Sinoboom GTZZ15J Operation Manual

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Maintenance manual (166 pages)

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Part No.504021100002

Rev: B

Nov. 2022

Operation

Manual

产品说明书

PRODU

C T MAN U AL

GTZZ15J/AB15J/AB480J

0608E (2132E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

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Page 1 Operation Part No.504021100002 Rev: B Manual Nov. 2022 产品说明书 PRODU C T MAN U AL GTZZ15J/AB15J/AB480J 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 Decals/Nameplates Inspection of the Operation Manual for details.) Trade Identification Model Serial No. Imperial Metric From 0402100841 to present GTZZ15J AB15J AB480J NOTE: • Product model is applied in product nameplate for distinction of products with 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
Decals/Nameplates (GB) ..10-2 Inspecting the Battery ....5-6 Decals/Nameplates (CE) ..10-5 GTZZ15J Operation Manual © Nov. 2022...
Page 10 Decals/Nameplate–AS ... .10-8 Appendix 1: Symbols and Description....... A-1 Appendix 2: Prepare the Work Record Before Delivery ..A-3 Appendix 3: Repair & Inspection Report ......A-5 Appendix 4: Major Modification and Repair Record ..... A-9 © Nov. 2022 GTZZ15J Operation Manual...
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.. GTZZ15J Operation Manual © Nov. 2022...
Page 13: Performance Parameters
PERFORMANCE PARAMETERS Table 1-1 GTZZ15J specifications AB15J (Metric) AB480J (Imperial) Items DIMENSION PARAMETERS Max platform height 48ft 3in 14.7m Max working height 16.7 m 54ft 9in Max horizontal reach 8.5 m 27ft 11in Max horizontal working envelope 9.1 m 29ft 10in Overall length (stowed) 7.35 m...
Page 14 PERFORMANCE PARAMETERS Table 1-1 GTZZ15J specifications (continued) AB15J (Metric) AB480J (Imperial) Items Turning radius (outside) 4.5 m 14ft 9in Max allowable side force 400 N 90 lbf Max operating noise level 82 dB IP rating IP54 POWER PARAMETERS Options 35.3 kW/3000 rpm/4TNV88-ZCDCSI/Yanmar/China T4 Engine (rated power/rpm) 34.5 kW /3000 rpm/ TNV88-BDFLTC/Yanmar/China T3...
Page 15 PERFORMANCE PARAMETERS Table 1-1 GTZZ15J specifications (continued) AB15J (Metric) AB480J (Imperial) Items Gross weight (unladen) 7080 kg (2WD)/7280 kg (4WD) 15609 lb (2WD)/16050 lb (4WD) Note: a) The platform height plus the operator height (taken as 2m [6ft 7in]) is the working height.
Page 16 PERFORMANCE PARAMETERS GTZZ15J Chart of working envelope 355° GTZZ15J（5°） © Nov. 2022 GTZZ15J Operation Manual...
Page 18 The articulated boom and main boom descends in place, and the main boom retracts in place. Operating/raised position: The articulated boom or main boom does not descends in place, or the main boom does not retracts in place. © Nov. 2022 GTZZ15J Operation Manual...
Page 19: Safety
In case of any accident involving the machinery of Also, people who have alcohol or drugs in their Hunan Sinoboom Intelligent Equipment Co., Ltd., notify system, or experience excessive fatigue or Hunan Sinoboom Intelligent Equipment Co., Ltd.
Page 20: Electrocution Hazards
Table 3-1 Minimum Safe Distance Voltage Minimum Safe Distance (Phase to Phase, kV) (m/ft) 0-50 3.05 (10) 50-200 4.60 (15) 200-350 6.10 (20) 350 -500 7.62 (25) 500 -750 10.67 (35) 750 -1000 13.725 (45) © Nov. 2022 GTZZ15J Operation Manual...
Page 21 When the machine is driven on • Do not use the platform or boom uneven ground with gravel or assembly to push other machines other uneven surfaces, or near or objects. holes and steep slopes, maintain GTZZ15J Operation Manual © Nov. 2022...
Page 22: Work Environment Hazards
