Sinoboom GTJZ1930SE Maintenance Manual
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Sinoboom GTJZ1930SE Maintenance Manual

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Part No.501056110002
Rev: C
Jan 2022
Maintenance
Manual
产品说明书
PRODU
C T MAN U AL
GTJZ0608SE/0608SE/1930SE
GTJZ0608ME/0608ME/1932ME
0608E (2132E)
G T JZ
0808E (2732E)
G T JZ
0808E (2732E)
G T JZ
G T JZ
0808E (2732E)

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Summary of Contents for Sinoboom GTJZ1930SE

  • Page 1 Maintenance Part No.501056110002 Rev: C Manual Jan 2022 产品说明书 PRODU C T MAN U AL GTJZ0608SE/0608SE/1930SE GTJZ0608ME/0608ME/1932ME 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 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/Nameplate 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

    ......4-1 Electrocution Hazards....1-2 Qualified Sinoboom equipment Tipping Hazards and Rated Load ..1-2 mechanic .
  • Page 10 Tank .......5-16 Sinoboom Control System ..6-16 C-2 Inspect Platform Weighing DTC-K500 Control System .
  • Page 11 Electrical Schematic Diagram ..6-43 Appendix 1: Prepare the Work Record Before Delivery ..A-1 Appendix 2: Repair & Inspection Report ......A-3 GTJZ0608SE&0608ME Maintenance Manual © Jan 2022...
  • Page 12 © Jan 2022 GTJZ0608SE&0608ME Maintenance Manual...

  • Page 13: 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.. GTJZ0608SE&0608ME Maintenance Manual © Jan 2022...
  • Page 14 This Page Intentionally Left Blank © Jan 2022 GTJZ0608SE&0608ME Maintenance Manual...

  • Page 15: Safety

    Failure to notify the manufacturer within SAFETY DEFINITIONS 48 hours of the incident involving the machine of Hunan Sinoboom Intelligent Equipment Co., Ltd. may void the product's warranty. This safety alert symbol appears with most safety statements. It means atten-...

  • Page 16: Electrocution Hazards

    SAFETY ELECTROCUTION TIPPING HAZARDS AND HAZARDS RATED LOAD NOTE: This machine is not insulated and does not have Maximum rated load bearing capacity of the platform: an electric shock protection function. Table 1-2 All operators and managers shall comply with national or local regulations regarding the minimum safe dis- tance of live conductors above the ground.
  • Page 17 SAFETY TIPPING HAZARDS TIPPING HAZARDS • Do not modify or change moving • Personnel, equipment and materi- aerial platforms without the manu- als on the platform must not ex- facturer’s prior written ceed the maximum load capacity. permission. • Only raise or extend the platform •...

  • Page 18: Work Environment Hazards

    0.8 km/h (0.5 mph) when the plat- cations, or by any other means, as specified by form rises. Sinoboom, it must be approved or guided by the • If the machine can be used out- manufacturer.

  • Page 19: Unsafe Operation Hazards

    SAFETY BEAUFORT METERS/ MILE/ DESCRIPTION GROUND CONDITION NUMBER SECOND HOUR 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 NOTICE Maximum climbing ability is suitable for machines with platform retracted. Maximum Slope: GTJZ0608SE: 25% (14°）...

  • Page 20: Fall Hazards

    SAFETY UNSAFE OPERATION HAZARDS UNSAFE OPERATION HAZARDS • Do not tie the platform onto near- • Do not push any object outside by objects. the platform. The maximum lateral • Do not put the load outside the force allowed is: platform.

  • Page 21: 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 22: Crush Hazards

    SAFETY EXPLOSION AND FIRE HAZARDS COLLISION HAZARDS • Never operate a machine danger- ously or for fun. EXPLOSION AND FIRE HAZARD CRUSH HAZARDS • Do not use the machine or charge the battery in hazardous or poten- tially flammable or explosive atmospheres.

  • Page 23: Bodily Injury Hazards

    SAFETY BATTERY HAZARDS UNSAFE OPERATION HAZARDS • Do not use the machine if it is FIRE AND EXPLOSION HAZARD damaged or not in proper operat- ing condition. • Batteries contain sulfuric acid and • Thoroughly inspect and test for all generate explosive mixtures of functions of the machine before hydrogen and oxygen gases.

