CAN3 signal lines between pump motor
0053 overload of pump voltage 59V and timeout 3s controller and machine main controller.
motor controller
CAN
communication Check CAN3 signal lines between FL motor
0152 between FL motor controller
timeout of FL motor controller and machine main controller.
and machine main controller.
controller
Communication
timeout between FL Check CAN3 signal lines between FL and FR
0153 between FL and FR motor
and FR motor motor controllers.
controllers
controllers

REPAIR PROCEDURES

Code
Communication
timeout between FL Check CAN3 signal lines between FL and RL
0154 between FL and RL motor
and RL motor motor controllers.
controllers
controllers
Communication
timeout between FL Check CAN3 signal lines between FL and RR
0155 between FL and RR motor
and RR motor motor controllers.
controllers
controllers
CAN
communication Check CAN3 signal lines between FR motor
0252 between FR motor controller
timeout of FR motor controller and machine main controller.
controller
Communication
timeout between FR FR motor controller timeout
Check CAN3 signal lines between FR and FL
0257 motor and main 1s to receive signal from FL
motor controllers.
control (FL) motor controller
CAN
communication Check CAN3 signal lines between RL motor
0352 between RL motor controller
timeout of RL motor controller and machine main controller.
controller
Communication
timeout between RL RL motor controller timeout
Check CAN3 signal lines between RL and FL
0356 motor and main 1s to receive signal from FL
motor controllers.
CAN
communication Check CAN3 signal lines between RR motor
0452 between RR motor controller
timeout of RR motor controller and machine main controller.
controller
Communication
timeout between RR motor controller timeout
Check CAN3 signal lines between RR and FL
0458 RR motor and main 1s to receive signal from FL
motor controllers.
Use and Maintenance of Lead-Acid • Sodium bicarbonate

Battery (requires maintenance) • Terminal post protector (i.e., petroleum jelly and
corrosion prevention spray, etc.)
REQUIRED EQUIPMENT • Voltmeter (for flooded/wet battery, colloid and AGM
battery)
• Protective goggles and gloves
• Wrench with rubber handle
Figure 6-17

REPAIR PROCEDURES
• Do not smoke near the battery, and keep the battery

away from sparks, flames and metal objects.
• Use a wrench with a rubber handle when
connecting the battery.
• The electrolyte is the mixed solution of acid and
water. Do not allow it to contact skin.
• Wash immediately with water if acid contacts the
skin or the eyes.
• Be sure the battery cable connectors are properly
tightened to the battery terminal. Battery cable
connectors that are too tight or loose could damage
the terminal or cause a fire.
• Avoid a short circuit by never placing objects on the
battery and touching both battery terminals at the
same time with a metal object.
• The wet lead-acid battery will release small
amounts of gas in the process of use, particularly in
the charging process. Be sure to charge the battery
in a well-ventilated place.
• Do not add acid into the battery.
Figure 6-18 • Always keep the battery vertical. The electrolyte in
the battery may spill from the battery if the battery is
• Distilled or purified water (deionized water and tilted or placed on its side.
reverse osmosis water, etc.) BATTERY CONNECTION INSTRUCTIONS
• Discharge tester (if required) Battery cable and torque value:
• Specific gravity hydrometer (for flooded/wet battery)
• The battery cable provides connection among and
between battery, equipment and charging system.
Connect the battery, the charging system and the
equipment with a flexible cable. An improper
connection could lead to poor performance, battery
damage or cause a fire.
• The tightening torque of cable fixation nut shall be
executed according to the following table:
Table 6-10
Nut
Torque
specifications
M8 9 ~ 11 Nm (80 ~ 97 ft-lb)
M10 18 ~ 23 Nm (160 ~ 204 ft-lb)
• Be sure the battery cable connectors are properly

tightened to the battery terminal. Battery cable
connectors that are too tight or loose could damage
the terminal or cause a fire.
• Battery terminals could become corroded if not kept
Figure 6-19
clean and dry. To prevent corrosion, apply a thin
layer of petroleum jelly or use a terminal protector.
BATTERY INSTALLATION SAFETY
INSTRUCTIONS PREVENTIVE MAINTENANCE
• Always wear protective clothing, gloves and goggles Inspection
when handling the battery.