1. Retract the telescopic boom; 2. Lower the articulated boom; 3. Lower the main boom. • The drive speed should not exceed 1.1 km/h (0.68 mph) when the platform is raised. © Nov. 2022 GTZZ15J Operation Manual...
Page 23 If the machine is to be used in increase the wind load on the any special workplace or by any special work method machine. other than those specified by Hunan Sinoboom Intelligent Equipment Co., Ltd., the manufacturer’s • Do not drive or lift the machine on approval and guidance should be obtained first.
Page 24: Unsafe Operation Hazards
The battery not only provides power, but also serves as a counterweight and is vital to maintaining the stability of the machine. • Do not place or attach any suspended load onto any part of the machine. © Nov. 2022 GTZZ15J Operation Manual...
Page 25: Fall Hazards
Maintenance Manual in addition to following more machine as stated in the operation manual and in the stringent industry regulations and workplace rules. maintenance manual in addition to following more stringent industry regulations and workplace rules. GTZZ15J Operation Manual © Nov. 2022...
Page 26: Crush Hazards
Set up roadblocks if necessary. • Limit the speed of travel according to ground conditions, crowding, gradients, the presence and location of personnel and any © Nov. 2022 GTZZ15J Operation Manual...
Page 27: Explosion And Fire Hazards
During operation, keep the left and right doors of the chassis closed and locked. Only trained service personnel can open the left and right doors to repair the machine. GTZZ15J Operation Manual © Nov. 2022...
Page 28: Battery Hazards
Do not throw the battery to a fire or heater. ELECTROCUTION HAZARD • Contact with hot circuit may cause serious injury or death. Be sure to wear goggles, gloves and protective clothing. • Remove all rings, watches and other accessories. © Nov. 2022 3-10 GTZZ15J Operation Manual...
Page 29 • Do not tamper with battery system to avoid serious accident. • Cut off the battery main switch if the battery is not to be used for an extended period. GTZZ15J Operation Manual 3-11 © Nov. 2022...
Page 30: Hydraulic Hazards
OFF position. 7. Turn the key switch at the ground controls to OFF position and remove the key to avoid unauthorized operation of the machine. 8. Turn off the main power switch. © Nov. 2022 3-12 GTZZ15J Operation Manual...
Page 31 SAFETY NOTICE After using the machine, the main power switch must be disconnected. GTZZ15J Operation Manual 3-13 © Nov. 2022...
Page 33: Jobsite Inspection
Operators must identify and avoid workplace hazards when mov- ing, installing and operating the machine. Unless approved by Sinoboom, never operate the ma- chine in a hazardous site. The following items present danger on the jobsite: •...
Page 35: Pre-Operation Inspection
• Only qualified maintenance technicians can repair this machine. the machine according to the manufacturer's regulations. After any maintenance, the operator GTZZ15J Operation Manual © Nov. 2022...
Page 36: Conducting A Pre-Operation
• Drive motor, drive reducer and slewing reducer determine if any problem exists in the hydraulic system. • Boom wear pads and telescopic boom wear pads © Nov. 2022 GTZZ15J Operation Manual...
Page 37: Inspecting Fuel Level
Low temperature region the diesel fuel level. -25°C to 25°C (-13°F to 77° L-HV32 High temperature region L-HM68 greater than 40°C (104°F) Extremely low temperature Special programmes region need to be identified. less than -30°C (-22°F) GTZZ15J Operation Manual © Nov. 2022...
Page 38: Inspecting Engine Oil Level
5. Switch off the engine, and 5 minutes later open the turntable cover on the right side. ambient temperature. 6. Remove the engine dipstick to inspect the engine oil level. 7. The engine oil level should be within the FULL and ADD marks. © Nov. 2022 GTZZ15J Operation Manual...
