Sinoboom GTJZ2146 Maintenance Manual
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Sinoboom GTJZ2146 Maintenance Manual

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Part No.501043110002
Rev: A
Aug 2020
Maintenance
Manual
产品说明书
PRODU
C T MAN U AL
GTJZ0612/0612/2146
GTJZ0812/0812/2746
0608E (2132E)
G T JZ
GTJZ1012/1012/3346
0808E (2732E)
G T JZ
GTJZ1212/1212/4047
0808E (2732E)
G T JZ
G T JZ
0808E (2732E)

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  • Page 1 Maintenance Part No.501043110002 Rev: A Manual Aug 2020 产品说明书 PRODU C T MAN U AL GTJZ0612/0612/2146 GTJZ0812/0812/2746 0608E (2132E) G T JZ GTJZ1012/1012/3346 0808E (2732E) G T JZ GTJZ1212/1212/4047 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 APPLICATION Use the following table to identify the specific serial number for models included in this manual. Check the model of your machine before consulting the manual, and then use the correct manual according to the serial number of the model. See the nameplate on your machine to identify the model and serial number.(See Decals/Nameplates Inspection of the Operation Manual for details.) Trade identification MODELS...
  • 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

    TABLE OF CONTENTS Machine Control System ....3-1 Introduction ......iii Safety Measures ..... . 3-1 1 Performance Parameters ..
  • Page 10 A-18 Perform Maintenance After Testing the Function Pump ..5-5 30 Days ......4-13 Removing the Hydraulic Power Unit 5-5 Checklist B Procedures .

  • 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.. GTJZ0612&0812&1012&1212 Maintenance Manual © Aug 2020...
  • Page 12 This Page Intentionally Left Blank © Aug 2020 GTJZ0612&0812&1012&1212 Maintenance Manual...

  • Page 13: Performance Parameters

    PERFORMANCE PARAMETERS SPECIFICATION Table 1-1 GTJZ0612 Specifications GTJZ0612 (METRIC) 2146 (IMPERIAL) MEASURE DIMENSION PARAMETERS Max. platform height 6.3m 20ft 8in. Max. working height 8.3m 27ft 3in. Max. horizontal extension 0.9m Length 2.45m Width 1.17m 3ft 10in. Height (stowed, rails folded) 1.6m 5ft 3in.
  • Page 14 PERFORMANCE PARAMETERS GTJZ0612 (METRIC) 2146 (IMPERIAL) MEASURE Turning radius (outside) 2.35m 7ft 8.5in. Rated load capacity of a single tire 1180kg 2601 lb Max. allowable manual force (indoor/ 400N 90 lbf outdoor) Max. noise 72dB POWER PARAMETERS Hydraulic tank capacity 3.3 gal(imperial)/4 gal(US) Hydraulic system capacity (including tank) 4.4 gal(imperial)5.3 gal(US)
  • Page 15 PERFORMANCE PARAMETERS GTJZ0812 (METRIC) 2746 (IMPERIAL) MEASURE Height (stowed, rails folded) 1.73m 5ft 8in. Height (stowed, rails up) 2.36m 7ft 9in. Wheel base 1.88m 6.17ft Wheel span 1.025m 3.36ft Ground clearance (pothole guards 0.1m 4in. retracted) Ground clearance (pothole guards 25mm 0.98in.
  • Page 16 PERFORMANCE PARAMETERS GTJZ0812 (METRIC) 2746 (IMPERIAL) MEASURE Max. allowable wind speed (indoor/ 0m/s(indoor)/12.5m/s(outdoor) 0 mph(indoor)/28 mph(outdoor) outdoor) Max. allowable altitude 1000m 3280.8ft Allowable ambient temperature (lead-acid -10℃ to 40℃ 14℉ to 104℉ batteries) Allowable ambient temperature (lithium -20℃ to 40℃ -4℉...
  • Page 17 PERFORMANCE PARAMETERS GTJZ1012 (METRIC) 3346 (IMPERIAL) MEASURE Drive speed (stowed) 0～2 mph 0～3.2 km/h Drive speed (raised) 0～0.5 mph 0～0.8 km/h Uptime (in a no-load state) 53～58 s Downtime (in a no-load state) 40～45 s Gradeability 3°(Front to back)/1.5°(Left to right) Max.
  • Page 18 PERFORMANCE PARAMETERS Table 1-4 GTJZ1212 Specifications GTJZ1212 (METRIC) 4047 (IMPERIAL) MEASURE DIMENSION PARAMETERS Max. platform height 11.9m(indoor)/ 9m(outdoor) 39 ft(indoor)/ 29.5 ft(outdoor) Max. working height 13.9m(indoor)/ 11m(outdoor) 45 ft 7 in(indoor)/ 36 ft(outdoor) Max. horizontal extension 0.9m Length 2.45m Width 1.17m 3ft 10in.

