Model

Classification

Chapter 2 Chapter 4 Chapter 6

Power Ground Control General
Components Display Maintenance

Chapter 1 Chapter 3
Chapter 5
Model Electrical
Failure Cases
Classification Components
— *—
 Straight boom

B T 22 RT
Rough-terrain
Max. working height
Straight boom
Boom type
 Articulating
boom
B A 28 RT
Rough-terrain
Max. working height
Articulating boom
Boom type
BA28RT

BA28RT
SPECIFICATION PERFORMANCE SPECIFICATION
MAINTENANCE SCHEDULE
Read and understand all the warnings and instructions before starting any maintenance operation.

Before carrying out any maintenance operation, make sure all the scheduled actions have been carried out as planned.

A Every 10 hours of operation or daily

A-1 Visual inspection - check

A-2 Engine oil level - check

A-3 Coolant level - check

A-4 Telescopic boom sliding blocks - check

A-5 Auxiliary pump - operating test

A-6 Overload sensor - check

B. Every 50 hours of operation or every 2 weeks

1. Transmission shaft - lubrication of universal joints

2. Axles - lubrication of oscillation bushes

3. Hydraulic oil level - check

4. Telescopic boom sliding blocks - lubrication

5. Fuel pre-filter - draining the water

6. Turret rotation slewing ring gear - lubrication

7. Wheels - check tightening of nuts

8. Radiator - cleaning by rotating reversely

9. Steering elements - lubrication

B. Every 250 hours of operation or every 3 months
1. Transmission belt - check

2. Differentials oil - check B. Every 1500 hours of operation

3. Wheel reduction gears oil - check 1. Fuel filter - clean mesh element
4. Turret rotation slewing ring gear - check reduction gear oil level
C. Every 2000 hours of operation or every 2 years
C. Every 500 hours of operation or every 6 months 1. Hydraulic fluid - change
1. Hydraulic oil filter - replacement 2. Air filter - replacing the safety cartridge
2. Engine oil and filter - replacement

3. Fuel pre-filter - replacement

4. Engine radiator - cleaning

5. Turret rotation slewing ring gear - check tightening of bolts

D. Every 1000 hours of operation or every year

1. Fuel filter - replacement

2. Air filter - replacement of primary cartridge

3. Differentials oil - change

4. Wheel reduction gears oil - change

5. Telescopic boom sliding blocks - adjust the play

6. Turret rotation slewing ring gear - change reduction gear oil - check play

7. Overload sensor – calibration

8. Dropbox oil - change

 Power
Components

Chapter 2 Chapter 4 Chapter 6

Power Ground Control General
Components Display Maintenance

Chapter 1 Chapter 3
Chapter 5
Model Electrical
Failure Cases
Classification Components
— *—
 Engine
Displacement 2.925L

Number of Cylinder 4

Bore & Stroke 92×110mm

Rated Power 36.4kW/2600r/min

Maximum Torque 147N.m/1800r/min

Firing Order 1-3-4-2

German Deutz TD2.9 series engine
Low idle 900r/min  Under the RPM of 2200~2600, the power range of the
Governor Electric
engine can be from 30 ~ 55.4 kW/40-74 hp, which can meet
Lubrication System
the power demand of arm-type products with a working
Oil Pressure (Low idle, Engine Warm) 140 kPa/1.4bar
height of 16 ~ 30 meters
Oil Capacity (without/with filter) 8L
 It can meet Euro IIIB, U.S. Tier 4 and Euro V emission
Oil Temperature in the lube oil Tray, maximum 125℃

Unit ships with 15W-40 oil, Extreme operating temperatures may require the use of alternative engine oils.
standards
Please refer the Engine Operator Manual for detail.
 Adopting the German BOSCH high-pressure common rail
system to provide high torque and strong power output
Fuel Requirement

The fuel added in should be satisfied with EN590. Refer to engine manual operation when the local
environment changes.
while ensuring fuel economy
Engine Coolant
 Deutz family classic series products, high quality and
Type of cooling water cooling
convenient maintenance
Capacity

V-belt tension (width 10mm) Pre-tensioning/Re-tensioning

3.5L
 Fuel consumption: 2500 rpm- 10.8litre/h
650±50/400±50N
 Fuel consumption: 900 rpm- 1.7litre/h
Drive axle

 20% higher transmission efficiency without pressure loss of the

diverter valve

 Completely rigid structure design is calculated for the operating

conditions of the AWP, the failure rate is basically 0.

 The axle comes with 4-wheel steering system (4WS), 30% more
accurate than conventional steering potentiometers and 100%
longer durable.

 100% hydraulic differential lock, and 30% higher Ground

clearance, ensure that can be used in the harsh conditions which
the traditional wheel reducer can't handle.
 Four-wheel turn
The whole series is equipped with four-wheel steering function,
which can adapt to different working conditions to make the machine
move more flexible.

U-turn Crab-turn
High pressure drive system

The whole series of models use the German Bosch

Rexroth high-pressure drive system, which is driven by a
high-pressure pump and a high-pressure motor.
Compared with the traditional one pump driving four
hydraulic motors, it has the characteristics of higher
transmission efficiency, stronger power and energy
saving and oil saving.
Engine cooling system

 The independent hydraulic pump drives the heat

dissipation system separately. Compared with the
traditional engine power transmission system, it has the
characteristics of adjustable speed ratio of the heat
dissipation fan and controllable forward/reverse direction.
 The integrated heat dissipation system has higher heat
dissipation efficiency than traditional heat dissipation
systems, and simplifies the characteristics of the
electronic control system and the hydraulic system
 BT-RT cylinder
Main boom
Main boom telescopic
cylinder Jib cylinder
cylinder

Platform
leveling cylinder

Platform
Right oscillating Left oscillating swing cylinder
cylinder cylinder
PVG valve group
The whole series use Danfoss PVG32 valve group
 CAN bus precision control, good micro-movement, simple electric
control circuit
 The system comes with fault diagnosis function, highly integrated,
compact structure, easy to troubleshoot
 Can withstand the maximum 350bar system pressure
Corresponding function of each electronic module
No. BT BA
1 Function enable Function enable
2 Main boom telescopic Main boom telescopic