  • Page 24: Welding And Polishing Requirements1-10

    SAFETY BATTERY HAZARD LITHIUM BATTERY HAZARD • Only connect the charger to a • Only use the dedicated charger to grounded 3–wire AC outlet. Be charge the battery. sure the charger is in proper • Do not allow lens, needles or operating condition before other sharp objects to contact charging.

  • Page 25: After Using The Machine

    SAFETY WELDING HAZARDS • Comply with the welder manufac- turer’s recommendations for pro- cedures concerning proper use of the welder. • Welding leads or cables may only be connected after turning off the power unit. • Carry out welding operations only after the welding cable has been correctly connected.
  • Page 26 SAFETY This Page Intentionally Left Blank © Jan 2022 1-12 GTJZ0608SE&0608ME Maintenance Manual...

  • Page 27: Specifications

    SPECIFICATIONS MACHINE SPECIFICATIONS Table 2-1 GTJZ0608SE Specifications 0608SE (METRIC) 1930SE (IMPERIAL) MEASURE DIMENSION Max. platform height (indoor only) 5.8m 19ft Max. working height (indoor only) 7.8m 25ft 7in Max. horizontal extension 0.9m Length 1.8m 5ft 11in Width 0.79m 2ft 7in Height (stowed, rails folded) 1.88m 6ft 2in...
  • Page 28 SPECIFICATIONS 0608SE (METRIC) 1930SE (IMPERIAL) MEASURE Turning radius (outside) 1.49m 4ft 10.7in Max. allowable manual force (indoor only) 400N 90 lbf Max. noise 72dB POWER Hydraulic tank capacity 1.3 gal (imperial)/1.6 gal (US) Hydraulic system capacity (including tank) 1.5 gal (imperial)/1.8 gal (US) Hydraulic system pressure 21MPa 3046 Psi...
  • Page 29 SPECIFICATIONS 0608ME (METRIC) 1932ME (IMPERIAL) MEASURE Quick fold- Rails down 1.9m 6ft 3in down Rails up 1.8m 5ft 11in platform Overall width-stowed 0.81m 2 ft 8in Rails down 1.88m 6ft 7in Fold-down Rails up-AS models 6ft 6 in platform Overall Rails up 2.14m height-...

  • Page 30: Power System Specifications

    SPECIFICATIONS 0608ME (METRIC) 1932ME (IMPERIAL) MEASURE Hydraulic system pressure 3046 psi 21MPa Battery specification (quantity × voltage, capacity) 4×6V, 225Ah System voltage 24VDC Control voltage 24VDC GROUND BEARING DATA 700 kg Max wheel load 1543 lb Pressure against ground 1230 KPa 178 Psi ENVIRONMENT 0m/s (indoor)/12.5m/s...

  • Page 31: Hydraulic Hose And Fitting

    SPECIFICATIONS MEASURE SPECIFICATIONS HYDRAULIC PUMPS Type Gear pump Displacement 2.5cc/r Maximum driving pressure 25MPa (3626 Psi) GEARED DRIVE MOTOR Type Gear pump Displacement 2.5cc/r Maximum driving pressure 25MPa (3626 Psi) FUNCTIONAL VALVES Lift relief valve pressure 21MPa (3046 Psi) Steer relief valve pressure 10MPa (1450 Psi) RETURN FILTER Bypass open pressure of return filter...

  • Page 32: Hydraulic Fitting Torque

    SPECIFICATIONS L (LIGHT-DUTY) S (HEAVY-DUTY) METRIC THREAD 90 ± 6 Nm (66 ± 4 ft-lb) M26 × 1.5 120 ± 8 Nm (89 ± 6 ft-lb) 140 ± 10 Nm (103 ± 7 ft-lb) M30 × 2 150 ± 12 Nm (111 ± 9 ft-lb) 180 ±...
  • Page 33 SPECIFICATIONS INSTALLED INTO INSTALLED INTO STEEL ALUMINUM THREAD SIZE ED, O-RING + CIRCLIP ED, O-RING + CIRCLIP O-RING 180 ± 10 Nm (133 ± 7 ft-lb) 320 ± 20 Nm (236 ± 15 ft-lb) 260 ± 15 Nm (192 ± 11 ft-lb) M33×2 240 ±...

