Sinoboom GTJZ0407SE Maintenance Manual

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Part No.501040110002

Rev: A

May 2020

Maintenance

Manual

产品说明书

PRODU

C T MAN U AL

GTJZ0407SE/0407SE/1330SE

0608E (2132E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

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Page 1 Maintenance Part No.501040110002 Rev: A Manual May 2020 产品说明书 PRODU C T MAN U AL GTJZ0407SE/0407SE/1330SE 0608E (2132E) G T JZ 0808E (2732E) G T JZ 0808E (2732E) G T JZ G T JZ 0808E (2732E)
Page 3 Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your...
Page 4 : No.128, East Jinzhou Avenue, Ningxiang High-tech Industrial Park, Changsha, Hunan, China Zip Code : 410600 Copyright © Hunan Sinoboom Intelligent Equipment CO.,Ltd. All Rights Reserved The final interpretation right of this manual belongs to Hunan Sinoboom Intelligent Equipment CO.,Ltd.
Page 5 See the nameplate on your machine to identify the model and serial number.(See of the Operation Manual for details.) Trade identification MODELS SERIAL NO. Imperial Metric GTJZ0407SE GTJZ0407SE 1330SE From 0104000650 to current NOTE: • Product model is applied in product nameplate for distinction of products of different main parameters.
Page 6 This Page Intentionally Left Blank...
Page 7 This manual covers the basic parts information of one or more products. Therefore, please use this manual according to your needs. If you find problems in the manual or have suggestions for improve- ment, feel free to share your feedback with Sinoboom, and we will address these issues as soon as possible.
Page 8 This Page Intentionally Left Blank...
Page 9: Table Of Contents
A-17 Inspect the battery level ..4-12 Electrical System ..... 3-1 GTJZ0407SE Maintenance Manual © May 2020...
Page 11: Introduction
The owner or administrator of the machine shall also provide the manufacturer’s maintenance information to the person responsible for maintaining the machine. If you have any questions, contact Hunan Sinoboom In- telligent Equipment Co., Ltd.. GTJZ0407SE Maintenance Manual © May 2020...
Page 13: Performance Parameters
PERFORMANCE PARAMETERS SPECIFICATION Table 1-1 GTJZ0407SE Specifications GTJZ0407SE (METRIC) GTJZ0407SE (IMPERIAL) MEASURE DIMENSION PARAMETERS Max. platform height 3.8 m 12 ft 5.6 in Max. working height 5.8 m 19 ft Max. horizontal extension 0.6 m 1 ft 11.6 in Length 1.42 m...
Page 14 The working height adds 2m (6ft 7in) of human height to platform height. b) In different areas, hydraulic oil, engine oil, coolant, fuel and lubrication should be added in accordance with the environmental temperature. c) In cold weather, auxiliary devices are needed to start the machines. © May 2020 GTJZ0407SE Maintenance Manual...
Page 15: Power System Specifications
Lift relief valve pressure 21MPa（3045 Psi） Steer relief valve pressure 21MPa（3045 Psi） HYDRAULIC RETURN FILTER Bypass pressure 0.25MPa（36 Psi） NOTICE Different hydraulic oils can be added according to customer requirements upon factory delivery, but cannot be mixed. GTJZ0407SE Maintenance Manual © May 2020...
Page 16: Hydraulic Hose Torque
35 ± 2 Nm (26 ± 2 ft-lb) M14×1.5 55 ± 4 Nm (41 ± 3 ft-lb) 60 ± 4 Nm (44 ± 3 ft-lb) 40 ± 3 Nm (30 ± 3 ft-lb) M16×1.5 © May 2020 GTJZ0407SE Maintenance Manual...
Page 17 185 ± 12 Nm (136 ± 9 ft-lb) 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) GTJZ0407SE Maintenance Manual © May 2020...
Page 18 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) © May 2020 GTJZ0407SE Maintenance Manual...
Page 19: Hydraulic Hose And Fitting Torque
500 Nm (369 ft-lb) 650 Nm(479 ft-lb ) 770 Nm (568 ft-lb) 600 Nm (443 ft-lb) 800 Nm (590 ft-lb) 980 Nm (723 ft-lb) 650 Nm (479 ft-lb) 850 Nm (627 ft-lb) 1050 Nm (774 ft-lb) GTJZ0407SE Maintenance Manual © May 2020...
Page 20 200 Nm (148 ft-lb) 9/16-18 13/16" 200 Nm (148 ft-lb) 280 Nm (207 ft-lb) 5/8-18 15/16" 350 Nm (258 ft-lb) 495 Nm (365 ft-lb) 3/4-16 1-1/8" 560 Nm (413 ft-lb) 780 Nm (575 ft-lb) 7/8-14 © May 2020 GTJZ0407SE Maintenance Manual...
Page 21: Safety
Table 2-1 , page 2-2. Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. GTJZ0407SE Maintenance Manual © May 2020...
Page 22: Tipping Hazards And Rated Load