3 Main boom luffing Main boom luffing

4 Turntable rotation Turntable rotation
5 Jib leveling Jib leveling
6 Platform function oil supply Platform function oil supply
7 / Articulating boom telescopic
8 / Articulating boom luffing
 Electrical
Components

Chapter 2 Chapter 4 Chapter 6

Power Ground Control General
Components Display Maintenance

Chapter 1 Chapter 3
Chapter 5
Model Electrical
Failure Cases
Classification Components
— *—
 Control panel
 CAN bus control, simplify the whole
electrical control circuit

 Large-size LED display design, easy and intuitive to

diagnose faults
 All-aluminum open mold integrated upper control
design, solid and durable, high waterproof level
 100% redundant design, in line with the latest EU
safety standards, safe and reliable
 Horn
Platform panel
Indicator
panel Axle Engine speed
Emergency
differential control switch
Automatic pump Driving speed
working lock
leveling switch
lamp
switch Engine
start/stop
button

Platform
leveling Jib Articulating
telescopic boom luffing,
telescopic switch Steering mode
switch
Platform
swing

Turntable Driving
rotation/jib luffing Bypass Hydraulic Main boom handle
handle switch generator Emergency telescopic /
(optional) stop switch luffing handle
 Platform display
Platform display connector pin definition
Pin No. Function Pin No. Function
1 T203 Overload light 11 T205 System warning light
2 S202 Generator light 12 T208 Front axle center
position light
3 T209 Rear axle center 13 T210 Turntable center light
position light
4 T206 Chassis tilt light 14 T204 Overload warning
light
5 T213 Fuel low light 15 S209 Differential lights
6 S208 Crab steer Light 16 S206 U-turn steer Light
7 S205 Fast gear indicator 17 /
8 S204 Climb-gear indicator 18 /
9 S203 Engine warning light 19 /
10 T215 Preheat lamp 20 39-GND
 Platform display
Icon Interpretation Icon Interpretation
Load indicator Fuel alarm indicator
The yellow indicator light indicates that the platform load exceeds the allowable limited The yellow indicator light is on to indicate low fuel inventory.
load. (At a restricted platform location)
Glow plug preheating
Platform overload indicator
The orange indicator light indicates the preheating of the glow plug after
The red indicator light indicates that the maximum load allowed on the platform is
the electrical system is powered on.
exceeded under any circumstances.
Wait for it to go out to start the engine.
Hazard warning indicator Engine fault indicator
The red indicator light is on when the machine is in a dangerous situation or when the The red indicator light is on to indicate engine failure. Turn off the engine
machine has a mechanical failure. and check the engine parameters on the machine console in the fuel tank
compartment.
Battery low voltage indicator
The red indicator light is on to indicate the engine has not started. Climbing mode indicator
If the indicator light is still on after starting the engine, it indicates that the battery The green indicator light is on to indicate that the driving operation for
voltage is too low or malfunctioning. At this time, the engine can be operated for a period overcoming the incline segment is started.
of time to charge the battery.
Front axle wheel alignment indicator Fast walking mode indicator
The green indicator light is on to indicate that the front axle wheels are aligned with the The green indicator light is on to indicate the driving operation at the
longitudinal axis of the machine. maximum speed.

Rear axle wheel alignment indicator U-turn steering mode indicator

The green indicator light is on to indicate that the rear axle wheels are aligned with the The green indicator light is on to indicate that the wheel and axle are used
longitudinal axis of the machine. for relative steering in order to reduce the ground turning radius.

Turntable/telescopic boom return indicator Crab steering mode indicator

The green indicator light is on to indicate that the turntable/telescopic boom is aligned The green indicator light is on to indicate that the wheel axle is parallel to
with the axis of the machine. the steering for lateral movement.

Tilt alarm indicator Differential lock working indicator

The indicator light is on to indicate that the tilt angle of the chassis has reached the The yellow indicator light is on to indicate the differential lock is turned
maximum allowable slope and the machine is not in the retracted state. on.
 BT panel
Platform Platform Jib
leveling swing telescopic
Emergency Overload
stop switch warning
light

Emergency
pump
Jib luffing

Main
boom
Enable telescopic
Jib
leveling

Diagnostic Main
panel boom
luffing
Bypass

Engine
start/stop button Turntable
rotation
Horn Key switch
 Bypass

Bypass function
1. When the machine has a sensor failure, you can
temporarily do some actions by operating this button.
If the bottom of the platform frame overwhelms the
ground and the load cell 2 is open, or the platform load
exceeds the limit, this switch is needed at this time.
2. When the main control loop is open, connect the
main loop by operating this button to temporarily
operate the machine.
3. The upper-controlled bypass switch is used for
the turntable to deviate from the neutral position and
tilt, and the boom is in the retracted state. At this time,
it can be forced to drive.
 PVG
It is used to control the boom function of
Each valve block has a status
indicator
the whole vehicle, with a high degree of
LED Status Specific Information integration, only 5 wires are needed to
Green (always)= OK
control the boom telescope/boom
luffing/rotary/jib leveling/platform function.
Flashing red = external fault
(input signal) It also comes with proportional control and
Red (always) = internal failure fault diagnosis feedback. PVG connector pin
definition
indicator
LED status

No color description
.
1 red 12V power
supply positive
input
2 green 12V power
supply positive
input
3 brow 12V power
n supply negative
 MC2M

Platform auxiliary controller: used to

collect information such as the handle,
weighing system, and switch input on the
platform, and transmit the information back to
the chassis main controller in the form of CAN
P
S bus.
T Chassis main controller: It uses CAN bus to
U communicate with various sensors and
Note: The platform and chassis controllers are controllers to coordinate and monitor the
similar in appearance but the internal program
parameters are different, so they must not be working status and conditions of various
used interchangeably. electrical devices. It has absolute control rights
 MC2M- P