  • Page 34: Hydraulic Hose And Fitting Torque

    SPECIFICATIONS Table 2-7 Hydraulic Fitting Torque – Unified Thread Standard (UNC/UNF) INSTALLED INTO INSTALLED INTO STEEL ALUMINUM THREAD SIZE O-RING O-RING L (LIGHT-DUTY) 7/16-20 21 ± 2 Nm (15 ± 2 ft-lb) 21 ± 2 Nm (15 ± 2 ft-lb) 9/16-18 34 ±...
  • Page 35 SPECIFICATIONS Table 2-8 Fastener Torque Specifications – Metric NOMINAL DIAMETER PITCH (MM) CLASS 8.8 CLASS 10.9 CLASS 12.9 (MM) 7 Nm (5 ft-lb) 9 Nm (7 ft-lb) 10 Nm (7 ft-lb) 12 Nm (9 ft-lb) 15 Nm (11 ft-lb) 18 Nm (13 ft-lb) 30 Nm (22 ft-lb) 35 Nm (26 ft-lb) 42 Nm (31 ft-lb)
  • Page 36 SPECIFICATIONS NOMINAL OPPOSITE NUT SIZE (S) CLASS 5 CLASS 8 DIAMETER (IN) 37 Nm (27 ft-lb) 51 Nm (38 ft-lb) 3/8-16 9/16" 60 Nm (44 ft-lb) 82 Nm (60 ft-lb) 7/16-14 5/8" 90 Nm (66 ft-lb) 130 Nm (96 ft-lb) 1/2-13 3/4"...

  • Page 37: System Descriptions

    SYSTEM DESCRIPTIONS POWER SAFETY MEASURES GTJZ0608SE&0608ME machines are powered by four A series of angle sensors and limit switches provides 6V batteries in series or a 24V lithium battery to drive a signals to the controllers. 24V DC motor which boosts the gear pump to provide The level sensor measures the angle of machine on X- power to the system.
  • Page 38 SYSTEM DESCRIPTIONS This Page Intentionally Left Blank © Jan 2022 GTJZ0608SE&0608ME Maintenance Manual...

  • Page 39: Service And Guidelines

    MECHANIC INSPECTION AND MAINTENANCE Qualified Sinoboom equipment mechanic is a person recognized by Sinoboom as one who, by possession of a recognized degree, certificate, training, has GENERAL successfully demonstrated the ability and proficiency to service, repair and maintain the subject Sinoboom product model.

  • Page 40: Preventive Maintenance

    Procedures in appropriate sections of this manual to perform the inspection and maintenance procedures. For the purpose of receiving the safety-related bulletins, it is important that Hunan Sinoboom Intelligent Equipment Co., Ltd. has updated ownership information for each machine. When performing each annual machine inspection, notify Hunan Sinoboom Intelligent Equipment Co., Ltd.

  • Page 41: Storage

    User or operator Operation Manual Inspection change. Maintenance Manual, Pre- Pre-delivery Prior to each sale, delivery Preparation Form, Owner, dealer or Qualified Sinoboom Inspection lease or rental delivery. and Maintenance Inspection user mechanic Report In service for 3 months or 150 hours, Maintenance Manual and whichever comes first;...

  • Page 42: Cleanliness

    SERVICE AND GUIDELINES • The qualified personnel should sign on the CLEANLINESS handover document to evidence the integrity of the machine. All inspection/test results should 1. The most important single item in preserving the be documented (including the inspector name, service life of a machine is to keep dirt and foreign title, organization and date).

  • Page 43: Pressure-Fit Parts

    SERVICE AND GUIDELINES accordance with recommended shop practices. PRESSURE-FIT PARTS (See Fastener Torque Specifications, page 2-8) When assembling pressure-fit part, use a molybdenum disulfide base compound or equivalent to lubricate the HYDRAULIC LINES AND mating surface. ELECTRICAL WIRING BEARINGS Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit.

  • Page 44: Pins And Composite Bearing

    SERVICE AND GUIDELINES • Avoiding oxidization of the mechanical joints 2. The composite bearing should be replaced if the between the male pins and female pins. following occurs: • Avoiding electrical failure due to low conductivity • Frayed or separated fibers on the liner surface. between the pins in humid environment.

  • Page 45: Repair

    REPAIR CONDUCTING A PRE- DELIVERY INSPECTION Repair procedures must be performed by qualified, trained and When the machine owner/company changes, in addi- competent personnel in a properly tion to conducting a pre-delivery inspection, the corre- equipped workshop. sponding inspection shall be carried out according to the maintenance schedule requirement and repair &...