REPAIR PROCEDURES
• Inspect the battery. The top of the battery and • The charge for this equipment is automatic and
terminal connections must be kept clean and free preprogrammed so that the user does not need to
from dust and corrosion and must remain dry. interfere with the charging process.
• Liquid on top of the battery could indicate there is • Charge the battery fully after each use.
too much water in the battery.
• The lead-acid battery does not have battery
• Inspect the connections between the battery cables memory. It is unnecessary to fully discharge it
and other components. Tighten all loose before recharging it.
connections.
• Inspect the electrolyte level height and ensure the
• Replace damaged battery cables. positive and negative electrode plates are not
flooded by the water before charging.
• Be sure the vent caps are properly installed on the
battery. • Before charging, be sure all the vent caps are
properly installed.
Cleaning
• Charge the battery only in a well-ventilated place.
• Clean the top, terminals and connections of the
battery with a cloth or brush and mixed solution of • The battery will discharge gas (bubble) at the end of
sodium bicarbonate and water. Do not let the charging. This bubbling indicates the electrolyte
cleaning solution enter the battery. solution is charged.
• Clean the top, terminals and connections with water • Avoid charging the battery when the temperature is
and wipe them dry with a cloth. Apply a thin layer of above 49°C (120°F).
petroleum jelly to the terminals or use terminal The following figure shows the battery charging
protector.
process.
• Keep the area around the battery clean and dry.
Filling in Distilled Water
• If necessary, add distilled water into the battery. The
frequency of adding water depends on the battery
applications and working temperature. Inspect the
battery every few weeks to determine if water needs
to be added. Generally, frequent battery use
requires frequent additions of water.
• Fully charge the battery before filling it with distilled
water. Only add distilled water into the discharged or
partially charged battery if the plate electrode is
exposed; in this case, fill it with distilled water to the
level just above the plate. Then, charge the battery
as follows: Figure 6-20
1. Clean the vent caps before removing them to EQUALIZATION
prevent dirt and debris from entering the battery.
Inspect the electrolyte level. If the level is highe Equalization is the deliberate process of overcharging
than the plate, add water. If the level is lower the flooded/wet battery after it has been fully charged.
than the plate, add distilled water or deionized Equalize the battery only when the specific gravity of
water. battery is low (less than 1.25) or the scope (0.030) of
the specific gravity is wide after the battery is fully
2. With a standard battery, add water until the level charged. Do not equalize other batteries. The
is 3 mm (0.12 in) below the vent well(the plastic conditions for equalizing a battery are as follows:
cover inside the vent).
• Verify whether the battery is flooded/wet battery.
3. After filling the battery with water, install the vent
caps on the battery. • Inspect the electrolyte level height to ensure that the
positive and negative electrode plates have not
BATTERY CHARGING been flooded before charging.
Proper charging is essential for maximizing the battery • Before charging, confirm that all the vent caps have
performance. Insufficient or excessive charging may been fixed on the battery properly.
shorten the service life of the battery significantly. Most
chargers are automatic and pre-programmed, but some • Set the charger to equalization mode.
chargers allow the user to set the voltage and current • The battery will bleed air in the equalization process
values. Details about proper charging are as follows: (forming bubbles).