Chassis Platform
pin No. color function pin No. color function
1 X201 red MC2M Output 1 1-030 red MC2M Output
positive power positive power
2 X202 red MC2M Output 2 2-030 red MC2M Output
positive power positive power
3 X203 red MC2M Output 3 3-030 red MC2M Output
positive power positive power
4 5- blac MC2M Output 4 37- blac MC2M Output
GND2 k negative power GND k negative power
 Platform
leveling sensor
Located on the side of the platform's swing cylinder, it is used
to monitor the angle of the platform in real time and send it to the
controller in the form of a CAN bus message for its processing. The
actual platform angle value can be viewed on the vehicle status
interface of the lower control display. Pin definition
No. Description
Note: Except for models with 1 CAN bus shield
jib telescopic, the sensor on 2 Sensor positive power supply
other models is labeled as jib 3 Sensor negative power supply
leveling sensor. 4 CAN H
5 CAN L
 Jib leveling
sensor
It is used to monitor the leveling angle of the
jib in real time and send it to the controller in the
form of a CAN bus message for its processing.
This sensor is only available on models with
telescopic jib.
If you replace the corresponding sensor again,
Jib leveling sensor Jib level indicator you can reset it on the sensor interface of the
display. Pin definition
No. Description
1 CAN bus shield
2 Sensor positive power supply
3 Sensor negative power supply

Note: The sensors are similar in appearance 4 CAN H

but the internal parameters are not the same 5 CAN L
and must not be interchangeable.
 Tilt sensor
It is used to monitor the real-time angle status of the
chassis in real time, and transmit it to the controller in the
form of CAN bus message for its processing to ensure the
safe and orderly operation of each component.
When the sensor's X-axis or Y-axis direction exceeds 5°
and the control logic is high-altitude state, the machine will
give a tilt alarm. Then at this time
• No jib and main boom extension function
• No articulating boom extension and crank up function
• No main boom luffing function Pin definition
• No driving function No. Description
• No turntable rotation function 1 CAN bus shield
2 Sensor positive power supply
3 Sensor negative power supply
Note: The sensors are similar in appearance
4 CAN H
but the internal parameters are not the same
and must not be interchangeable. 5 CAN L
 Length&Angle
sensor
It is used to monitor the angle and length of
the main boom in real time and transmit it to the
controller in the form of CAN bus message for its
processing.
The actual length and angle of the main boom
can be viewed on the vehicle status interface of
the ground control display.
5
4 Pin definition
1
No. Description
3
1 CAN bus shield
2
2 Positive power supply
3 Negative power supply
There is a label on 4 CAN H
the side of the pin
hole 5 CAN L
 Display

Used for fault diagnosis, speed setting, parameter verification, sensor status display and
other functions. The external USB interface is located on the side or below the ground control
panel, and the program in the display can be upgraded through the U disk to achieve more and
more comprehensive function expansion. Pin definition
No Description
.
1 12V Positive power supply
2 12V Negative power supply
3 12V Positive power supply
4 12V Positive power supply
5 CAN H
6 CAN L
23 USB Vbus
24 USB Host DM
25 USB Host DP
 Engine ECU

Engine ECU: The brain of the engine is used to

receive real-time engine operating information
from various sensors on the engine, and control
the actions of various actuators after processing.
The real-time engine operating status
information is transmitted to the machine control
system through the CAN bus, and displayed on
the engine interface of the lower control display.
At the same time, the engine speed control is also
realized through the CAN bus.
When the engine is abnormal, the lower
control display screen will display the specific
fault code. Refer to the SPN and FMI fault
codes, check the engine alarm message or
consult the engine manufacturer. When the
engine is faulty, the engine fault code is
displayed cyclically.
 Chassis device

Auxiliary power supply connection pile Fullriver maintenance-free battery

It is used to connect the external The battery voltage is 12V,
battery to provide auxiliary starting power which provides initial power for the
for the vehicle when the battery is losing whole vehicle when the engine is not
power and the engine cannot be started. started, and can also have a better
power supply performance in a low
temperature environment.

Main power switch

It is used to cut off the power supply circuit between
the battery and the load. The switch should be in the open
state (vertical position) during normal operation. If the
machine needs to be parked for a long time, the switch
should be set to and off (horizontal position) to reduce the
self-discharge of the battery and extend the storage time of
the battery.
 Chassis device
Electric fuel pump
Controlled by the engine BOSCH ECU,
the electronic fuel pump will work when the
power is turned on. When the fuel rail
pressure reaches 3Bar, the engine start is
valid, otherwise the start signal will be
regarded as an invalid input.

Diesel oil filter

Filter out the small particles in the fuel to
ensure that the fuel entering the engine is
clean, and the sensor detects the output
pressure of the fuel pump.

Water separator
Filter out water and larger particles in
the fuel, and trigger an engine alarm when
the water level reaches a preset value.
 Chassis device

Air filter clogging sensor

Using switch signal, when
Emergency pump contactor the air filter is blocked, the
It is controlled by the vehicle’s internal switch is turned off, no
main controller MC2M to control low-level signal is output to the
the emergency pump. main controller, and the
display will show the air filter
failure prompt.

Preheat contactor
Controlled by the engine
BOSCH ECU, it controls the glow
plugs in the four cylinders of the
engine. At the same time with one
way of preheating signal feedback.
 Emergency
pump
Located in the power cabin, in the event of a failure of the 80V
power system, the emergency pump will provide power to the
hydraulic system for operating the platform's main boom down,
main boom retract, forearm down, turntable rotation, and platform
rotation.
It is recommended to operate the emergency only under the
following conditions:
1.Engine won't start
2.The overload limit frame is lowered, and the emergency
pump is temporarily used to lower it (this function is limited to
the lower control operation).
 High current
fuse box
Located on the engine side, it is used to protect the
high-current working devices of the vehicle to prevent
damage after overloading. Including engine generator fuse,
emergency pump motor fuse, electrical control circuit fuse,
engine preheating fuse.