  • Page 46: Following Amaintenance Schedule

    REPAIR PREPARE THE WORK RECORD BEFORE DELIVERY Maintenance Procedure Functional Inspection Machine Buyer/ Renter Inspector Signature Inspector Title Inspector Company FOLLOWING A COMPLETING A REPAIR & MAINTENANCE SCHEDULE INSPECTION REPORT Regular maintenance inspections must occur daily, 1. Divide the Repair & Inspection Report into four quarterly, biannually (every 6 months) and annually,and sections (A, B, C and D) according to the time must be performed by the personnel qualified in the...
  • Page 47 REPAIR REPAIR & INSPECTION REPORT A-5 Inspect Hydraulic Oil Leakage A-6 Functional Tests A-7 Inspect the Battery Level A-8 Perform Maintenance After 30 Days Checklist B Procedures REPAIRED/ YES/Machine is NO/Machine Has Problem Machine Has Items in Good Damage or Description Been Repaired Condition...

  • Page 48: Checklist Aprocedures

    REPAIR REPAIR & INSPECTION REPORT Checklist D Procedures REPAIRED/ YES/Machine is NO/Machine Has Problem Machine Has Items in Good Damage or Description Been Repaired Condition Malfunction D-1 Inspect Scissor Arm Installation Bearing D-2 Inspect Chassis Slider D-3 Replace Hydraulic Oil User Inspector Signature Inspection Date...

  • Page 49: Inspect Hydraulic Oil Level

    REPAIR Inspect the entire machine and check whether any exists in the hydraulic system. Be sure to correct the parts are damaged, installed improperly or lost, problem before operating the machine. including; Perform the following procedures with the platform • Electrical components, wirings and cables retracted: •...

  • Page 50: Functional Tests

    REPAIR situation, poor machine performance and damage to hydraulic components if the leak is not repaired. Inspect for overflowing, dripping or residual marks on or around the following components: • Hydraulic oil tank, pipe fittings, oil pipe, power unit • All hydraulic valve blocks •...
  • Page 51 REPAIR Figure 5-4 Platform controller (SINOBOOM) Figure 5-5 Platform controller (DTC) 8. Emergency stop 8. Emergency stop 1. Steer right 1. Steer right button button 9. Display screen 9. Display screen (to display battery (to display battery 2. Steer left 2.

  • Page 52: Inspect The Battery Level

    REPAIR A-7 Inspect the Battery Level The battery power level can be checked through the platform screen. Table 5-5 PLATFORM POWER DISPLAY POWER RATIO DESCRIPTION The battery has been fully charged. 90-100% The battery is at 70% of its capacity. The battery is at 50% of its capacity.

  • Page 53: Inspect Rim, Tire And Fasteners5-9

    REPAIR 2. Inspect the flexile joints, and confirm that the joints are tight and the sensor lines are not damaged. ELECTRICAL SHOCK HAZARD B-2 Inspect Rim, Tire and Fasteners Be sure to disconnect the battery from the machine and the charger Good maintenance of rims and tires is important for the from the AC outlet before inspecting safe operation of the machine.

  • Page 54: Inspect Battery

    REPAIR Torque Value Name Slotted nut (non-steering wheel mounting) 420Nm(310 ft-lb) Bolt (drive deceleration motor installed) 51 Nm(38 ft-lb) Bolt (mounting place of hub and axle seat) 130Nm(96 ft-lb) 4. Replace the cotter pin and bend it to the locking 1.

  • Page 55: Inspect Hydraulic Oil

    REPAIR satisfying the Result 1, proceed with the next NOTICE step. Shut off the drive motor/hydraulic motor before Note: if the Result 1 cannot be met even after many inspection. attempts, the battery may have malfunctions. 9. Check the battery electrolyte level, add distilled 1.

  • Page 56: Inspect Brake Manual Release

    10. After the towing is completed, re-energize the ma- chine, the brake can operate properly. 11. Remove the chokes as needed. SINOBOOM system 1. Chock the wheels from rolling. 2. Ensure the path of travel is clear of obstructions. © Jan 2022 5-12 GTJZ0608SE&0608ME Maintenance Manual...

  • Page 57: Inspect Emergency Lowering

    REPAIR 3. Pull out the emergency stop button on the platform controller to ON position. 4. Pull out the emergency stop button on the ground controller to the ON position, and meanwhile press the Enter key, the adjustment screen will show on the display..