REPAIR PROCEDURES
• Measure the specific gravity every hour; stop • Disconnect the power-off plug to prevent potential
charging in equalization mode when the specific parasitic loading, which may cause electrical
gravity does not increase. leakage of the battery.
STORAGE • The battery will self-discharge gradually during
storage. Monitor the specific gravity or the voltage
• Charge the battery before storage. every 4～6 weeks. The comparison of the charging
• Store the battery in a shady, cool and dry place that state with specific gravity and open-circuit voltage is
is free of the influence of the weather. shown in the following table.
Table 6-11
Open-Circuit Voltage (V)

Percentage Charging Specific Gravity
（%） Battery Cell 6V 12V
100 1.277 2.122 6.37 12.73
90 1.258 2.103 6.31 12.62
80 1.238 2.083 6.25 12.50
70 1.217 2.062 6.19 12.37
60 1.195 2.040 6.12 12.24
50 1.172 2.017 6.05 12.10
40 1.148 1.993 5.98 11.96
30 1.124 1.969 5.91 11.81
20 1.098 1.943 5.83 11.66
10 1.073 1.918 5.75 11.51
• Recharge the battery in quick mode when the 2. Record the current in the last half an hour (if
battery level is 70% or lower. possible) and measure the voltage of the battery
rack when charging.
• Recharge the battery before use after removing it
from storage. 3. At the end of charging, check if the current is lower
than 5A and the voltage of the battery rack is higher
• Storage in hot environments (above 32°C [90°F]):
than the following values:
During storage, do not expose the battery directly to
the heat source. The self-discharge process will 56V for 48V system; 28V for 24V system; 14V for
accelerate in warmer temperatures. If storing the 12V system or 7V for 6V system; if so, proceed to
battery in hot temperatures or during hot weathe the next step. Otherwise, inspect whether the
monitor the specific gravity or the voltage more output of the charger is correct and recharge the
frequently (about every 2 - 4 weeks). battery as required. If the voltage of the battery rack
is still very low, a problem may exist with the
• Storage in cold environments (below 0°C [32°F]):
battery.
During storage, do not store the battery in a place
with an estimated temperature reaching the freezing 4. Measure the voltage of each individual battery
point; if the battery has not been fully charged, it when the battery is in the charging state. If the
may freeze in cold temperatures. If storing the voltage of any battery is lower than the following
battery in cold temperatures or during cold weather, values, a problem could exist with the battery:
fully charge the battery. This point is very
important. 7V for 6V battery, the voltage difference between
the battery and any other batteries in the battery
TROUBLESHOOTING rack is larger than 0.5V; 14V for 12V battery, the
voltage difference between the battery and any
Follow the battery testing guidelines to determine if the other batteries in the battery rack is larger than
battery needs to be replaced. 1.0V.
Voltage Test When Charging Test of Specific Gravity
1. Disconnect and reconnect the DC plug to restart the 1. Fill and drain the specific gravity hydrometer 2～3
charger. times. Then, obtain a sample from the battery.