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 2-2 GTJZ0407SE Retracting 240 kg(526 lb) © May 2020 GTJZ0407SE Maintenance Manual...
Page 23 • Do not modify or change moving aerial platforms without the manu- facturer’s prior written permission. • On the platform, do not attach an additional device for placing tools GTJZ0407SE Maintenance Manual © May 2020...
Page 24: Work Environment Hazards
Whole trees in motion. Effort needed to Near gale/moderate gale 13.9～17.1 32～38 walk against the wind. Twigs broken from trees. Cars veer on Fresh gale 17.2～20.7 39～46 road. Strong gale Light structure damage. 20.8～24.4 47～54 © May 2020 GTJZ0407SE Maintenance Manual...
Page 25: Unsafe Operation Hazards
Do not use the platform to push the machine or other objects. • Do not allow the platform to touch nearby objects. • Do not tie the platform onto nearby objects. • Do not put the load outside the platform. GTJZ0407SE Maintenance Manual © May 2020...
Page 26: Fall Hazards
COLLISION HAZARDS At a minimum, operators must operate and maintain the machine as stated in this manual and in the Mainte- nance Manual in addition to following more stringent in- dustry regulations and workplace rules. © May 2020 GTJZ0407SE Maintenance Manual...
Page 27: Crush Hazards
• Maintain good judgment and plan- ning when using the controller on the ground to operate the ma- chine. Maintain proper distance between operator, machine and fixed object. GTJZ0407SE Maintenance Manual © May 2020...
Page 28: Damaged Machine Hazards
During operation, the battery. 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. © May 2020 GTJZ0407SE Maintenance Manual...
Page 29: Charging The Battery
WELDING AND POLISHING REQUIREMENTS Before welding, grinding and polishing operations, al- ways ensure you read and understand all operation and maintenance requirements in this manual and the Main- tenance Manual. GTJZ0407SE Maintenance Manual © May 2020...
Page 30: After Using The Machine
5. Block the wheels with the wheel wedges. 6. Charge the battery. NOTICE After using the machine, the power off switch must be disconnected. © May 2020 2-10 GTJZ0407SE Maintenance Manual...
Page 31: System Descriptions
A series of angle sensors and limit switches provides signals to the controllers. The level sensor measures the angle of machine on X-axis and Y -axis. When the angle on X-axis exceeds 1.5 degrees or the angle on Y- GTJZ0407SE Maintenance Manual © May 2020...
Page 33: Maintenance
1. Prepare the machine before delivery, which in- – Park the machine on flat, level, firm ground. cludes performing a pre-delivery inspection, follow- – Keep the machine in the stowed position. ing maintenance procedures and performing functional inspections. GTJZ0407SE Maintenance Manual © May 2020...
Page 34: Following Amaintenance Schedule
"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 appropri- ate inspection procedure based on the inspection type. © May 2020 GTJZ0407SE Maintenance Manual...
Page 35 A-13 Test the Pothole Guard A-14 Inspect Platform Weigh- ing System(optional) A-15 Inspect the Raised Limit Function A-16 Inspect Platform Lower- ing Limit A-17 Inspect the battery level A-18 Perform Maintenance After 30 Days Checklist B Procedures GTJZ0407SE Maintenance Manual © May 2020...
Page 36 D-2 Inspect Chassis Slider D-3 Replace Hydraulic Oil Tank Return Oil Filter Element D-4 Inspect and Replace Hy- draulic Oil D-5 Inspect Key Structural Parts User Inspector Signature Inspector Date Inspector Title Inspector Company © May 2020 GTJZ0407SE Maintenance Manual...
Page 37: Checklist Aprocedures
If needing to replace the decals, contact Hunan Sino- NOTICE boom Intelligent Equipment Co., Ltd.. For any damaged, improperly installed or missing parts, correctly install new parts immediately. If the fasteners are loose, tighten them immediately. GTJZ0407SE Maintenance Manual © May 2020...
Page 38: Inspect Hydraulic Oil Level
Position Switch Inspect for overflowing, dripping or residual marks on or 4. Key Switch around the following components: Testing the Ground Controller Function • Hydraulic oil tank, filters, pipe fittings, oil pipe, power unit © May 2020 GTJZ0407SE Maintenance Manual...