  • Page 58: Full Lifting And Full Lowering

    REPAIR 3. —SINOBOOM system：Move upwards the lift func- B-9 Full Lifting and Full Lowering Time tion enable switch on the platform controller, the in- Test dicator light should be on. —DTC system：Press the lift function enable Appropriate lifting or lowering speed is important for the button, the button should be lit.

  • Page 59: Inspect The Tilt Protection

    5in） is less than 50s, immediately tag and re- move the machine from service. High speed testing： 9. —SINOBOOM system：Move downwards the drive high/low speed select switch on the platform con- troller, the high drive speed mode should be active.

  • Page 60: Test The Pothole Guard

    REPAIR 8. Fully lower the platform. Switch the machine from lift CHECKLIST C function to drive function. Drive the machine off and PROCEDURES remove the wooden blocks. 9. Place two wooden blocks under the two wheels on the front or back side of the machine, and then drive C-1 Replace Air filter of Hydraulic Tank the machine onto the blocks.

  • Page 61: Inspect Platform Weighing

    REPAIR 2. Use ground controller to lift and lower the platform C-2 Inspect Platform Weighing System without loading twice; the platform must operate in (optional) its normal state. 3. Lower the platform until the scissor arm is in the The platform weighing system is optional. Make sure fully retracted state.

  • Page 62: Checklist Dprocedures

    REPAIR CHECKLIST D Figure 5-11 PROCEDURES D-3 Inspect and Replace Hydraulic Oil D-1 Inspect Scissor Arm Installation Bearing Inspecting and replacing the hydraulic oil is important for the proper operation and service life of the machine. The machine may be unable to operate properly if the Effectively maintaining the scissor arm installation hydraulic oil and the filter screen become dirty, and the bearing is important for proper operation of the...
  • Page 63 REPAIR Figure 5-12 4. After the hydraulic oil is completely drained, remove the fastening screws of the hydraulic oil tank and re- move the hydraulic oil tank from the power unit. Figure 5-13 5. Wash the oil tank inside with neutral solvents and allow the hydraulic oil tank to dry.
  • Page 64 REPAIR This Page Intentionally Left Blank © Jan 2022 5-20 GTJZ0608SE&0608ME Maintenance Manual...

  • Page 65: Platform Components

    MAINTENANCE This section provides detailed procedures for regular • While maintaining the machine, replace any parts maintenance inspections. For further information about on the machine using the same parts or the maintenance, please see Maintenance Manual. equivalent parts of the original machine. •...

  • Page 66: Removing The Platform

    MAINTENANCE 2. Locate the cable connected to the bottom of the platform controller. 3. Tag and disconnect the cable from the bottom of the platform controller. 4. Remove the retaining screws from the platform controller and remove the platform controller. 5.

  • Page 67: Lift Cylinder

    2. Support the scissor arm with the safety arm. Replacing tires and rims 3. Disconnect and plug the hoses and fittings on the Hunan Sinoboom Intelligent Equipment Co., Ltd. hydraulic cylinder. recommends the replacement tires be of the same size, ply rating and brand as the original tires.

  • Page 68: Removing The Geared Travel Motor

    MAINTENANCE to the Part Manual. If the replacement tires are not as Hunan Sinoboom Intelligent Equipment Co., Ltd. recommends, the following requirements of tires should be met: 1. Ply rating/rated load and dimension equal or greater than the original. 2. Tire tread contact width equal or greater than the original.

  • Page 69: Front Wheel Bracket

    MAINTENANCE Make sure to use a lifting device with enough capacity to lift the chassis. Place the lifting lug to a proper location on the frame. Figure 6-6 Remove the geared travel motor 1. Place the machine on a solid, level surface. Figure 6-7 2.

  • Page 70: Battery

    MAINTENANCE 2. Disconnect and plug the hoses and fittings on the 1. Open the left door. steer cylinder, and tag the machine. 2. Label and disconnect the wires connected to the 3. Remove the retaining ring and clevis pin connecting battery.