REPAIR PROCEDURES
2. Measure the specific gravity of all battery cells. will illuminate after charging and the red indicator
lamp will illuminate if the battery has a problem.
3. When the temperature is above 27°C (80°F), add
0.004 to correct the reading of the specific gravity • Charging brake: All functions of the machine will not
every 5°C (40°F) higher. When the temperature is operate when charging.
below 27°C (80°F), deduct 0.004 to correct the
reading of the specific gravity every 5°C (40°F)
lower. Use and Care of Lead-acid Battery
4. If the specific gravity of each battery in the battery (maintenance-free)
rack is lower than 1.250, the battery rack may not
be sufficiently charged. Recharge the battery rack. The use and care requirements for lead-acid
5. If the specific gravity difference between any battery maintenance-free batteries are as follows:
in the battery rack is over 0.050, equalize this PREPARATION
battery rack.
• Before checking the fault, the operator must wear
6. The battery in the battery rack may have a problem
safety equipment, including insulating gloves,
if the difference still exists.
helmets and other necessary safety supplies and
Open-Circuit Voltage Test (Rarely Used) multimeters.
1. To obtain an accurate voltage reading, do not use • Inspect the battery system cabinet for problems
the battery for at least 6 hours, but, it is best not to such as battery deformation, damage of the positive
use the battery for 24 hours. and negative terminals, etc.
2. Measure the voltage of each individual battery. • Check and confirm the fault description and analyze
the cause.
3. Equalize the battery rack if the voltage of any
battery is 0.3V higher than that of other batteries in CHARGING
the battery rack.
• Do not use an external charger.
4. Re-measure the voltage of each individual battery.
• Charge using the correct AC input voltage indicated
5. The battery may have a problem if the voltage of on the decal.
any battery is 0.3V higher than that of other
• Make sure the battery is connected before charging.
batteries in the battery rack.
• Connect the battery charger to a grounded AC
There are other battery tests to evaluate battery
circuit.
performance, such as discharge tests, that are not
described here. • Charge the battery every time after using.
HIGH-FREQUENCY BATTERY CHARGER CARE
Relevant Technical Parameters: • While wearing proper hand and face protection,
wipe the top and sides of the battery.
• Input voltage: AC100～240V
• Do not rinse or spray the battery pack with a water
• Output voltage: 24V
hose.
Precautions: • Be sure the cable connector is tight on the terminal.
• Low-input voltage protection: The battery charger • Do not leave the battery in a discharged state during
will shut down when the input AC voltage is lower storage, as it will shorten the service life.
than 85V. It will automatically resume charging
when the voltage becomes normal. CAUTIONS
• Reverse-polarity protection: In case of the reverse • Because there is a risk of high voltage, do not touch
polarity of the battery, the battery charger will non-insulated terminals or connectors.
terminate the connection between the internal circuit
and the battery to avoid charging and damaging the • The battery terminal and related accessories
battery. contain lead and lead components. Wash your
hands after handling them.
• Output short-circuit protection: When there is an
accidental output short circuit of the battery charger,
the battery charger will shut down the output Use and Care of Lithium Battery
automatically to troubleshoot the problem. Then, the
battery charger will restart after a delay of 10
seconds. The requirements for the use and care of lithium
batteries are as follows:
• Charging indication: The yellow indicator lamp will
illuminate when charging, the green indicator lamp PREPARATION

REPAIR PROCEDURES
• Before checking the fault, the operator must wear • Discarded batteries may cause danger to people
safety equipment, including insulating gloves, face and the environment. Be sure to properly discard
shields and other necessary safety supplies and them according to the rules of your workplace and
special tools such as multimeters, communication your local laws.
tools (485 communication box or CAN) and
computers, etc. • Do not apply external force to the battery or drop it
from a high altitude.
• Inspect the battery system cabinet for problems
• The lithium battery has an automatic protection
such as deformation of the cabinet, damage of the
function: if the cell voltage is higher than 3.4V, the
positive and negative terminals, loose connection of
battery system activates for a long period of time
the communication navigation plug, etc.
without an output current (≤5A) for 36H, or the cell
• Check if the harness on the communication voltage is lower than 3.4V, the battery is used for a
navigation plug is misaligned. long time. When the system is active and no current
is output (≤5A) for 8H, the system will automatically
• When the system is powered, the battery
cut off the contactor protection. If so, re-key the
information is read through 485 communication or
battery to activate it.
CAN communication.
• Check and confirm the fault description and analyze
the cause. Electrical Symbols
CAUTIONS
Table 6-12
• In the driving process (traveling or lifting), if there is
no emergency, do not arbitrarily disconnect the key
to forcibly cut off the battery system main relay. Symbol Desription
-
+
• When the display shows that the battery voltage is CHARGE
too low, charge the battery as soon as possible to
prevent the battery from being over-discharged.
• After using the battery for a long period of time, Buzzer
charge the battery as soon as possible before
leaving it for a long period of time to prevent the 棕兰
M
battery from over-discharging due to
selfconsumption of the battery system. 黑
• If there is heat, deformation, liquid leakage, odor or
MP 28.5682
46.7096
28.5682
smoke while using the battery, immediately stop 28.5682
28.5682
46.7096
A using the battery and place the battery in an open Valve
place away from anyone.
• The battery is only suitable for this particular QF
棕兰
M
product. Never use the battery with other
equipment. θ 黑
-
+
MP
B • Do not use a wire to directly short-circuit the battery Two lines connected
output. CHARGE
QF -
+
8.4982
CHARGE
压原理图
17.4787
002
• Do not immerse the battery in water, acid, alkaline
19.9977
or a salt solution and avoid rain.