High current fuse box function table

Mark Specification Function remarks
FU13 125A Engine generator fuse
FU14 175A Emergency pump fuse
FU15 150A Engine glow plug fuse
FU16 80A Function relay fuse

For replacement, please use the same fuse

 Insurance and
relay box
Located in the door of the lower control No. Description

operation panel, it is used to protect and control FU1 30A Engine BOSCH ECU output power supply

the low-current working devices of the whole FU2

FU3
25A
30A
Hydraulic oil cooling fan*2
Main controller output power supply
vehicle to prevent damage after overload FU4 20A Engine electronic fuel pump

operation. FU5 25A FU7+FU8

FU6 30A FU9+FU10+FU11
Relay function table
FU7 7.5A Horn
No. Description (Key switch, bypass switch, lower control emergency stop, upper control
FU8 5A emergency stop for output power supply) Total power relay & MC2M output relay
K1 Hydraulic oil cooling fan relay
FU12 & engine BOSCH ECU logic power supply & down control display & level
FU9 7.5A sensor & down control MC2M main controller logic power supply
Main controller output power
K2
relay (4-pin connector power FU10 10A PVG function valve group power supply
supply) Main boom lower limit proximity switch*2&Length angle sensor power supply &
Broken chain detection switch&Main boom luffing safety valve pressure sensor
K3 Fuel pump relay power supply&Working bucket leveling sensor power supply (BT30RT)&Forearm
leveling sensor power supply & Forearm retracting approach Switch*2 (BT30RT)
K4 Horn relay & power supply for all electrical components of the upper control platform
FU11 15A Folding arm lower limit switch*2Folding arm upper limit switch*2&Folding arm
K5 Total power relay safety valve pressure sensor power supply&Folding arm retract switch*2&Main
arm lower limit proximity switch*2

Engine generator magnetization & lower control panel & engine cover switch &
FU12 5A turntable left / center / right proximity switch / floating bridge floating spool
For replacement, please use the same fuse detection switch / front and rear axle center detection switch *2
 Axle center
detection sensor
Located on the axle steering cylinder, the front Input pin Diagnostic interface status
Platform icon
and rear drive axles have neutral detection sensors, Non-median Medium display
which are used to detect whether the tires on both
sides of the drive axle are in the neutral position. If
U37 0 1
they are in the neutral position, the corresponding Center of
front and rear axles on the upper control display the front
screen are green axle
THE AXLE CENTER SENSOR HAS A
CERTAIN AMOUNT OF DEFLECTION, U38 0 1
Center of
AND A SMALL AMOUNT OF
the rear
DEVIATION IS NORMAL. axle
Pin definition
No. Color Description
A Gray The middle position signal output, the
middle position output high level, the
non-neutral position output low level.
B Brown Sensor positive power supply
C Black Sensor negative power supply
 Fuel level sensor
Located on the diesel tank, it is Pin definition
used to detect the oil level of the
fuel tank in real time, and convert No. Description
the change of the oil level into a
1 /
change of an electrical signal. The
real-time oil level is displayed on Signal output
2
(resistance value)
the main interface of the lower
control display. 3 Power negative
 Hydraulic oil
temperature sensor
Located on the oil return radiator, it is
used to detect the oil temperature change
of the return oil in real time. When the oil Pin definition
temperature reaches the set temperature,
the main controller controls the hydraulic No. Description
oil cooling fan to work to dissipate heat Signal output
for the hydraulic system. The real-time 1 (resistance value)
hydraulic oil temperature can be
displayed and viewed on the vehicle 2 Power negative
status interface of the lower control
display screen.
 Overload
system

Load sensor Weighing signal amplifier Platform & Chassis Controller

Platform overload display Chassis overload display Real-time load display on chassis display
 Load sensor

Located on the platform swing cylinder, it converts the Pin definition

No. Description
actual platform load into a voltage signal. This voltage 1 Weighing signal 1+
change is a very weak (mV level) differential signal. 2 8V Power positive
input
3 Weighing signal 1-
4 Weighing signal 2+
5 8V Power negative
input
6 Weighing signal 2-
7 /
8 /

NOTE: WHEN THE LOAD CELL IS INSTALLED, IT IS NECESSARY TO

ENSURE THAT THE FIXING SCREWS MEET THE CORRESPONDING
TORQUE REQUIREMENTS, OTHERWISE IT MAY CAUSE THE WEIGHING
FUNCTION TO FAIL.
 Driving handle
4-pin connector pin definition
All series of speed control handles use Pin Function Description
Hall sensors. The advantage is that there is no 1 5V positive input
5V power input of the sensor inside the
contact point, which reduces the failure caused handle
2 5V negative input
by poor contact. The Hall sensor detects the
Maximum forward output voltage: 0.5V
distance of the magnet to change the output Drive signal 1 Median output voltage: 2.5V
3
voltage. output (0.5-4.5V) Maximum output voltage back:
4.5V
The analog output power supply Maximum forward output voltage: 4.5V
of the handle 5V is provided by the 4
Drive signal 2 Median output voltage: 2.5V
output (0.5-4.5V) Maximum output voltage back:
platform controller MC2M. 6-pin connector pin definition
0.5V
Pin Function Description
1 Turn button 12V input
Pin 1 is the common terminal. When the left turn
Left turn signal button is pressed, pin 1 and pin 2 are connected,
2
output and when the right button is pressed, pin 1 and
Right turn signal pin 3 are connected.
3
output
4 Enable button 12V input When the handle enable button is pressed, pin 4
5 Enable signal output and pin 5 are connected.
 Pin definition of main boom luffing/retractable handle connector
Double shaft
Pin Function Description
1 5V- input 5V power input of the sensor inside the
handle
2 5V+ input handle All series of speed control handles
Main boom amplitude
Maximum output voltage on luffing: 0.5V
Handle mid-position output voltage: 2.5V
use Hall sensors. Because there are no
3
signal output (0.5-4.5V) Maximum output voltage under variable amplitude:
4.5V
contact points, it reduces the faults
Maximum output voltage when the main arm
like poor contact of sliding resistance
Main boom telescopic
extends: 4.5V
Handle mid-position output voltage: 2.5V
handles. The Hall sensor detects the
4
signal output (0.5-4.5V) Maximum output voltage when the main arm is distance of the magnet and changes
retracted: 0.5V
the output voltage.
Pin definition of jib luffing/turntable rotary handle connector
1 5V- input 5V power input of the sensor inside the
2 5V+ input handle
Maximum output voltage for left rotation: 4.5V
Turntable rotation signal Handle mid-position output voltage: 2.5V
3
output (0.5-4.5V) Maximum output voltage when turning right: 0.5V