  • Page 19: Power System Specifications

    PERFORMANCE PARAMETERS GTJZ1212 (METRIC) 4047 (IMPERIAL) MEASURE Hydraulic tank capacity 3.3 gal(imperial)/4 gal(US) Hydraulic system capacity (including tank) 7.7 gal(imperial)/9.2 gal(US) Hydraulic system pressure 24MPa 3046 psi Battery specification (quantity × voltage, 4×12V, 240Ah capacity) System voltage 24 VDC Control voltage 24 VDC ENVIRONMENTAL REQUIREMENT Max.

  • Page 20: Specifications

    PERFORMANCE PARAMETERS MEASURE SPECIFICATIONS HYDRAULIC PUMPS Type Gear pump Flow rate (RPM = 3000 r/min) 12 L/min Maximum driving pressure 24.8MPa（3597 Psi） DRIVE HYDRAULIC MOTOR Type Cycloid motor 300cc/r Displacement 350cc/r（GTJZ1212） FUNCTIONAL VALVES Lift relief valve pressure 21MPa（3046 Psi） Steer relief valve pressure 15MPa（2176 Psi）...

  • Page 21: Hydraulic Hose Torque

    PERFORMANCE PARAMETERS HYDRAULIC HOSE AND FITTING SPECIFICATIONS HYDRAULIC HOSE TORQUE Hydraulic hoses must be torqued to the following specifications. Table 1-6 Hydraulic Hose Torque L (LIGHT-DUTY) S (HEAVY-DUTY) METRIC THREAD 19 ± 1 Nm (14 ± 1 ft-lb) M12 × 1.5 26 ±...
  • Page 22 PERFORMANCE PARAMETERS INSTALLED INTO INSTALLED INTO STEEL ALUMINUM THREAD SIZE ED, O-RING + CIRCLIP ED, O-RING + CIRCLIP O-RING 75 ± 5 Nm (55 ± 4 ft-lb) 75 ± 5 Nm (55 ± 4 ft-lb) 45 ± 3 Nm (33 ± 4 ft-lb) M18×1.5 90 ±...
  • Page 23 PERFORMANCE PARAMETERS INSTALLED INTO INSTALLED INTO STEEL ALUMINUM THREAD SIZE ED, O-RING + CIRCLIP ED, O-RING + CIRCLIP O-RING G1-1/2A 280 ± 20 Nm (207 ± 15 ft-lb) 540 ± 30 Nm (398 ± 22 ft-lb) S (HEAVY-DUTY) G1/4A 40 ± 3 Nm (30 ± 2 ft-lb) 43 ±...

  • Page 24: Hydraulic Hose And Fitting Torque

    PERFORMANCE PARAMETERS 3. Properly seat the O-ring. HYDRAULIC HOSE AND FITTING TORQUE PROCEDURE 4. Position the tube and nut squarely on the fitting. Then tighten the nut as required. The hydraulic hose and fitting must be torqued to the 5. Tighten the nut or fitting to the torque specified in following requirements when they are installed.
  • Page 25 PERFORMANCE PARAMETERS NOMINAL DIAMETER PITCH (MM) CLASS 8.8 CLASS 10.9 CLASS 12.9 (MM) 750 Nm (553 ft-lb) 1050 Nm (774 ft-lb) 1250 Nm (923 ft-lb) 800 Nm (590 ft-lb) 1100 Nm (811 ft-lb) 1300 Nm (959 ft-lb) 1150 Nm (848 ft-lb) 1500 Nm (1106 ft-lb) 1800 Nm (1327 ft-lb) 1500 Nm (1106 ft-lb)
  • Page 26 PERFORMANCE PARAMETERS This Page Intentionally Left Blank © Aug 2020 1-14 GTJZ0612&0812&1012&1212 Maintenance Manual...