46.7096
14.7538
• Do not use or store the battery in environments 34.4087

such as corrosive, explosive and high-temperature
14.7538
areas. Keep the battery out of棕areas

and exposure to fire or sun.
兰 with high heat θ M Motor
34.3393
32.0000
30.0000
• Use a special charger when charging, and avoid 28.5682
charging under direct sunlight. 黑

Do not charge the 16.0000
28.5682
battery repeatedly after the battery is full. Keep 28.5682

46.7096
16.0000
children away from the charging charger.

28.5682
28.5682
46.7096
• The battery system is not suitable for extended use.

It should be placed in a suitable environment Storage battery
θ (-
temperature below 40°C, humidity less than 90%), SQ
and charged once with a dedicated charger for at
棕兰
least three months.
黑
-
+
MP
QF -
+
8.4982
CHARGE
17.4787 © Oct 2020 6-38 AB18EJ&18HJ Maintenance Manual
19.9977
46.7096
46.8000
+ Li REPAIR PROCEDURES
16.0373
34.3393
-
Symbol 28.5682 Desription Symbol Desription
+ Li
M Lithium battery
Warning lamp
-
M
θ
Toggle switch
Valve
M
-
M
+
CHARGETwo lines non-
Level switch
connected
M
棕兰
Oil temperature Proximity switch/

θθ switch 黑
28.5682
46.7096
Pressure sensor
28.5682
28.5682
28.5682
46.7096
Delay relay
棕兰
黑
-
+
Fuel level sensor
MP
Power-off switch QF -
+
8.4982
CHARGE
17.4787
19.9977
46.7096
14.7538
34.4087
14.7538
Relay Horn + Li
34.3393
32.0000
-
30.0000
28.5682
16.0000
16.0000

REPAIR PROCEDURES
Symbol Desription
Key switch
Preheating wire

REPAIR PROCEDURES
Electrical Schematic
Figure 6-21 Electrical schematic of turntable

REPAIR PROCEDURES
Figure 6-22 Electrical schematic of platform

APPENDIX 1: PREPARE THE WORD
RECORD BEFORE DELIVERY
PREPARE THE WORK RECORD BEFORE DELIVERY
Model
Serial No.
YES/Machine is in NO/Machine Has REPAIRED/Machine
Inspection Item
Good Condition Damage or Malfunction Has Been Repaired
Pre-operationalInspection
Maintenance Procedure
Functional Inspection
Machine Buyer/ Renter
Inspector Signature
Inspector Title
Inspector Company
NOTE:
1. Prepare the machine before delivery, which includes performing a pre-delivery inspection, following
maintenance procedures and performing functional inspections.
2. Use the table to record the results. After each section is complete, mark the appropriate box.
3. Record the inspection results. If any inspection results are "NO", the machine must be stopped and re-
inspected after repair is completed and marked in the box marked "inspection".
AB18EJ&18HJ Maintenance Manual A-1 © Oct 2020

REPAIR PROCEDURES
© Oct 2020 A-2 AB18EJ&18HJ Maintenance Manual

APPENDIX 2: REPAIR & INSPECTION
REPORT
Model
Serial No.
Checklist A Procedures
Problem
Description
A-2 Inspect All Decals
A-3 Inspect Damaged, Loose

or Lost Parts
Level
Leakage
A-6 Inspect Fuel Level (AB18

HJ only)
A-7 Inspect Fuel Leakage

(AB18 HJ only)
A-8 Inspect Engine Oil Level

(AB18 HJ only)
A-9 Inspect Coolant Level

(AB18 HJ only)
A-10 Inspect Engine Belt (AB

18HJ only)
A-11 Inspect Fuel Filter (AB

18HJ only)
A-12 Inspect Cooling Fan

(AB18 HJ only)
A-13 Inspect Engine Intake


A-16 Perform Maintenance

after 30 Days
Checklist B Procedures

REPAIR PROCEDURES

Problem
Description
B-1 Replace Hydraulic Oil

Tank Return Filter Element
B-2 Inspect Rim ,Tire and
Fasteners
B-3 Inspect Hydraulic Oil
B-4 Inspect Cooling System