Maximum output voltage on forearm luffing: 0.5V

Jib luffing signal output Handle mid-position output voltage: 2.5V
4 Maximum output voltage under forearm luffing:
(0.5-4.5V)
4.5V
 Platform anti-
squeeze
Located on the upper control platform, the switch is triggered during operation
and the action stops immediately to ensure personal safety in the platform. When it is
triggered by mistake, the foot switch can be released once to eliminate the fault. This
function can be turned off in the lower control.
 Pedal

Located in the upper control platform, the

switch needs to be operated when the platform is
operating. When the foot switch is triggered for a
long time and there is no operation action, the
input signal will be regarded as invalid. At this
time, if an operation action is required, the foot
switch needs to be operated again.

When the platform anti-squeeze switch is

triggered by mistake, the foot switch needs to be
operated again to eliminate the anti-squeeze alarm
at this time.
 Limit switch

There are two types of limit switches for the whole series of models, mechanical and
inductive. The whole vehicle adopts the redundant design of the electrical system, so the two
switches are connected in NO (normally open) and NC (normally closed). Multi-channel
detection ensures safe use.

Magnetic induction proximity switch is used

1. Turntable rotation status detection
Mechanical limit switches are used Micro switch is used 2. BA main/ articulating boom luffing lower
1. BA articulating boom luffing upper limit 1. BT main boom chain limit
2. BA articulating boom fully retracted limit looseness detection 3. BT lower limit
2. Engine cover status detection 4. Jib telescopic
 B T- R T l i m i t

Chain detection switch

Jib retract limit switch
Boom lower limit switch

Engine compartment open

detection switch
Turntable center switch
 Engine compartment
open detection switch
Located in the engine compartment, it is used to detect
the state of the engine cover. When the engine cover is
opened, the switch will work. The lower control will display
the engine compartment door open prompt, and this will
affect the engine start function. If the engine needs to be
repaired or the original car When the battery is fed by an
external power supply, you need to temporarily turn off the
function in the quick function opening interface.
 Main boom lower
limit switch

Located in the upper arm and lower

It is located on the turntable and arm connecting seat, it is composed of two
consists of two limit switches, one limit switches, one normally open and one
normally open and one normally closed normally closed to realize redundant
respectively to achieve redundant detection. The working status of the limit
detection. The working state of the limit switch will affect the driving speed,
switch will affect the vehicle's driving loading mode, tilt alarm and other
speed, loading mode, tilt alarm and other functions of the vehicle.
functions.

BT BA
 Interface
power on

MACHINE: Machine model ；

SW: Software version ；
DISPLAY: Display version ；
Dingli Logo, date, week and
other information ；
 Main interface

Normal interface

Engine bus fault

status interface

Alarm/reminder interface
 Symbols on
main menu

The above icons change according to the actual status of the vehicle ；

System no alarm System alarm

Engine generator power supply Battery powered
Engine pre-heating not work Engine pre-heating work
U-turn Crab steering Front wheel steering
Brake open Brake on
Light off Light on
Normal engine refueling pressure Low engine refueling pressure
Differential work off Differential work on
Float axle lock Float axle open
Fans turn off in reverse Fans turn on in reverse
Slow speed Fast speed
Platform working Chassis working
 Machine status

Engine interface Machine status interface

 Function
parameter

F3 Vehicle general setting button (press and hold for 1 second), enter the vehicle
quick setting interface, you can modify the platform anti-extrusion, loading mode,
safe receiving of the main arm and folding arm, low-power working mode without a
password And other modes. (No password required)
 Loading mode

In order to facilitate transportation, our products have a loading mode function, and
all series of models can be directly loaded into the container.
BA series BT series
Only when the actual status of the Only when the actual status of the
machine meets the following conditions machine meets the following conditions can
can the loading mode be activated. the loading mode be activated.
1. Under control operation 1. Under control operation
2. The horizontal angle of X & Y are 2. The horizontal angle of X & Y are both
both less than 5° less than 5°
3. The main boom angle is less than 20° 3. The main boom angle is less than 20°
4. The main boom extends less than 1 4. The main boom extends less than 1 meter
meter
5. The crank arm is folded
 Menu

The directory is divided into

diagnostic interface, tool interface,
password interface.
The diagnostic interface is divided
into: basic information; controller
I/O; sensor status; action control
status.
 Diagnose
interface

There are
Basic information; controller
I/O; sensor status; engine
alarm; action control status
 Basic data

The interface displays: chassis controller

software version, platform controller
software version, display software
version, vehicle model and compliance
standards;
Press to return to the main interface;
Press to return to the diagnosis
interface.
 I/O status

The controller is distributed from

bottom to top as chassis controller
and platform controller.

Press to return to the main

interface;
Press to return to the diagnosis
interface.
 Sensor status

This interface records the information of

all bus sensors or analog sensors
Press to return to the main interface;
Press to return to the diagnosis
interface.
 Sensor status
Chassis angle status
Diagnose the information of the bus
type chassis angle sensor.

Press the and to switch the

list;
Press to return to the main
interface;
Press to return to the sensor
status diagnosis interface.
 Sensor status
Main boom angle status

Diagnose the information of the bus

type main boom angle sensor.