  • Page 27: Safety

    SAFETY Read, understand and comply with the safety rules and NOTICE regulations of your workplace and your government. Indicates a situation that can cause damage to the Before using the machine, obtain proper training on engine, personal property and/or the environment, or safe machine operation and make sure you can safely cause the equipment to operate improperly.

  • Page 28: Tipping Hazards And Rated Load

    SAFETY Extending: Extension only 120 kg(265 lb) GTJZ0812 ELECTRICAL SHOCK HAZARDS Retracting 450 kg(992 lb) • Always maintain a safe distance Extending: Stationary only 330 kg(728 lb) from power lines and electrical equipment in accordance with ap- Extending: Extension only 120 kg(265 lb) plicable government regulations and see...
  • Page 29 SAFETY TIPPING HAZARDS TIPPING HAZARDS • Do not replace key parts that af- • Personnel, equipment and materi- fect machine stability with differ- als on the platform must not ex- ent weights or specifications. ceed the maximum load capacity. • Do not modify or change moving •...

  • Page 30: Work Environment Hazards

    SAFETY WORK ENVIRONMENT HAZARDS TIPPING HAZARDS intend to lower the platform with a ground controller, you must oper- ate it only after all personnel have left the platform. UNSAFE JOBSITE HAZARDS • Do not operate the machine on surfaces, edges or potholes that cannot bear the weight of the ma- chine.

  • Page 31: Unsafe Operation Hazards

    SAFETY Table 2-3 BEAUFORT METERS/ MILE/ DESCRIPTION GROUND CONDITION NUMBER SECOND HOUR Calm. Smoke rises vertically. 0～0.2 0～0.5 Calm Light air 0.3～1.5 1～3 Wind motion visible in smoke. Light breeze Wind felt on exposed skin. Leaves rustle. 1.6～3.3 4～7 Leaves and smaller twigs in constant 3.4～5.4 8～12 Gentle breeze...

  • Page 32: Fall Hazards

    SAFETY UNSAFE OPERATION HAZARDS UNSAFE OPERATION HAZARDS • Do not place or attach any • Do not push any object outside suspended load onto any part of the platform. The maximum lateral the machine. force allowed is: • Do not use the machine as a crane.

  • Page 33: Collision Hazards

    SAFETY FALL HAZARDS COLLISION HAZARDS • Each person on the platform must • Pay attention to the field of sight wear harnesses or use safety and the presence of blind spots equipment consistent with gov- when moving or operating the ernment regulations.

  • Page 34: Crush Hazards

    SAFETY DAMAGED MACHINE HAZARDS COLLISION HAZARDS • Never operate a machine danger- NOTICE ously or for fun. To avoid machine damage, follow all operation and maintenance requirements in this manual and the Maintenance Manual. CRUSH HAZARDS A potential crush hazard exists during movement of the machine.

  • Page 35: Battery Hazards

    SAFETY BATTERY HAZARDS NOTICE After charging the battery, be sure that: • The battery cable connections are free of corrosion. FIRE AND EXPLOSION HAZARD • The battery hold-down and cable connections are secured. • Batteries contain sulfuric acid and Adding terminal protection and anti-corrosion generate explosive mixtures of sealants will help reduce corrosion of the battery hydrogen and oxygen gases.

  • Page 36: Hydraulic Systems Hazard

    SAFETY HYDRAULIC SYSTEMS HAZARD WELDING HAZARDS • Comply with the welder manufac- turer’s recommendations for pro- cedures concerning proper use of BURN AND HIGH PRESSURE the welder. HAZARD • Welding leads or cables may only be connected after turning off the •...