  • Page 71: Hydraulic Valves

    MAINTENANCE 7. 2-position 4-way cartridge 8. Direct-acting relief valve 9. 3-position 4-way cartridge solenoid valve solenoid valve 10. Air filter Remove the hydraulic power unit 1. Open the right door of the chassis and locate the hydraulic power unit. 2. Tag and disconnect the cables on the power unit. 3.
  • Page 72 MAINTENANCE Table 6-2 Lift control valve (PN.202040003293) Name Function Torque To keep the fluid flowing in 27Nm (20ft-lb) Check valve one direction To lower the platform 27Nm (20ft-lb) Solenoid valve Throttle screw 2Nm (1.5ft-lb) Throttle screw 2Nm (1.5ft-lb) Figure 6-11 Lift control valve (PN.202040003295) Table 6-3 Lift control valve (PN.202040003295) Name Function...
  • Page 73 MAINTENANCE Figure 6-12 Lift control valve (PN.202040003315) Table 6-4 Lift control valve (PN.202040003315) Name Function Torque To keep the fluid flowing in 27Nm (20ft-lb) Check valve one direction To lower the platform 27Nm (20ft-lb) Solenoid valve Throttle screw 2Nm (1.5ft-lb) Throttle screw 2Nm (1.5ft-lb) GTJZ0608SE&0608ME Maintenance Manual...
  • Page 74 MAINTENANCE Figure 6-13 Lift control valve (PN.202040003323) Table 6-5 Lift control valve (PN.202040003323) Name Function Torque To keep the fluid flowing in 27.1Nm (20ft-lb) Check valve one direction Damper 4Nm (3ft-lb) To lower the platform 22.7Nm (17ft-lb) Solenoid valve Damper 4Nm (3ft-lb) Remove the lift control valve N N O O T T I I C C E E...

  • Page 75: Regulating The Platform Lifting

    MAINTENANCE NOTICE Do not allow the machine to operate if there is air en- CRUSH HAZARDS trainment in the pump, or else, the pump could be damaged. Make sure to keep your hands and other parts of your body away from the scissor arm when Adjusting the Emergency Lowering lowering the platform.

  • Page 76: Hydraulic Symbols

    34.4087 MAINTENANCE 32.0000 16.0000 6. Adjust the mounting nut so that the distance be- Symbol Description 28.5682 28.5682 tween the end of the handle and the mounting nut is 46.7096 28.5682 46.7096 no more than 3 mm (0.12 in.). 28.5682 7.

  • Page 77: Hydraulic Schematic Diagram

    MAINTENANCE Hydraulic Schematic Diagram GTJZ0608SE&0608ME hydraulic schematic diagram lift cylinder Overload sensor Overload sensor Steering cylinder 2 10bar GTJZ0608SE&0608ME Maintenance Manual 6-13 © Jan 2022...

  • Page 78: Electrical System

    MAINTENANCE ELECTRICAL SYSTEM UNSAFE OPERATION HAZARD Use and Maintenance of Battery • Strictly follow the manufacturer’s The battery falls into 3 types: lead acid, lead acid recommendations on how to maintenance-free and lithium batteries. The lithium properly use and maintain the battery and lead acid maintenance-free battery are free battery.
  • Page 79 MAINTENANCE See the Charging the Battery section of Operation The battery will bleed air in the equalization process Manual. (forming bubbles). Equalizing 5. Remove the vent cap every hour to measure the gravity of all battery cells, if the gravity doesn’t Equalization is the deliberate process of overcharging increase, stop the charging in equalization mode.

  • Page 80: Charger Troubleshooting

    • All operations in this section must guaranteed. be performed by qualified personnel who have been This section is applicable to Sinoboom system with the professionally trained and software version of JZ.C.00.W 1.01. authorized by Sinoboom, otherwise the consequences will ECU main interface be at your own risk.
  • Page 81 MAINTENANCE 1. Emergency stop button 6. PgDn key 2. Enter key 7. PgUp key 3. Platform control position 8. Esc key 4. Key switch (ground/platform control 9. Screen select switch) 5. Ground control position Pull out the emergency stop button to “ON” position and turn the key switch to Ground control position.
  • Page 82 MAINTENANCE ECU main interface System Unlock Parameter IO functional test Info query settings vehicle debugging Battery pack Curtis Driver PCU Information Trouble code GPS Information Switching value Language information query Information Service See the inquiry Service input check setting next page Battery cell Bus timing System Version...
  • Page 83 MAINTENANCE ECU main interface(continued) Unlock System IO functional test Parameter debugging Info query vehicle settings Access with a password see the previous page Manufacturer parameters Access with a password Warning parameters System Parameters Warning setting Level gauge Up limit switch X-axis warning Overload limit Level gauge...
  • Page 84 USB flash disk: ECU_MAIN.bin. In the Warning parameters menu of Parameter debugging, the parameters of level gauge X-axis Note: please contact Sinoboom after-sales warning, level gauge Y-axis warning, raised/stowed personnel to get the program. shift point, allowable overload lowering height, walk 3.
  • Page 85 MAINTENANCE ON (depend on Outdoor mode models) Weighing device ON (depend on Angle sensor models) Down overload restraint Walk limit on pit Foot switch 80/90 overweight alarm 3. Return to the main interface through the Esc key, 4. Calibrate joystick lower end: push the joystick to the and power off the machine as needed.
  • Page 86 MAINTENANCE 2. Select and enter Full-load calibration interface, Figure 6-23 and press the Enter key to start automatic calibration. 6. Return to the main interface through the Esc key, lower the platform to the stowed position, and Full-load calibration power off the machine as needed. Calibrate weight Figure 6-26 NOTICE...