Press the and to switch the

list;
Press to return to the main
interface;
Press to return to the sensor
status diagnosis interface.
 Sensor status
Load cell status

Diagnose the information of the load

sensor

Press to return to the main interface;

Press to return to the sensor status
diagnosis interface.
 Sensor status
Fuel level gauge status

Diagnose the information of analog

fuel sensor

Press to return to the main

interface;
Press to return to the sensor
status diagnosis interface.
 Movement
diagnose

Through this interface, from the input of

the handle or switch to the output of the
valve block, all changes in the
intermediate variables of the action can be
queried.

Press to return to the main interface;

Press to return to the diagnosis
interface.
 Password
interface

•When the correct 4-digit password is entered, the

icon is displayed;
•The password is divided into two levels. The
password is "4482" for rental customers and
"9735" for OEM manufacturers;
•After the password is entered correctly, press
and keep it valid for 1 second to enter the function
setting interface.
 Function setting

There are:
Parameter setting;
Calibration setting OEM;
Event logger OEM;
Bypass OEM.
 Parameter
setting

Parameter setting:
Function Parameter OEM;
Limit Parameter;
Movement Parameter.
 Parameter
Limit parameter interface setting
Function limit parameter list
P140 PaLoweBoomUp_RPM P153 PaCageRotCCW_RPM

P141 PaLoweBoomDw_RPM P154 PaTurretRotCW_RPM

P142 PaLoweBoomOut_RPM P155 PaTurretRotCCW_RPM

P143 PaLoweBoomIn_RPM P160 PaCageLivUp_RPM

P144 PaMainBoomUp_RPM P161 PaCageLivDw_RPM

Press and button to switch to modify the function
P145 PaMainBoomDw_RPM P162 PaJibLivUp_RPM
limit parameter list, the selected parameter has a yellow
P146 PaMainBoomOut_RPM P163 PaJibLivDw_RPM
background;
P147 PaMainBoomIn_RPM P158 PaMultiMov_RPM
Press button to enter the parameter setting modification
P148 PaJibUp_RPM P180 PaTravelH_RPM

interface; P149 PaJibDw_RPM P181 PaTravelH_RPM

Press button to save the modified value and enter the P150 PaJibOut_RPM P182 PaTravelH_RPM

parameter saving interface at the same time; P151 PaJibIn_RPM P183 PaTravelH_RPM

Press button to return to the parameter setting interface. P152 PaCageRotCW_RPM P184 PaTravelUTurn_RPM
 Parameter
Movement parameter setting interface setting

Press and to switch the movement Press and to switch to modify the function
parameter setting list, the selected directory is limit parameter list, the selected parameter has a yellow
indicated by the green arrow ; background;
Press to return to the main interface; Press to enter the parameter setting modification
Press to return to the parameter setting interface;
interface; Press to save the modified value and enter the
Press to enter the corresponding parameter saving interface at the same time;
parameter setting options; Press to return to the parameter setting interface.
 Sensor
calibration
Chassis angle calibration

Press to reset the chassis angle

sensor to zero;
Press to save the modified zero-
setting parameter when the save command
is 0, indicating that the save was
successful.

Please ensure that the vehicle is currently on a level

ground before operating the horizontal reset button.
Incorrect operation may cause the vehicle to tip over.
 Sensor
calibration

Load sensor reset

Press to reset the load cell to zero;

Press to save the modified zero-

setting parameter when the save command
is 0, indicating that the save was
successful.
 Bypass
parameter

When the overload alarm is

triggered and the vehicle
movement is restricted, all vehicle
movements are restricted. If the
operator confirms that the vehicle
load is within a reasonable range,
the overload force function can be
adopted to facilitate the movement
of the vehicle or the boom.
 Overload alarm

Case 1: The upper part of the platform frame hits an obstacle,

causing an overload alarm of the machine.

Solution 1 ： Enter the password on the lower control screen to

enter the bypass interface, select F601 overload function
mandatory (valid for three minutes), and turn on the right
switch. Relevant actions can be temporarily operated to remove
the boom from obstacles. After the operation is completed, turn
off this function or restart the system power supply.
Solution 2 ： Enter the password on the lower control screen
to enter the sensor calibration interface, and select the
weighing sensor to reset. After you click to enter, long press
the Set button, and after the platform load weight is displayed
as 0, you can temporarily perform related actions to remove
the boom from the obstacle and restart the system after the
operation is completed.

Note: Do not operate the Save command after

 Load sensor open
circuit failure

Case 2: The bottom of the platform frame hits the ground or other obstacles, and
the down control displays the load cell 2 open circuit error.

Solution ：
During normal operation of forearm
raising, press and hold the bypass
switch of the lower control panel to
temporarily remove the platform frame
from the ground or obstacles, and the
alarm code will be automatically
eliminated after the ground is lifted.
 CAN bus multiple device communication failure
When the bus is abnormal, the lower control display will show that multiple bus devices have
communication failures at the same time.
First of all, ensure that the power supply of the bus device with communication failure is
normal. If the FU11 15A fuse in the relay box is blown, there will be a communication failure of the
length angle sensor, the communication failure of the arm angle sensor, the communication failure
of the platform leveling sensor, and the communication failure of the platform controller. After
confirming that the sensor power supply is normal, use a multimeter to measure the bus resistance
and the voltage during bus communication.
Pin definition

12.25V No. Description

1 CAN bus shield

2 Positive power

3 Negative power

4 CAN H

Upper control 5 CAN L

power fuse
 CAN bus resistance measurement

Before measuring the CAN bus

resistance, make sure that the electrical
control system is in a power-off state.
Normal bus
A – CAN High resistance

B – CAN Low
C– / ground control X57 bus connector

Abnormal bus Abnormal bus

resistance resistance
Short Open
circuit circuit
 CAN bus voltage measurement

Before measuring the CAN bus voltage, turn on all

A – CAN High
the power switches of the vehicle to ensure that the power
supply of each bus device is normal. If necessary, check B – CAN Low
each bus device one by one. C– /

CAN HIGH – CAN LOW –

2.7V 2.3V
CAN HIGH Normal CAN LOW Normal
voltage voltage
 General Maintenance

Chapter 2 Chapter 4 Chapter 6

Power Ground Control General
Components Display Maintenance

Chapter 1 Chapter 3
Chapter 5
Model Electrical
Failure Cases
Classification Components
— *—
 Routine maintenance