  • Page 37: System Descriptions

    SYSTEM DESCRIPTIONS platform and controls lift and drive functions. The POWER controller exchanges data through a high-speed data bus. GTJZ0612&0812&1012 machines are powered by four 6V batteries in series or a 24V lithium battery to drive a 24V DC motor. Gear pump and motor output shaft is SAFETY MEASURES splined to provide power to the system.
  • Page 38 SYSTEM DESCRIPTIONS This Page Intentionally Left Blank © Aug 2020 GTJZ0612&0812&1012&1212 Maintenance Manual...

  • Page 39: Maintenance

    MAINTENANCE This section provides detailed procedures for regular – Ensure the key switch of the ground controller is maintenance inspections. in the OFF position and remove the key to pre- vent unauthorized use of the machine. – Place the red emergency stop button on the plat- form control box and ground controller in the OFF position to avoid accidental start-up of the UNSAFE OPERATION HAZARD...

  • Page 40: Following Amaintenance Schedule

    MAINTENANCE 2. Use the following table to note the results. After re-inspected after repair is completed and marked each section is complete, mark the appropriate box. in the box marked "inspection". 3. Record the inspection results. If any inspection re- sults are "NO", the machine must be stopped and Table 4-1 PREPARE THE WORK RECORD BEFORE DELIVERY...
  • Page 41 MAINTENANCE Table 4-3 REPAIR & INSPECTION REPORT Model Serial No. Checklist A Procedures REPAIRED/Ma- YES/Machine is NO/Machine Has Problem chine Has Been Items in Good Damage or Description Repaired Condition Malfunction A-1 Inspect All Manuals A-2 Inspect All Decals A-3 Inspect Damaged, Loose or Lost Parts A-4 Inspect Hydraulic Oil Level...
  • Page 42 MAINTENANCE REPAIR & INSPECTION REPORT REPAIRED/Ma- YES/Machine is NO/Machine Has Problem chine Has Been Items in Good Damage or Description Repaired Condition Malfunction B-1 Inspect Electric Wires B-2 Inspect Rim ,Tire and Fasteners B-3 Inspect Battery B-4 Inspect Hydraulic Oil B-5 Inspect Hydraulic Oil Tank Ventilation System B-6 Inspect Brake Manual...

  • Page 43: Checklist Aprocedures

    MAINTENANCE CHECKLIST A A-3 Inspect Damaged, Loose or Lost Parts PROCEDURES Inspecting the condition of the machine daily is important for the safe and reliable operation of the A-1 Inspect All Manuals machine. Never operate a machine with damaged, loose or lost parts. Replace damaged/lost parts and Storing the Operation Manual and the Maintenance tighten loose parts before operating the machine.

  • Page 44: Inspect Hydraulic Oil Level

    MAINTENANCE • Hydraulic oil tank, filters, pipe fittings, oil pipe, power A-4 Inspect Hydraulic Oil Level unit • All hydraulic cylinders, pumps , motor, brake manual Ensuring appropriate hydraulic oil is important for proper operation of the machine. Operating the release valve machine with an improper hydraulic oil level can •...
  • Page 45 MAINTENANCE Figure 4-2 9. Backspace Key 1. Insurance 2. Emergency Stop Button 10. Page Up Key 1. Hold down the enabling and lifting key at the same time to start the lifting function. Ensure the 11. Enabling Key 3. OFF Position platform lifts.
  • Page 46 MAINTENANCE 1. Right 8. Emergency Stop Button 9. Display Screen 2. Left Enabling key 3. Enabling Key 10. Lifting/Lowering Do not press the enabling key on the control handle. 4. Lifting 11. Horn Push the control handle forward and backward . Ensure that all walking and lifting functions stop 5.

  • Page 47: Inspect Emergency Lowering

    MAINTENANCE 5. The platform shall descend to the lowest position. Forward Back A-8 Test Braking Device Braking device must operate smoothly and be in good condition for safe and proper operation of the machine. 1. Press the driving and steering button. The button Do not operate the machine if the brakes make a should illuminate.