Page 39: Inspecting Coolant Level
Through the daily check, the inspector can know about the changes in coolant level which may indicate a system distress with the engine. GTZZ15J Operation Manual © Nov. 2022...
Page 40: Inspecting The Battery
• Connect the charging plug to a 220V socket. Result: The battery could be charged normally, and the charge indicator is lit. © Nov. 2022 GTZZ15J Operation Manual...
Page 41 (the red cable to the positive, and the black cable to the negative). • Connect the charging plug to a 220V socket. Result: The battery could be charged normally, and the charge indicator is lit. GTZZ15J Operation Manual © Nov. 2022...
Page 43: Pre-Operation Function Test
All function tests of the ground controller should be completed in one cycle. Do not use a machine with problems or malfunctions. Mark the machine and do not use it if you discover any GTZZ15J Operation Manual © Nov. 2022...
Page 44 21. OFF position 5. Enable switch 6. Main boom luffing switch 14. Jib boom up/down switch 7. Articulated boom luffing switch 15. Main boom telescoping switch 16. Emergency stop button 8. Turntable rotation switch © Nov. 2022 GTZZ15J Operation Manual...
Page 45 9. Platform info 33. Overload limit 10. Alarm message 34. Drive limit (operating position) 22. Overload alarm 35. Drive and boom functions 11. Fault alarm 23. Not used allowed 12. Glow plug 24. Not used GTZZ15J Operation Manual © Nov. 2022...
Page 46 The functional operation should only be allowed on the platform controller, while the ground controller should be inoperative. Flip the engine start switch, the engine should be Enable switch started smoothly without abnormal noise. © Nov. 2022 GTZZ15J Operation Manual...
Page 47 2. Flip the enable switch and meanwhile move Platform rotation switch downward the main boom luffing switch, the main boom shall go down and the buzzer will sound. Main boom telescoping switch GTZZ15J Operation Manual © Nov. 2022...
Page 48: Testing The Platform Controller
When the emergency power is in use, do not TESTING THE PLATFORM perform two or more functions simultaneously, otherwise the auxiliary motor and pump will get CONTROLLER overloaded. NOTICE All tests of the platform controller should be completed within one cycle. © Nov. 2022 GTZZ15J Operation Manual...
Page 49 35. Main boom luffing proportional 11. Chassis tilt indicator light 23. Jib boom up/down switch control direction 36. Turntable rotation proportion 12. Overload indicator light 24. Platform leveling switch control direction GTZZ15J Operation Manual © Nov. 2022...
Page 50 Run the engine at low idle for 3-5min to preheat the engine before applying any loads. Flip the glow plug switch and hold it for 6-10s, the engine should take in air for preheating. © Nov. 2022 GTZZ15J Operation Manual...
Page 51 2. Depress the foot switch and move backward the Drive/Steer proportional control handle, the machine should drive backward smoothly without noticeable impact in startup; when the handle is released, the machine should be held reliably. GTZZ15J Operation Manual © Nov. 2022...
Page 52 2. Depress the foot switch and move downward the counterclockwise. articulated boom luffing switch, the articulated boom should descend smoothly. Note: The turntable rotation speed is in direct proportion to the stroke of control handle. Platform leveling switch Main boom luffing © Nov. 2022 6-10 GTZZ15J Operation Manual...
Page 53 Speed adjusting knob When the rear position indicator light is flashing, the drive function should be closed. Flip the rear position drive switch, the indicator light shall be lit and the drive function should resume. GTZZ15J Operation Manual 6-11 © Nov. 2022...