  • Page 87: Dtc-K500 Control System

    PCU, ECU, sensors, etc. are precisely adjusted and protected before delivery. Therefore, personnel who have not been professionally trained and authorized by Sinoboom cannot disassemble their housings, otherwise moisture and dust will enter the internal mechanism and normal operation will not be guaranteed.
  • Page 88 MAINTENANCE ECU 主界面 1. Set Speed 2. Set Option 5. Fault History 3. Calibration 4. Machine Mode 6. Link Host PC 标定 连接 PC 速度设置 选配设置 机器模式 历史错误 Execute No Load Max Fast Speed Machine Type OL Descent Height Access ECU Calibration? 高速行驶速度最大值...
  • Page 89 Sinoboom to the original settings set by the control height. system manufacturer. Therefore, it is prohibited to update the program without the authorization of 2.
  • Page 90 MAINTENANCE 2. After entering the ECU menu selection mode, select Figure 6-36 and enter “OL Descent Height” interface. 3. The platform will rise and descend for three OL Descent Height times automatically: rise to the highest position and descend to the stowed position (the first, second and third ascending and descending movements are for height calibration, static calibration and dynamic calibration respectively).

  • Page 91: Trouble Diagnosis

    For the causes and solutions of fault codes, please refer to Trouble Diagnosis , page 6- 27). Table 6-8 Trouble Description and Inspection (SINOBOOM System) Cod- Problem Action Limit Solution System Initialization Fault: ECU may be...
  • Page 92 MAINTENANCE Cod- Problem Action Limit Solution the bound relationship or replace the GPS module. Indoor Models Switch Outdoor Alarm only Switch outdoor model to indoor model Mode Fault Toggle Switch Up or Down Fault: Make sure nothing is pressing the chassis toggle switch or Disable Chassis ECU Key Fault ECU button, check the wiring of the chassis...
  • Page 93 MAINTENANCE Cod- Problem Action Limit Solution Pressure Sensor 2 Fault: Check the wiring to the sensor and then the sensor itself. Also check to Disable All Pressure Sensor 2 Fault make sure that the correct option is properly Motion selected for load sensing. Disable Lifting, Battery Drain Alarm: Battery voltage is low, Battery Drain Alarm...
  • Page 94 MAINTENANCE Cod- Problem Action Limit Solution so, check the coil itself to see if it is open or shorted. Left Turn Coil Fault: Check the connections to the Disable Lifting Coil’s terminals and make sure they are tight. If Left Turn Coil Fault and Driving so, check the coil itself to see if it is open or shorted.
  • Page 95 MAINTENANCE Cod- Problem Action Limit Solution connections and tight or clean. Check the voltage to the ECU and PCU. High Neutral Current: The MC is sensing current in the motors when there should not be. This High Neutral Current Fault (Zapi Disable Lifting could occur anytime the MC thinks the brakes are on and the motors are still turning.
  • Page 96 MAINTENANCE Cod- Problem Action Limit Solution Drive Motor Short Fault: Check the Motor Disable Lifting Drive Motor Short Fault connections and make sure they are tight. Check and Driving the Motor for short-circuit. Left Brake Coil Fault: Check the connections to Disable Lifting the Coil’s terminals and make sure they are tight.
  • Page 97 MAINTENANCE Code Problem Action Limit Solution Invalid Option Setting Invalid Option Setting Fault: Set appropriate option Disable All Motion Fault for this lift. Calibration Fault: Re-calibrate the system, or Calibration Fault Disable All Motion check the angle and pressure sensor. GPS Communication Fault: Check communications cable connections and other GPS Communication...
  • Page 98 MAINTENANCE Code Problem Action Limit Solution make sure that the correct option is properly selected (or not) for load sensing. Battery Drain Alarm: Battery voltage is low, charge Battery Drain Alarm Lift Slow to Drive Speed the battery. Battery Drain Shutdown: Battery enters into sleep Battery Drain mode, and operate the joystick or button on ECU Disable All Motion...
  • Page 99 MAINTENANCE Code Problem Action Limit Solution Parallel Coil Fault: Check the connections to the Disable Lifting and Driving Coil’s terminals and make sure they are tight. If so, Parallel Coil Fault check the coil itself to see if it is open or shorted. Motor Controller Fault: Check the connections to Disable Lifting and Driving Motor Controller Fault...
  • Page 100 MAINTENANCE Code Problem Action Limit Solution contactor if necessary. Replace the Motor Controller if necessary. Motor Controller Over Voltage Fault. Check battery voltage and make sure the battery charger is not Motor Controller Over Disable Lifting and Driving on. Then cycle power to the lift. If that does not Voltage Fault resolve the issue, try replacing the Motor Controller.
  • Page 101 MAINTENANCE Code Problem Action Limit Solution Brake Release Switch Brake Release Switch On: Check the wires to Diagnostic Message Only brake release switch or look for a stuck switch. Brake Release Not Stowed: Check if the platform Brake Release Switch Diagnostic Message Only is below down limit height.