  • Page 48: Testing Traveling Speed

    MAINTENANCE Table 4-5 NOTICE Models Platform Lift Time If the machine takes less than 54 seconds to travel 12 m (39.4 ft), stop the machine and GTJZ0612 33～38 s determine the cause. GTJZ0812 33～38 s 6. Press the walking and steering button, then press GTJZ1012 53～58 s the high/low speed button.

  • Page 49: Inspect The Tilt Protection

    MAINTENANCE 6. Press the walking and steering button, then press 8. Place the two wooden boards under the two wheels the high/low speed button. The slow mode activates on the front or back side of the machine, and then when the light of the low-speed traveling button drive the machine onto the two boards.
  • Page 50 MAINTENANCE 1. Park the machine on flat, level and firm ground. 3. Lower the platform until the scissor arm is in the Lubricate the bearings and sliding slots. fully retracted state. Gradually add a load to the platform. 2. Use ground controller to lift and lower the platform without loading twice;...

  • Page 51: Limit

    MAINTENANCE Table 4-8 2. Operate on the platform controller and raise the platform to the highest position. Model Test Result 3. Then Lower the machine with platform controller to a height of approximately 1.7～2.3 m(66.9～90.5 in) 6.2～6.3 m (20.2～20.7 ft) GTJZ0612 (GTJZ0612)/2～2.6 m(78.7～102.4 in) (GTJZ0812)/ 2.5～3.1 m(98.4～122 in) (GTJZ1012&1212).

  • Page 52: Checklist Bprocedures

    MAINTENANCE • D-3 Replace hydraulic oil tank return oil filter • Battery harness element. • Charger harness • Scissor arm harness • Power unit harness CHECKLIST B • Ground controller junction box PROCEDURES • Platform controller junction box 2. Inspect the flexile joints, and confirm that the joints B-1 Inspect Electric Wires are tight and the sensor lines are not damaged.

  • Page 53: Inspect Battery

    MAINTENANCE Figure 4-5 Table 4-10 Torque Value/Nm(Ft-Lb) Name Slotted nut (steering wheel mounting) 420Nm （310 ft-lb） Slotted nut (non-steering wheel mounting) 420Nm （310 ft-lb） Bolt (drive motor installed) 130Nm （96 ft-lb） Bolt (brake installed) 130Nm （96 ft-lb） 4. Replace the cotter pin and bend it to the locking NOTICE position.

  • Page 54: Inspect Hydraulic Oil

    MAINTENANCE INSPECT THE MAINTENANCE-FREE pump and its normal service life. The hydraulic pump would operate abnormally if the air filter of the hydraulic BATTERIES oil tank is dirty or blocked, and hydraulic components • Wear protective clothing and goggles properly. may be damaged after repeated use of a dirty or blocked air filter.

  • Page 55: Checklist Cprocedures

    MAINTENANCE BURN HAZARD Allow the hydraulic oil to cool to room temperature before servicing the hydraulic system. Figure 4-6 HIGH-PRESSURE HAZARD Table 4-11 Slowly remove the hydraulic components to reduce hydraulic Description oil pressure. High hydraulic oil pressure could penetrate the skin. reversing valve Seek medical attention immediately.

  • Page 56: Inspect Chassis Slider

    MAINTENANCE D-2 Inspect Chassis Slider NOTICE Perform this procedure when the hydraulic pump is Properly maintaining the slider is important for safe turned off. operation of the machine. The chassis slider slides on the channel steel surface to form a friction pair. Use of 1.

  • Page 57: Inspect Key Structural Parts

    MAINTENANCE 3. Disconnect and plug the oil suction pipe. 4. Disconnect and plug the oil return pipe. ELECTRICAL SHOCK HAZARD 5. Remove the bolts from the hydraulic oil tank. 6. Remove the oil tank from the machine. Be sure to disconnect the battery 7.
  • Page 58 MAINTENANCE This Page Intentionally Left Blank © Aug 2020 4-20 GTJZ0612&0812&1012&1212 Maintenance Manual...