Page 54 Low engine oil pressure high idle indicator light should be on. • High engine water temperature Anti-pinch/soft contact unlock switch (if • CAN bus error equipped) • Other faults Chassis tilt indicator light CAUTION © Nov. 2022 6-12 GTZZ15J Operation Manual...
Page 55: Testing The Drive Speed
POSITION MAX DRIVE SPEED Operating 1.1km/h (0.68mph) Non-operating 5km/h (3.1mph) NOTICE If the drive speed exceeds the test results as shown above by 10%, please immediately tag and remove the machine from service. GTZZ15J Operation Manual 6-13 © Nov. 2022...
Page 56: Testing The Tilt Protection System
With the boom in operating position (except GB): When the load exceeds 250kg (551 lb), the buzzer will sound continuously, the overload indicator light will flash, the display screen will indicate platform overload, all functions are restricted and will not resume until the excessive load is removed. © Nov. 2022 6-14 GTZZ15J Operation Manual...
Page 57 Before conducting any override operation, please make sure the surrounding area and the whole machine are in a safe state, try to avoid operation in a dangerous direction and ensure personal safety. GTZZ15J Operation Manual 6-15 © Nov. 2022...
Page 59: Operating The Machine
• Check the work site. • Check the safety decals/ nameplate on the machine. • Only use the machine according to the instructions in this manual and for its intended purpose. GTZZ15J Operation Manual © Nov. 2022...
Page 60 Main boom kept horizontal; Telescopic boom fully extended; Jib boom kept horizontal; The machine will tip over in the direction as indicated by the arrow if overloaded or operated on surfaces beyond the maximum allowable inclination angle. © Nov. 2022 GTZZ15J Operation Manual...
Page 61: Emergency Stop
Push the power disconnect switch on the left side of chassis to OFF, the system power will be disconnected and all functions will become inoperative. The power disconnect switch is located as shown in the Figure below. GTZZ15J Operation Manual © Nov. 2022...
Page 62: Emergency Lowering
3. Loosen the bolts on each drive hub, then reverse the cover of drive hub. 4. Tighten the bolts, till now the drive hub is disengaged and ready for towing/dragging. © Nov. 2022 GTZZ15J Operation Manual...
Page 63: Operation From Ground
Before applying any load, warm up the engine by running it at low speed for 3–5min. To position platform: 1. Move the enable switch and meanwhile move upwards/downwards the main boom up/down switch to raise or lower the main boom. GTZZ15J Operation Manual © Nov. 2022...
Page 64: Operation From Platform
OFF position after being 3. Depress the footswitch and meanwhile move released. backwards/forwards the main boom telescope/jib © Nov. 2022 GTZZ15J Operation Manual...
Page 65: Driving On A Slope
Uphill: 40%/21° right. To select drive speed: The machine in non-operating position and with outriggers fully retracted can run in two drive speed modes (high/low speed). GTZZ15J Operation Manual © Nov. 2022...
Page 66 2. Measure the height (H) and length/distance (L) of the slope. Figure 7-5 3. Slope grade= H/L x 100%. NOTICE To prevent the tires running suspended, the machine must not drive for over 2min on the maximum permissible slope grade. © Nov. 2022 GTZZ15J Operation Manual...
Page 67: Transporting And Lifting The Machine
When using a forklift or crane to lift the machine, try to prevent the machine from colliding with nearby objects. • Lock the wheels of the machine after it has been loaded to prevent the machine from rolling. GTZZ15J Operation Manual © Nov. 2022...
Page 68: Lifting The Machine With A Crane
Follow these requirements when transporting the machine by truck or trailer: To protect the machine, choose the rigging with 1. Before transporting, turn the key switch on ground appropriate length. controller to OFF, and remove the key. © Nov. 2022 GTZZ15J Operation Manual...