Page 39 5. Lowering 12. Walking and Steering INSPECT PLATFORM CONTROLLER 13. High/Low Speed 6. Front 7. Back NOTICE Testing the Platform Controller Test all functions of the platform controller in one cycle. GTJZ0407SE Maintenance Manual © May 2020...
Page 40 Enabling key Do not press the enabling key on the control handle. Push the control handle forward and backward . Ensure that all walking and lifting functions stop working. Testing the Lifting and Lowering Functions © May 2020 GTJZ0407SE Maintenance Manual...
Page 41: Inspect Emergency Lowering
Pull the emergency stop button on the ground con- troller and platform control box out to the “ON” position. 2. Move the lifting/lowering switch of the platform to the lifting position until the platform lifts to the high- est position. GTJZ0407SE Maintenance Manual © May 2020...
Page 42: Testing Traveling Speed
The slow mode activates 7. Hold the enabling key on the control handle and when the light of the low-speed traveling button gently push the control handle forward to the full- illuminates. © May 2020 4-10 GTJZ0407SE Maintenance Manual EMERGENCY...
Page 43: Inspect The Tilt Protection
Gradually add a load to the raise the platform about 2 m (6.6 ft). Ensure the platform. platform stops moving and tilt the alarm bell. Ensure GTJZ0407SE Maintenance Manual 4-11 © May 2020...
Page 44: Limit
A-17 Inspect the battery level Using the Battery Level Indicator Table 4-9 PLATFORM POWER DISPLAY POWER RATIO DESCRIPTION The battery has been fully charged. 90-100% The battery is at 70% of its capacity. © May 2020 4-12 GTJZ0407SE Maintenance Manual...
Page 45: Perform Maintenance After
The machine is equipped with solid tires that do not damaged or corroded wires before operating the need to be inflated. machine. 1. Inspect for cuts, cracks, puncture or abnormal wear patterns on all tires. GTJZ0407SE Maintenance Manual 4-13 © May 2020...
Page 46: Inspect Battery
When inspecting the retaining nut, replace the split pin frequently. Never reuse the split pin. B-3 Inspect Battery NOTE: Perform this procedure every 125 hours. © May 2020 4-14 GTJZ0407SE Maintenance Manual...
Page 47: Inspect Hydraulic Oil
Obtain a sample of the hydraulic oil and inspect it in Result: Replace the battery if the electrolyte density sunlight. Rub the oil between two fingers to of any battery cell is below 1.026. determine if it contains metal particles. GTJZ0407SE Maintenance Manual 4-15 © May 2020...
Page 48: Inspect Hydraulic Oil Tank
Machine Mode", then press the enter button. Method 1: 5. Press page down key until the display appears "- 1. Wedge the tires to prevent the machine from rolling. Break Release", then press the enter button. © May 2020 4-16 GTJZ0407SE Maintenance Manual...
Page 49: Checklist Cprocedures
2. Install and tighten the new air filter. 3. Clean all oil spills during the replacement process. 4. Start the machine and inspect the filter and hydraulic components to ensure no leakage exists. GTJZ0407SE Maintenance Manual 4-17 © May 2020...
Page 50: Replace Hydraulic Oil Tank
Inspecting and replacing the hydraulic oil is important for the proper operation and service life of the machine. 11. Install the oil return pipe onto the hydraulic oil tank. The machine may be unable to operate properly if the © May 2020 4-18 GTJZ0407SE Maintenance Manual...
Page 51: Inspect Key Structural Parts
Be sure the chassis has no traces of oil, accumulated debris and is not deformed or Chassis cracked. Be sure all hardware is tight. Pothole guard device The pothole guard device cannot be pushed from the outside when fully extended. GTJZ0407SE Maintenance Manual 4-19 © May 2020...
Page 53: Maintenance Procedures
Be sure to disconnect the battery from the machine and the charger 4. Move the platform away. from the AC outlet before performing this procedure. Contact with live conductors could result in death or serious injury. GTJZ0407SE Maintenance Manual © May 2020...
Page 54: Removing The Extension Platform
3. Disconnect and plug the hoses and fittings on the While removing the rubber hose and connector, hydraulic cylinder. be sure to remove and mark the O-rings at the end of the rubber hose or hose. © May 2020 GTJZ0407SE Maintenance Manual...