  • Page 59: Maintenance Procedures

    MAINTENANCE PROCEDURES NOTICE Perform this procedure when the scissor arm has been fully retracted. Maintenance procedures must be performed by qualified, trained and competent personnel in a properly 1. Disconnect the external power supply. Turn the equipped workshop. emergency stop button on the platform controller and ground controller to the OFF position.

  • Page 60: Removing The Extension Platform

    MAINTENANCE PROCEDURES 3. Connect the scissor arm with a traveling crane. Removing the Extension Platform 4. Remove the bolts of the fixed clevis pin. 1. Remove the platform. Refer to Removing the Platform, page 5-1. 2. Loosen the bolts of all rails. Remove rails and put them aside.

  • Page 61: Chassis Components

    MAINTENANCE PROCEDURES 1. Remove the cotter pin from the front wheel. 2. Remove the grooved bolts for tire mounting and remove the front wheel mounted on the drive motor. 3. Disconnect and plug the hose and fitting on the drive motor. 4.

  • Page 62: Removing The Steering Cylinder

    MAINTENANCE PROCEDURES Removing the Steering Cylinder CRUSH HAZARD NOTICE When installing the removed hose and fitting, it must Be sure to chock the wheels before be tightened according to the specified torque. See releasing the brake if the machine is Hydraulic Hose and Fitting Specifications, page on any slope.

  • Page 63: Hydraulic System

    MAINTENANCE PROCEDURES 3. Use the appropriate lifting equipment to remove the Removing the Hydraulic Power Unit battery. HYDRAULIC SYSTEM BURN AND HIGH-PRESSURE HAZARDS Testing the Function Pump Allow the hydraulic components to cool to room temperature before performing service. Loosen the NOTICE hydraulic hoses and fittings slowly to relieve pressure.

  • Page 64: Removing The Hydraulic Oil Tank

    MAINTENANCE PROCEDURES Removing the Hydraulic Oil Tank 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 1-12. BURN AND HIGH-PRESSURE HAZARDS 1. Open the right door of the chassis and locate the hydraulic valve block.

  • Page 65: Regulating The Platform Lifting

    MAINTENANCE PROCEDURES Figure 5-8 Table 5-1 Description Tightening Torque Function 2-position 4-way solenoid valve High low speed switching 34 Nm (25 ft-lb) Steering overflow valve Steering overflow 24 Nm (17.7 ft-lb) Lifting overflow valve Lifting overflow 27 Nm (20 ft-lb) System overflow 27 Nm (20 ft-lb) Main overflow valve...

  • Page 66: Adjusting The Steering Overflow

    MAINTENANCE PROCEDURES tank until the pump properly operates. Do not allow 13. Remove the pressure gauge. the oil to overflow from the oil tank. Adjusting the Emergency Lowering NOTICE Handle Do not allow the machine to operate if there is pump suction air.

  • Page 67: Hydraulic Symbols

    46.7096 28.5682 34.4087 28.5682 46.7096 28.5682 28.5682 MAINTENANCE PROCEDURES 32.0000 46.7096 28.5682 棕 兰 16.0000 黑 Hydraulic Symbols Symbol Description 棕 兰 黑 Table 5-2 棕 兰 28.5682 Pressure-gradient control 46.7096 黑 28.5682 28.5682 valve 17.4787 Symbol Description 46.7096 28.5682 电驱剪叉液压原理图...

  • Page 68: Hydraulic Schematic Diagram

    MAINTENANCE PROCEDURES Hydraulic Schematic Diagram GTJZ0612&0812 hydraulic schematic diagram Lift cylinder Load sensor Load sensor Steer cylinder Brake valve © Aug 2020 5-10 GTJZ0612&0812&1012&1212 Maintenance Manual...
  • Page 69 MAINTENANCE PROCEDURES GTJZ1012&1212 hydraulic schematic diagram Lift cylinder, upper Lift cylinder, lower Load sensor Load sensor Steer cylinder Brake valve GTJZ0612&0812&1012&1212 Maintenance Manual 5-11 © Aug 2020...