Page 69 4. Use at least 4 ropes/belts to fasten the chassis and the rope/belt fastened near the platform. It is 1 rope/belt for the platform. recommended to add a foam layer beneath the platform and ensure the platform is suspended. Figure 8-3 GTZZ15J Operation Manual © Nov. 2022...
Page 71: Maintenance
& counterbalance valve on the cylinder. inspection report and must complete the repair & inspection report. • Immediately remove a damaged or malfunctioning machine from service, mark and stop using it. GTZZ15J Operation Manual © Nov. 2022...
Page 72: Conducting A Pre-Delivery Inspection
Every half a year or every 500 involved. Use the table to help you adhere to a routine A+B+C hours maintenance schedule. Every year or every 1000 hours A+B+C+D © Nov. 2022 GTZZ15J Operation Manual...
Page 73: Completing A Repair & Inspection
A-9 Inspect Coolant Level (water-cooled engine) A-10 Inspect Engine Belt A-11 Inspect Fuel Strainer (fuel-water separator) A-12 Inspect Cooling Fan A-13 Inspect Engine Intake System A-14 Functional Tests A-15 Perform Maintenance after 30 Days GTZZ15J Operation Manual © Nov. 2022...
Page 74 B-12 Inspect worm gear end 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 Inspect Oscillate Cylinder Exhausting and Counterbalance Valve Locking B-18 Inspect Electrical Wiring © Nov. 2022 GTZZ15J Operation Manual...
Page 75 Gear Oil D-2 Replace Hydraulic Oil D-3 Inspect Boom Wear Pads D-4 Replace Hydraulic Tank Suction Filter D-5 Replace Coolant and Coolant Hoses (water-cooled engine) D-6 Replace Fuel Hoses User Inspector Signature Inspection Date GTZZ15J Operation Manual © Nov. 2022...
Page 76: Major Modification And Repair Record
“Good” condition before company. continuing to use the machine. Table 9-4 Major Modification and Repair Record Model Serial No. Machine Repair- Repairman’s Status Problem Description Modification/Repair Item Date Company and Signature Position ter Change © Nov. 2022 GTZZ15J Operation Manual...
Page 79: Decals/Nameplates Inspection
Do not operate the engine if there are missing or badly worn safety labels. GTZZ15J Operation Manual 10-1 © Nov. 2022...
Page 80: Decals/Nameplates (Gb)
DECALS/NAMEPLATES INSPECTION DECALS/NAMEPLATES (GB) (28) (20) 24 (18) (18) (19) (20) (18) (10) © Nov. 2022 10-2 GTZZ15J Operation Manual...
Page 81 104011100018 Decal-Burns hazard 104011100008 Decal-Noise of 82dB Decal-Explosion hazard 104011100005 LOGO-Symbol (small sticker) 103008103006 Nameplate-GB 105001100057 215050000001 Blind rivet Decal-Direction marking 105001100053 Decal-Direction marking 105001100051 Decal-Hydraulic oil level 104011100010 Decal-Hydraulic oil level 104011100003 GTZZ15J Operation Manual 10-3 © Nov. 2022...
Page 82 DECALS/NAMEPLATES INSPECTION Description Qty. Part No. Remarks Decal-Hydraulic oil temperature range 104010100021 Decal-Hydraulic oil marking 104009100018 104011100012 Decal-Fall hazard Decal-Oil-water separater 104009100020 Decal-Diesel marking 104009100019 Environmental label imprint position © Nov. 2022 10-4 GTZZ15J Operation Manual...
Page 83: Decals/Nameplates (Ce)
DECALS/NAMEPLATES INSPECTION DECALS/NAMEPLATES (CE) (27) (20) 23 (18) (18) (18) (19) (20) (10) GTZZ15J Operation Manual 10-5 © Nov. 2022...
Page 84 Decal-Explosion hazard 104011100005 103008103006 LOGO-White sticker Nameplate-UKCA&CE (AB) 103011103013 215050000001 Blind rivet 105001100053 Decal-Direction mark 105001100051 Decal-Direction mark Decal-Hydraulic oil level 104011100010 Decal-Hydraulic oil level 104011100003 Decal-Hydraulic oil temperature range 104010100021 Decal-Hydraulic oil 104009100022 © Nov. 2022 10-6 GTZZ15J Operation Manual...