Page 55: Chassis Components
Use a properly rated lifting jack to lift the machine and properly rated jack stands to support the 4. Remove the front wheel bracket. machine while lifted. GTJZ0407SE Maintenance Manual © May 2020...
Page 56: Removing The Steering Cylinder
So start the pump 3. Use the appropriate lifting equipment to remove the within a very short time interval, and verify the battery. reading. Do not overload the pump. 5. Remove the pressure gauge. © May 2020 GTJZ0407SE Maintenance Manual...
Page 57: Removing The Hydraulic Power Unit
4. Remove the mounting bolts of the hydraulic pump and carefully remove the hydraulic pump. NOTICE When installing the removed hose and fitting, it must be tightened according to the specified torque. See Hydraulic Hose and Fitting Torque Procedure, page 1-7. GTJZ0407SE Maintenance Manual © May 2020...
Page 58: Installing The Cartridge Valve
Platform lifting 34 Nm (25 ft-lb) 3-position 4-way solenoid valve Left/right steering 34 Nm (25 ft-lb) Lifting overflow valve Lifting overflow 27 Nm (20 ft-lb) Steering overflow valve Steering overflow 24 Nm (18 ft-lb) © May 2020 GTJZ0407SE Maintenance Manual...
Page 59: Regulating The Platform Lifting
5-6.) 2. Connect a pressure gauge 0 - 40 MPa (0 - 5,800 psi) to the system pressure measuring port. 3. Remove the platform controller from the platform. Operate the controller from the ground. GTJZ0407SE Maintenance Manual © May 2020...
Page 60: Hydraulic Symbols
兰共页第页奇志日期 2018.10.25 黑 Table 5-2 Check valve 46.7096 17.4787 Symbol Description 34.4087 17.4787 46.7096 32.0000 Filter 34.4087 46.7096 16.0000 34.4087 32.0000 Brake 28.5682 32.0000 16.0000 28.5682 16.0000 © May 2020 GTJZ0407SE Maintenance Manual...
Page 61: Hydraulic Schematic Diagram
MAINTENANCE PROCEDURES Hydraulic Schematic Diagram GTJZ0407SE hydraulic schematic diagram Lifting Cylinder Apolegamy Overweight sensor Overweight sensor ∅0.9 ∅1.2 Steering Cylinder 0bar 1.1cc/r DC24V/1.6kW GTJZ0407SE Maintenance Manual © May 2020...
Page 62: Electrical System
• Protective goggles and gloves • Wrench with rubber handle Figure 5-9 Figure 5-11 • Sodium bicarbonate • Terminal post protector (i.e., petroleum jelly and BATTERY INSTALLATION SAFETY corrosion prevention spray, etc.) INSTRUCTIONS © May 2020 5-10 GTJZ0407SE Maintenance Manual...
Page 63 PREVENTIVE MAINTENANCE values. Details about proper charging are as follows: GTJZ0407SE Maintenance Manual 5-11 © May 2020...
Page 64 Battery Cell 1.277 2.122 6.37 12.73 1.258 2.103 6.31 12.62 1.238 2.083 6.25 12.50 1.217 2.062 6.19 12.37 1.195 2.040 6.12 12.24 1.172 2.017 6.05 12.10 1.148 1.993 5.98 11.96 1.124 1.969 5.91 11.81 © May 2020 5-12 GTJZ0407SE Maintenance Manual...
Page 65 • Reverse-polarity protection: In case of the reverse 1.0V. polarity of the battery, the battery charger will GTJZ0407SE Maintenance Manual 5-13 © May 2020...
Page 66: Use And Care Of Lead-Acid Battery
Keep the battery out of areas with high heat • Because there is a risk of high voltage, do not touch and exposure to fire or sun. non-insulated terminals or connectors. © May 2020 5-14 GTJZ0407SE Maintenance Manual...
Page 67: Trouble Diagnosis
Discharge Current High Fault 1: Tell BMS factory Diagnostic Message Only High Fault 1 to check battery. Disable Lifting, and Driving Total Voltage Low Fault 1: Tell BMS factory to Total Voltage Low on low speed check battery. Fault 1 GTJZ0407SE Maintenance Manual 5-15 © May 2020...
Page 68 Message: Make sure that the Joystick is in the Joystick Not In neutral (upright) position. Check the neutral zone Lift Slow to Drive Speed Neutral parameter setting in the LabView Programmer. If it’s OK, consider replacing the Joystick or the PCU. © May 2020 5-16 GTJZ0407SE Maintenance Manual...
Page 69 Make sure the correct throttle type is selected in Throttle Fault the Motor Controller. Motor Controller Emergency Reverse Fault: Motor Controller Ensure that the Emergency Reverse Check Emergency Reverse Disable All Motion parameter is off in the Motor Controller. Fault GTJZ0407SE Maintenance Manual 5-17 © May 2020...