  • Page 70: Electrical System

    MAINTENANCE PROCEDURES • Voltmeter (for flooded/wet battery, colloid and AGM ELECTRICAL SYSTEM battery) Description Batteries are divided into three types: lithium battery, lead-acid battery and lead-acid maintenance-free battery. The lithium battery and lead-acid maintenance- free battery require some care but no maintenance. BATTERY HAZARDS Always read and comply with the battery manufacturer’s...
  • Page 71 MAINTENANCE PROCEDURES • Always wear protective clothing, gloves and goggles Inspection when handling the battery. • Inspect the battery. The top of the battery and • Do not smoke near the battery, and keep the battery terminal connections must be kept clean and free away from sparks, flames and metal objects.
  • Page 72 MAINTENANCE PROCEDURES • The charge for this equipment is automatic and EQUALIZATION preprogrammed so that the user does not need to Equalization is the deliberate process of overcharging interfere with the charging process. the flooded/wet battery after it has been fully charged. •...
  • Page 73 MAINTENANCE PROCEDURES Open-Circuit Voltage (V) Percentage Charging Specific Gravity （%） Battery Cell 1.098 1.943 5.83 11.66 1.073 1.918 5.75 11.51 • Recharge the battery in quick mode when the Test of Specific Gravity battery level is 70% or lower. 1. Fill and drain the specific gravity hydrometer 2-3 •...

  • Page 74: Use And Care Of Lead-Acid Battery

    MAINTENANCE PROCEDURES terminate the connection between the internal circuit • The battery terminal and related accessories and the battery to avoid charging and damaging the contain lead and lead components. Wash your battery. hands after handling them. • Output short-circuit protection: When there is an accidental output short circuit of the battery charger, Use and Care of Lithium Battery the battery charger will shut down the output...

  • Page 75: Trouble Diagnosis

    MAINTENANCE PROCEDURES • Use a special charger when charging, and avoid • The lithium battery has an automatic protection charging under direct sunlight. Do not charge the function: if the cell voltage is higher than 3.4V, the battery repeatedly after the battery is full. Keep battery system activates for a long period of time children away from the charging charger.
  • Page 76 MAINTENANCE PROCEDURES Code Problem Action Limit Solution Cell Voltage Low Fault 1: Tell BMS factory to check Disable Lifting, and Driving Cell Voltage Low on low speed battery. Fault 1 Cell Voltage Low Fault 2: Tell BMS factory to check Cell Voltage Low Disable Lifting and Driving battery.
  • Page 77 MAINTENANCE PROCEDURES Code Problem Action Limit Solution Forward Coil Fault: Check the connections to the Disable Lifting and Driving Coil’s terminals and make sure they are tight. If so, Forward Coil Fault check the coil itself to see if it is open or shorted. Reverse Coil Fault: Check the connections to the Disable Lifting and Driving Coil’s terminals and make sure they are tight.
  • Page 78 MAINTENANCE PROCEDURES Code Problem Action Limit Solution Motor Controller HPD Fault: Look at motor enable delay with the Scissor Programmer, it may be too Motor Controller HPD Disable All Motion short. Make sure other Motor Controller Fault parameters are properly selected. Total Voltage Low Fault 2: Check battery voltage Total Voltage Low and charge if necessary.
  • Page 79 MAINTENANCE PROCEDURES Code Problem Action Limit Solution Pump Motor Short Fault: Check connections to the Pump Motor Short Disable Lifting and Driving pump motor. Cycle power to the lift and if that does Fault not resolve the issue, replace the Motor Controller. Left Drive Motor Short Fault: Check the Motor Left Drive Motor Short Disable All Motion...