Page 85 DECALS/NAMEPLATES INSPECTION Description Qty. Part No. Remarks 104011100012 Decal-Fall hazard Decal-Oil-water separator 104009100020 Decal-Diesel marking 104009100021 GTZZ15J Operation Manual 10-7 © Nov. 2022...
Page 86: Decals/Nameplate-As
DECALS/NAMEPLATES INSPECTION DECALS/NAMEPLATE–AS (27) (18) (20) 23 (18) (19) (20) (18) (10) © Nov. 2022 10-8 GTZZ15J Operation Manual...
Page 87 Decal-Noise of 82dB Decal-Explosion hazard 104011100005 LOGO-Symbol (small sticker) 103008103006 Nameplate-AS 105018100005 215050000001 Blind rivet Decal-Direction marking 105001100053 Decal-Direction marking 105001100051 Decal-Hydraulic oil level 104011100010 Decal-Hydraulic oil level 104011100003 Decal-Hydraulic oil temperature range 104010100021 GTZZ15J Operation Manual 10-9 © Nov. 2022...
Page 88 DECALS/NAMEPLATES INSPECTION Description Qty. Part No. Remarks Decal-Hydraulic oil marking 104009100022 104011100012 Decal-Fall hazard Decal-Oil-water separater 104009100020 Decal-Diesel marking 104009100021 © Nov. 2022 10-10 GTZZ15J Operation Manual...
Page 89: Appendix 1: Symbols And Description
Never use machine Never use machine Never push or pull Never suspend objects Never place ladders during strong, gusty during strong, gusty objects outside from platform and scaffolding on the wind wind platform platform GTZZ15J Operation Manual © Nov. 2022...
Page 90 No smoking Lifting point Lashing points Tire to ground load Hydraulic oil filler Platform carrying Do not use damaged Tool or weight Fast/high speed Slow/low speed capacity cords Horn © Nov. 2022 GTZZ15J Operation Manual...
Page 91: Appendix 2: Prepare The Work Record Before Delivery
2. Use the table to record the results. After each section is complete, mark the appropriate box. 3. Record the inspection results. If any inspection result is “NO”, the machine must be stopped, and then re- inspected after repair is completed, and the box marked “REPAIRED” shall be checked. GTZZ15J Operation Manual © Nov. 2022...
Page 93: Appendix 3: Repair & Inspection Report
A-14 Functional Tests A-15 Perform Maintenance after 30 Days A-16 Perform Oscillate Cylinder Exhausting Checklist B Procedures YES/Machine is REPAIRED/ NO/Machine Has Problem in Good Condition Machine Has Items Damage or Description Been Repaired Malfunction GTZZ15J Operation Manual © Nov. 2022...
Page 94 B-17 Inspect Oscillate Cylinder Exhausting and Counterbalance Valve Locking B-18 Inspect Electrical Wiring B-19 Inspect the Battery B-20 Test Oscillate Outriggers and Oscillate Multi-way Valve Lever B-21 Test Drive Speed B-22 Inspect Emergency Lowering © Nov. 2022 GTZZ15J Operation Manual...
Page 95 D-2 Replace Hydraulic Oil D-3 Inspect Boom Wear Pads D-4 Replace Hydraulic Tank Suction Filter D-5 Replace Coolant and Coolant Hoses (water-cooled engine) D-6 Replace Fuel Hoses User Inspector Signature Inspection Date Inspector Title GTZZ15J Operation Manual © Nov. 2022...
Page 96 4. If any inspection item is marked as “NO”, the machine must be stopped, and after the repair is completed, the machine shall be re-inspected and the box marked “REPAIRED” shall be checked. Select the appropriate inspection procedure based on the inspection type. © Nov. 2022 GTZZ15J Operation Manual...
Page 97: Appendix 4: Major Modification And Repair Record
Modification/Repair” in the form will be “Good” and the machine can be used. If either inspection result is “NO”, the machine must be re-inspected after the repair is completed until the machine is in “Good” condition before continuing to use the machine. GTZZ15J Operation Manual © Nov. 2022...
Page 98 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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