  • Page 102: Fundamental Troubleshooting

    MAINTENANCE Fundamental Troubleshooting Table 6-10 Problem Cause Solution • The key switch is in the OFF position. • The platform controller or the ground controller emergency stop button is in the OFF position. The equipment has not been Machine power off powered on •...
  • Page 103 MAINTENANCE Problem Cause Solution The platform controller The platform is limited to 1.2 Reset the handle and resume lowering. does not lower when there is no alarm • Inspect whether the on-off input plug is inserted properly and firmly. • Inspect whether the wiring of the plug switch is The platform controller Height calibration is wrong/...
  • Page 104 MAINTENANCE Problem Cause Solution • The sensor has not been calibrated. The load has not been No overload warning calibrated or the height is • The wiring of the load sensor is incorrect. incorrect • The sensor is not in good condition. The machine moves •...

  • Page 105: Electrical Symbols

    MAINTENANCE Electrical Symbols Table 6-11 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 28.5682 棕...
  • Page 106 46.7096 46.7096 46.8000 34.4087 34.4087 MAINTENANCE 32.0000 28.5682 Symbol Description Symbol Description 28.5682 16.0000 Storage battery Lithium battery 46.8000 Fuse © Jan 2022 6-42 GTJZ0608SE&0608ME Maintenance Manual...
  • Page 107 emer g ency st o p Fuse1 Down limit switch Controller Power Communication Batter And Charger Manul Switch Main Contactor Fuse1 Keyswitch f l a sh l i g ht down l i m i t Pot h ol e Swi t c h buzzer l e vel sensor Hight Lift Rangr Walk...
  • Page 108 MAINTENANCE This Page Intentionally Left Blank © Jan 2022 6-44 GTJZ0608SE&0608ME Maintenance Manual...
  • Page 109 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 110 MAINTENANCE This Page Intentionally Left Blank © Jan 2022 GTJZ0608SE&0608ME Maintenance Manual...
  • Page 111 APPENDIX 2: REPAIR & INSPECTION REPORT REPAIR & INSPECTION REPORT Model Serial No. Checklist A Procedures REPAIRED/ YES/Machine is NO/Machine Has Problem Machine Has Items in Good Damage or Description Been 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 112 MAINTENANCE REPAIR & INSPECTION REPORT B-9 Test Lift/Lower Speed B-10 Test Drive Speed B-11 Inspect Tilt Protection B-12 Inspect Pothole Guards Checklist C Procedures REPAIRED/ YES/Machine is NO/Machine Has Problem Machine Has Items in Good Damage or Description Been Repaired Condition Malfunction C-1 Replace Hydraulic Oil...
  • Page 113 MAINTENANCE REPAIR & INSPECTION REPORT Inspector Company NOTES: 1. The Repair & Inspection Report shall include the inspection table of each regular inspection. 2. Duplicate the Repair & Inspection Report template 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 114 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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