Hydraulic system Tires and drive wheels

Turntable rotary reducer

Routine
Engine
maintenance
Axles

Battery
Boom
Routine maintenance of machine
hydraulic system
Replacement of Replacement of
hydraulic oil hydraulic filter
 Hydraulic system

Good clean hydraulic oil is very important for machine

performance and service life. Dirty hydraulic oil and filter
elements can lead to poor machine performance, and
continuous use may cause damage to parts.
Hydraulic oil maintenance cycle: Every two years or 2000
hours of operation. Working in extremely harsh environments
requires more frequent maintenance.
The brand and model of hydraulic oil used by our company:
Kunlun low condensation anti-wear 46#.
If the temperature is low, 32# is recommended.
 Hydraulic oil
filter
The machine is equipped with three hydraulic oil filters: one is a suction
return filter, which is located inside the hydraulic oil tank, and has both the
function of an oil suction valve and an oil return valve. The other two are
high-pressure pipeline filters, located on the back of the tank side cabin
and on the side of the telescopic arm, used to filter the high pressure oil at
the outlet of the oil pump and the inlet of the upper control valve group to
reduce the risk of valve block clogging.
Hydraulic oil filter maintenance cycle:
It is recommended to change the hydraulic oil filter
High pressure filter
every 1000 hours of operation or 6 months.

Suction return filter High pressure filter (Oil pump

outlet)
 Hydraulic oil
filter
Replacement steps of hydraulic oil filter-(145lit.HM46)
1. Stabilize the machine, clean the housing and surrounding area of the filter to prevent
dirt from entering the loop. Unscrew the cover.
2. Pull out the filter element and insert a new filter element of the same type.
3. Re-tighten the filter cover. Start the engine and check for leaks.
4. Check whether the oil level displayed by the visual level gauge on the oil tank has
dropped; if necessary, add the amount of oil required for the correct oil level.
(It is not necessary to empty the oil tank to replace the filter element: the filter box is
equipped with a special shut-off system. But during the extraction process, there will be
normal oil leakage inside the filter)
1. Clean the area around the filter and remove the filter cover.
2. Pull out the filter element from the filter cavity.
3. Install the new filter element into the filter.
4. Reinstall the filter cover and remove the hydraulic oil spilled during the process of
replacing the filter element.
 Engine
maintenance
Engine oil & oil
filter replacement
Engine air
filter Engine fuel
maintenance prefilter
maintenance
Engine fuel
filter Engine
replacement coolant
maintenance
 Engine
Maintenance of engine coolant maintenance

Engine coolant maintenance cycle:

Check whether the coolant level is normal before daily operation.
Replace the engine coolant every two years or 2000 hours of operation.

It is recommended to use antifreeze as the coolant, especially when the ambient

temperature is low and the altitude is high. Antifreeze has the functions of antifreeze, anti-
corrosion, anti-cavitation, anti-scaling, high boiling point, etc., which can solve the hidden
danger of freezing and cracking of the body in winter.
Using low-quality antifreeze will not only prevent freezing and boiling, but will
accelerate the corrosion of the cooling system.
Different brands of coolant have different formulations, and mixed use may have
adverse effects on the engine.
The coolant, when the engine heats up, is pressurized
and is at a high temperature. Remove the cover at this time,
the liquid can be violently ejected and cause severe burns.
 Engine
Engine oil filter replacement maintenance
1. Use a tool to loosen the filter and remove it.
2. Wipe off any engine oil flowing out.
3. Use a clean cloth to clean the sealing surface of the
filter holder.
3. Gently drip engine oil into the sealing ring of DEUTZ
original new filter element.
4. Tighten the new filter manually until it is tight

Engine oil filter maintenance cycle:

The first guarantee is 50 hours.
Replace the engine oil filter with a
new engine every 500 hours or 3
months thereafter.
 Engine
Engine oil maintenance maintenance
Different brands of engine oils have different formulations, and mixed use
may have adverse effects on the engine.
When the oil becomes thin, thick, black, or loses viscosity, the oil must be
replaced in time.
When changing the oil, the oil filter must be replaced at the same time.
Choose different engine oil labels for different use environments. It is
recommended to use oil with good low-temperature fluidity in cold winter
areas.
Our factory oil is Mobil 15W-40

Engine oil maintenance cycle:

The first guarantee is 50 hours.
Replace the engine oil with a new engine every 500 hours or 3 months thereafter.
 Engine
Maintenance of engine air filter maintenance
The performance and service life of the engine largely depend on
the quality of the intake air. A very dirty or damaged air filter will
seriously affect the good operation of the engine and increase the
possibility of failure.
If you need to use the machine in a particularly dusty environment
or in an air with a high concentration of pollutants, you should shorten
the cycle of replacing the new filter.
When the filter paper of the main filter element has distortion,
adhesion, uneven spacing, etc., the filter hole of the filter paper is
blocked, the filter paper is damaged, etc., it must be replaced; when
the color of the inner and outer surfaces of the safety filter become
basically the same, it must be replaced in time.

Engine air filter maintenance cycle:

Replace the new main air filter every 1000 hours of operation or every year.
Replace with a new safety filter element every 2000 hours of operation or 2 years.
 Engine
Engine fuel filter replacement maintenance
1. Use a tool to loosen the filter and remove it.
2. Use a clean cloth to clean the sealing surface
the filter holder.
3. Gently lubricate the sealing surface of DEUT
original new filter element.
4. Tighten the new filter manually until it is tigh
5. Switch the power supply of the system to fill
electronic oil suction pump.