  • Page 80: Fundamental Troubleshooting

    MAINTENANCE PROCEDURES Code Problem Action Limit Solution Machine Tilted Beyond Safe Limits Fault: If the machine is tilted, find a way to make it level. If the Disable Lifting and Driving Machine Tilted machine is level, check the wiring to the tilt sensor and then the sensor itself.
  • Page 81 MAINTENANCE PROCEDURES Problem Cause Solution • Inspect whether the level switch is inserted properly Level status tilting is The level switch has not been and firmly. always sounding alarm connected or has trouble • Inspect whether the level switch is malfunctioning. •...
  • Page 82 MAINTENANCE PROCEDURES Problem Cause Solution • The high-speed hydraulic valve is connected There is no warning incorrectly. after descending to the Pothole protector minimum limiting • The installation of the travel switch is abnormal. position • The hydraulic valve is malfunctioning. •...

  • Page 83: Electrical Symbols

    MAINTENANCE PROCEDURES Electrical Symbols Table 5-7 Symbol Description Symbol Description Warning lamp Solenoid coil 8.5682 兰 棕 棕 兰 Charger Level switch 黑 28.5682 黑 28.5682 46.7096 28.5682 46.7096 28.5682 兰 棕 Two lines connected Two lines non-connected 黑 兰 棕...
  • Page 84 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 © Aug 2020 5-26 GTJZ0612&0812&1012&1212 Maintenance Manual...

  • Page 85: Electrical Schematic Diagram

    MAINTENANCE PROCEDURES Electrical Schematic Diagram Emergency Power of Down limit Main Emergency Battery and charger Fuse Fuse Key switch stop switch contactor stop switch controller switch 01 QF F2(10A) F1(275A) 4*6V Battery K1 Main contactor 100Ω Positive voltage A-35 A-4 A-5 A-25 A-14 A-17...
  • Page 86 MAINTENANCE PROCEDURES Flash Up limit Pothole guard Foot Overhead Angle Pressure Pressure Level sensor Up-down switch Alarm CAN communication Platform control box beacon switch deploy detect switch protection sensor sensor1 sensor2 PLATFORM CANH PCBA CANH CANL CANL 07 00 07 00 brown blue black...

  • Page 87: Appendix 1: Prepare The Work Record Before Delivery

    APPENDIX 1: PREPARE THE WORK RECORD BEFORE DELIVERY PREPARE THE WORK RECORD BEFORE DELIVERY Model Serial No. REPAIRED/Machine YES/Machine is in NO/Machine Has Damage Inspection Item Has Been Repaired Good Condition or Malfunction Pre-operational Inspection Maintenance Procedure Functional Inspection Machine Buyer/ Renter Inspector Signature Inspector Title Inspector Company...
  • Page 88 MAINTENANCE PROCEDURES This Page Intentionally Left Blank © Aug 2020 GTJZ0612&0812&1012&1212 Maintenance Manual...

  • Page 89: Appendix 2: Repair & Inspection Report

    APPENDIX 2: REPAIR & INSPECTION REPORT REPAIR & INSPECTION REPORT Model Serial No. Checklist A Procedures REPAIRED/Ma- YES/Machine is NO/Machine Has Problem chine Has Been Items in Good Damage or Description Repaired Condition Malfunction A-1 Inspect All Manuals A-2 Inspect All Decals A-3 Inspect Damaged, Loose or Lost Parts A-4 Inspect Hydraulic Oil...
  • Page 90 MAINTENANCE PROCEDURES REPAIR & INSPECTION REPORT A-18 Perform Maintenance After 30 Days Checklist B Procedures REPAIRED/Ma- YES/Machine is NO/Machine Has Problem chine Has Been Items in Good Damage or Description Repaired Condition Malfunction B-1 Inspect Electric Wires B-2 Inspect Rim ,Tire and Fasteners B-3 Inspect Battery B-4 Inspect Hydraulic Oil...
  • Page 91 MAINTENANCE PROCEDURES REPAIR & INSPECTION REPORT Inspector Title Inspector Company NOTES: 1. The Repair & Inspection Report shall include the inspection table of each regular inspection. 2. Duplicate the Repair & Inspection Report for each inspection. Store the completed tables for 10 years or until the machine is no longer in use or as required by machine owner/company/custodian.
  • Page 92 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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