(AB18 HJ only)
B-5 Replace Fuel Filter and

High-Pressure Filter (AB18HJ
only)
B-6 Inspect Air Filter of

Hydraulic Tank
B-7 Replace High-Pressure

Filter Element
B-8 Replace Air Filter of
Engine (AB18HJ only)
B-9 Inspect Angle Sensors

and Travel Switch
B-10 Inspect Engine Exhaust
B-11 Inspect Drive Reducer

Oil Level
B-12 Inspect Slewing
Reducer Oil Level
B-13 Inspect Slewing Bearing
Bolts
B-14 Lubricate Slewing
Bearing
B-15 Inspect Platform Rotate

Cylinder Fasteners
B-16 Test Cylinder Drift
B-17 Test Oscillate Cylinder

Exhausting and
Counterbalance Valve
Locking
B-19 Inspect the Battery
B-20 Test Oscillating

Outriggers and Inspect
Oscillating Multi-way Valve
Tie Rod

REPAIR PROCEDURES

B-21 Test Drive Speed
B-22 Test Emergency

Lowering (AB18EJ only)
B-23 Test Tilt Protection
Checklist C Procedures
Problem
Description
C-1 Replace Fuel Filter

Element (AB18HJ only)
C-2 Replace Air Filter of

Hydraulic Tank
C-3 Replace Engine Oil

(AB18 HJ only)
C-4 Replace Engine Oil Filter

(AB18HJ only)
Checklist D Procedures
Problem
Description
D-1 Replace Drive Reducer

Gear Oil
D-2 Replace Slewing
Reducer Gear Oil
D-3 Replace Hydraulic Oil
D-4 Replace Hydraulic Tank

Suction Filter
D-5 Replace Coolant and
Coolant Hoses (AB18HJ
only)
D-6 Replace Fuel Hoses (-

AB18HJ only)
D-7 Inpsect Boom Wear Pads
User
Inspector Signature

REPAIR PROCEDURES

Inspector Date
Inspector Title
Inspector Company

新的高度
Alw ays For B et t er A ccess Solution度
ys For B et 我们一直在追求新的高
t er A ccess Solution s
s Part
ess Solution says For B et t er A ccess Solution s
Alw
Always for Better Access Solutions
AS/NZS
Hunan Sinoboom Intelligent Equipment Co., Ltd.
长沙市宁乡高新技术产业园区金洲大道东
No.128, East Jinzhou Avenue, Ningxiang High-tech 128 Industrial
号 Park, Changsha, Hunan, China
市宁乡高新技术产业园区金洲大道东 128 号
0086-0731-87116222
金洲大道东 128 号 (Sales) & 0086-0731-87116333
. com. cn ww (Service)
w.sinoboom. com. cn
长沙市宁乡高新技术产业园区金洲大道东
[email protected]
. com. cn ww 128
w.sinoboom. com. cn 号
. com. cn www.sinoboom.com
ww w.sinoboom. com. cn
0731-87116111 hr@sinoboom . com. cn ww w.sinoboom. com. cn
0731-87116111 hr@sinoboom
87116111 hr@sinoboom
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North American Subsidiary Europe Subsidiary Korea Subsidiary
Sinoboom North American LLC Sinoboom B.V. Sinoboom Korea Co., Ltd.
310 Mason Creek Drive Nikkelstraat 26, NL-2984 AM Ridderkerk, 95, Docheong-ro, Yeongtong-gu, Suwon-
unit #100 The Netherlands si, Gyeonggi-do, Republic of Korea
Katy, TX 77450, US Tel: +31 180 225 666 Tel: 010–8310–8026
Tel: (281) 729–5425 E-mail: [email protected] E-mail: [email protected]
E-mail: [email protected]
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Sinoboom Intelligent Equipment Pty Star Access Solutions Pte. Ltd.
Ltd.
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VIC 3205, Australia Singapore 068902
E-mail: [email protected]