Engine fuel filter maintenance cycle:

Replace with a new fuel filter every 250 hours of
operation.
 Engine
Maintenance of engine oil-water separator maintenance
Steps:
1. Stop the engine.
2. Turn off the fuel supply to the engine
3. Place a suitable collection container.
4. Disconnect the cable.
5. Loosen the drain plug to allow the liquid to flow out.
6. Remove the filter element.
7. Remove any dirt on the sealing surface of the new filter
element and the other side of the filter head.
8. Use fuel to slightly moisten the sealing surface of the filter
element, and then turn the filter head clockwise (17-18 Nm).
(1) Fuel supply of pump
9. Install the drain plug with a torque of 1.6±0.3Nm.
(2) Vent screw 10. Restore the cable installation
(3) Water level sensor
(4) Drain plug Engine fuel pre-filter maintenance cycle:
(5) Filter element Discharge water every 50 hours or 2 weeks of operation.
(6) Fuel tank inlet Replace the fuel pre-filter every 250 hours of operation.
 Battery
maintenance
As the power source of the machine, the battery is very
important for daily maintenance. Incorrect maintenance
may shorten the service life of the battery. HC110

Maintenance cycle: Clean the surface of the battery

every week,and check the oxidation of the pile head of
the battery cable and the torque of the cable every
month. If the battery is stored for a long time, please
fully charge the battery once a month.
FULLRIVER maintenance-free battery

note:
•When the battery is used in an environment below 25°C, the battery capacity will be lower than the rated
capacity. For example, the battery will provide 65% of the capacity at -15°C and 100% of the capacity at
25°C. So this is one of the reasons why the engine will be more difficult to start in the cold winter.
 Tires and drive
wheels

Replacing the lubricating oil in the drive hub is

essential to prolong the life of the machine and maintain
good operating performance. Failure to change the
lubricating oil regularly will cause the performance of
2

the machine to deteriorate,and running the machine

1
under the condition of insufficient lubrication will cause
damage to the parts.

Maintenance cycle: Check the oil level every 3

1. Place a container with appropriate capacity under the
months or 150 hours of operation; change the reducer. Adjust the plug of the reducer to position ①.

lubricating oil every 1 year or 1000 hours of operation. 2. Remove the plug and wait for the oil to drain completely.
3. Adjust the plug of the reducer to position ②. Add oil from
Our company uses Mobil 80W-90 as the lubricant.
the hole to the correct level.
4. Close the stopper again.
Note: Each hub only needs about half the volume of
5. Repeat the same operation for each wheel.
the lubricating oil.
 Turntable rotary
reducer
Running the machine with insufficient lubrication will cause damage to parts.
Lubricate the two tracks of the slewing ring bearing through the two grease nipple
located inside. Raise the main telescopic arm to approach the inner side of the slewing
ring bearing, then inject grease several times, and rotate the turntable to distribute the
grease evenly. Lubricate the outer tooth surface of the supporting bearing. Use a brush to
apply grease manually. Make sure that the lubricant is evenly distributed. Remove the
accumulation of grease.

Maintenance cycle: every 2 weeks or 50 hours.

 Turntable rotary
reducer
1. Fully retract and raise the telescopic boom.
Turn the turntable to get better access to the 2
reducer.
2. Check the oil level through the monitoring
window ①. When it appears on the edge, the oil
level is correct.
3. If necessary, add proper amount of oil from the
oil filling hole ②.
When checking the oil level, visually check
the fixing bolts of the reducer on the frame. If 1

there is any abnormality (loose or missing nut),

please contact our company immediately.
Maintenance cycle: Check the oil level every 3 months or 150 hours of operation; change the gear oil
every 1 year or 1000 hours of operation.
Our company uses Mobil 80W-90 as the lubricant.
 Engine radiator
cleaning
Engine radiator fan reverse cleaning
In order to give full play to the cooling
effect of the radiator, the fan needs to be
cleaned frequently. In order to improve the
cleaning efficiency, this equipment provides a
self-cleaning method.

After the machine has been running for a period of time, the self-cleaning
method of the fan cannot completely clean the dust and debris of the radiator core.
You can use compressed air, high-pressure water or steam for cleaning. It is
recommended to use compressed air.
When using high-pressure water, keep the nozzle of the cleaner at least 50cm
away from the radiator core. If the radiator core is too close to the nozzle, there is a
risk of damaging the radiator. And try to ensure that the water/air flow is
perpendicular to the heat dissipation surface.

Maintenance period:
Clean every 6 months or 500 hours of operation.
 Axles

Lubrication and maintenance of drive shaft universal joint

Lubrication and maintenance of steering components

Maintenance of front axle swing bushing

Inspection and maintenance of differential oil

 Axles

Lubrication and maintenance of drive shaft universal joint

1. Adjust the machine to the parking

position. Make sure that no one is near
the work area.
2. Inject grease from the grease nipple to
lubricate the universal joint.
3. Repeat this operation for all drive shaft
joints. Remove excess grease.

Maintenance period:
Add butter for 2 weeks or 50 hours of
operation.
 Axles

Lubrication and maintenance of steering components

2
Pour grease into a special lubricator to
lubricate the rotating pin of the wheel
1
①. Remove excess grease.
Pour grease into a special lubricator and
lubricate the ball joint ②. Remove
excess grease.

Maintenance period:
Add butter for 2 weeks or every 50 hours of operation.

1
 Axles

Maintenance of front axle swing bushing

1. Adjust the machine to the parking
position. Make sure that no one is near
the work area.
2. Move to the position corresponding to
the swing bushing of the front axle.
Inject grease from the grease nipple on
both sides (front and rear) of the axle.
3. Repeat the same lubrication operation
for the rear axle.

Maintenance period:
Add butter for 2 weeks or every 50 hours of operation.
 Axles
Inspection and maintenance of differential oil
1. Adjust the machine to the parking position. Make
sure that no one is near the work area.
2. Remove the level plug ①The oil should come out
2
from the orifice.
3. If necessary, remove the filling plug ②. Add oil to
the correct level. Close the liquid level plug ①, and
then close the filling plug ②. Clean the oil on the
1 surface of the axle.
4. Repeat the same operation for the front differential
and the rear differential.

Maintenance cycle: Check the oil level every 3 months or

150 hours of operation; change the gear oil every 1 year or
③ is the drain port 1000 hours of operation.
3 3 3 Our company uses Mobil 80W-90 as the lubricant.