Page 70 Motor Controller Right Drive Motor Fault: Check Motor Controller Right connections to the motors. Cycle power to the lift Disable Lifting and Driving Drive Motor Fault and if that does not resolve the issue, replace the Motor Controller. © May 2020 5-18 GTJZ0407SE Maintenance Manual...
Page 71 Do not add more load. Overloaded Platform Fault: Remove the excess Overloaded Platform Disable All Motion load immediately. Fault PlatformHighestPosit- Platform Highest Position Warning:Lower the Disable Lifting ion Warning machine. GTJZ0407SE Maintenance Manual 5-19 © May 2020...
Page 72: Fundamental Troubleshooting
The system has not been powered off after the turned to the operation of the platform controller is program is downloaded to the platform controller. platform control position invalid • Inspect whether the platform controller is malfunctioning. © May 2020 5-20 GTJZ0407SE Maintenance Manual...
Page 73 The backward function The backward moving • Check whether the connection of the forward valve fails without a warning capability is malfunctioning is normal. • Inspect whether the lower platform controller is malfunctioning. GTJZ0407SE Maintenance Manual 5-21 © May 2020...
Page 74 After setting, the • The parameters cross the line. parameters could not The storage is abnormal be saved successfully • The lower platform controller is malfunctioning. after several trials. © May 2020 5-22 GTJZ0407SE Maintenance Manual...
Page 75: Electrical Symbols
28.5682 16.0000 28.5682 棕兰 32.0000 32.0000 Key switch Buzzer 兰棕黑黑 28.5682 28.5682 16.0000 兰 16.0000 棕 17.4787 + Li 黑 46.8000 17.4787 GTJZ0407SE Maintenance Manual 5-23 © May 2020 46.7096 28.5682 46.7096 46.8000 46.7096 46.8000 34.4087...
Page 76 46.7096 46.7096 46.8000 34.4087 34.4087 MAINTENANCE PROCEDURES 32.0000 28.5682 Symbol Description Symbol Description 28.5682 16.0000 Storage battery Lithium battery 46.8000 Fuse © May 2020 5-24 GTJZ0407SE Maintenance Manual...
Page 77: Electrical Schematic Diagram
Speed Reduction Forward Walking Speed Fault Enable Left Left Connector Back Enables Reduction Hint Brake Walking Brake Lifting Hight Speed Speed Status Status 220V 220V External Power Socket Charging Socket Leakage Switch 101040060001 GTJZ0407SE Maintenance Manual 5-25 © May 2020...
Page 78 Brake Hint Speed Enables Right Coil break RS8865 320 321 coil Warning Lamp Electric Relay Electric Meter Left Brake Coil Right Brake Coil Flicker Code Horn Rise Decline Left Turn Right Turn 101040060001 © May 2020 5-26 GTJZ0407SE Maintenance Manual...
Page 79: Appendix 1: Prepare The Work Record Before Delivery
2. Use the table to record the results. After each section is complete, mark the appropriate box. 3. Record the inspection results. If any inspection results are "NO", the machine must be stopped and re-in- spected after repair is completed and marked in the box marked "inspection". GTJZ0407SE Maintenance Manual © May 2020...
Page 81: Appendix 2: Repair & Inspection Report
A-12 Inspect the Tilt Protec- tion Function A-13 Test the Pothole Guard A-14 Inspect Platform Weigh- ing System(optional) A-15 Inspect the Raised Limit Function A-16 Inspect Platform Lower- ing Limit A-17 Inspect the battery level GTJZ0407SE Maintenance Manual © May 2020...
Page 82 D-1 Inspect Scissor Arm In- stallation Bearing D-2 Inspect Chassis Slider D-3 Replace Hydraulic Oil Tank Return Oil Filter Element D-4 Inspect and Replace Hy- draulic Oil D-5 Inspect Key Structural Parts User Inspector Signature Inspector Date © May 2020 GTJZ0407SE Maintenance Manual...
Page 83 4. Record the inspection results. If any inspection results are "NO", the machine must be stopped and re-in- spected after repair is completed and marked in the box marked "inspection". Select the appropriate inspection procedure based on the inspection type. GTJZ0407SE Maintenance Manual © May 2020...
Page 84 Solution s Alw ays For B et t er A ccess Solution s Always for Better Access Solutions AS/N ZS Hunan Sinoboom Intelligent Equipment CO.,Ltd. 长沙市宁乡高新技术产业园区金洲大道东 128 号 No.128, East Jinzhou Avenue, Ningxiang High-tech Industrial Park, Changsha, Hunan, China 市宁乡高新技术产业园区金洲大道东...

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