AB18EJ&18HJ Maintenance Manual

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AB18EJ AB18EJ AB600EJ From 0300800100 to present

AB18HJ AB18HJ AB600HJ From 1200100100 to present

AB18EJ&18HJ Maintenance Manual i © Oct 2020

© Oct 2020 ii AB18EJ&18HJ Maintenance Manual

AB18EJ&18HJ Maintenance Manual iii © Oct 2020

AB18EJ&18HJ Maintenance Manual v © Oct 2020

© Oct 2020 vi AB18EJ&18HJ Maintenance Manual

NOTICE REPORTING ACCIDENTS

This safety alert symbol appears with NOTICE

Indicates a hazardous situation that, if not

AB18EJ&18HJ Maintenance Manual 1-1 © Oct 2020

Imperial 507 lb (unrestricted/2 persons & tools)

Voltage Minimum Safe Distance

0-50 3.05 (10)

50-200 4.60 (15)

200-350 6.10 (20)

350 -500 7.62 (25)

500 -750 10.67 (35)

750 -1000 13.725 (45)

TIPPING HAZARDS AND

© Oct 2020 1-2 AB18EJ&18HJ Maintenance Manual

TIPPING HAZARDS TIPPING HAZARDS

2. Lower secondary boom; • Do not place ladders or

AB18EJ&18HJ Maintenance Manual 1-3 © Oct 2020

© Oct 2020 1-4 AB18EJ&18HJ Maintenance Manual

UNSAFE JOBSITE HAZARDS UNSAFE JOBSITE HAZARDS

AB18EJ&18HJ Maintenance Manual 1-5 © Oct 2020

UNSAFE JOBSITE HAZARDS UNSAFE JOBSITE HAZARDS

BEAUFORT METERS/ MILE/ DESCRIPTI-

1 0.3～1.5 1～3 Light air Wind motion visible in smoke.

Gentle Leaves and smaller twigs in constant motion.

Strong Large branches in motion. Flags waving near

9 20.8～24.4 47～54 Strong gale Light structure damage.

Uphill: 40% / 21°

© Oct 2020 1-6 AB18EJ&18HJ Maintenance Manual

AB18EJ&18HJ Maintenance Manual 1-7 © Oct 2020

UNSAFE OPERATION HAZARDS FALL HAZARDS

© Oct 2020 1-8 AB18EJ&18HJ Maintenance Manual

COLLISION HAZARDS COLLISION HAZARDS

AB18EJ&18HJ Maintenance Manual 1-9 © Oct 2020

EXPLOSION AND FIRE BODILY INJURY HAZARDS

EXPLOSION AND FIRE HAZARDS

Do not use the machine or charge the BODILY INJURY HAZARDS

DAMAGED MACHINE NOTE: The operator must carry out maintenance

DAMAGED MACHINE HAZARDS FIRE AND EXPLOSION HAZARD

• Do not use the machine if it is • Batteries contain sulfuric acid and

© Oct 2020 1-10 AB18EJ&18HJ Maintenance Manual

CHEMICAL BURN HAZARD

• Daily check the battery cable for

AB18EJ&18HJ Maintenance Manual 1-11 © Oct 2020

Before performing welding, grinding and polishing work,

AFTER USING THE

© Oct 2020 1-12 AB18EJ&18HJ Maintenance Manual

MEASURE AB18EJ (Metric) AB600EJ (Imperial)

Platform dimension (L×W×H) 1.83 × 0.85 × 1.1 m 72 × 33.5 × 43 in

Turntable rotation / continuous 355°/uncontinuous

Max drive speed (raised) 1.1 km/h 0.68 mph