Sinoboom GTJZ0612E Maintenance Manual
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Sinoboom GTJZ0612E Maintenance Manual

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Part No.501048110002
Rev: C
Mar. 2022
Maintenance
Manual
产品说明书
PRODU
C T MAN U AL
GTJZ0612E/0612E/2146E
GTJZ0812E/0812E/2746E
0608E (2132E)
G T JZ
GTJZ1012E/1012E/3346E
0808E (2732E)
G T JZ
GTJZ1212E/1212E/4047E
0808E (2732E)
G T JZ
G T JZ
0808E (2732E)

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  • Page 1 Maintenance Part No.501048110002 Rev: C Manual Mar. 2022 产品说明书 PRODU C T MAN U AL GTJZ0612E/0612E/2146E GTJZ0812E/0812E/2746E 0608E (2132E) G T JZ GTJZ1012E/1012E/3346E 0808E (2732E) G T JZ GTJZ1212E/1212E/4047E 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 Decals/Nameplates Inspection section of the Operation Manual for details.) Trade identification MODELS SERIAL NO. Imperial Metric From 0105100139 to present GTJZ0612E 0612E 2146E From 0105200562 to present GTJZ0812E 0812E 2746E From 0104800852 to present...
  • 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

    Electrical System ..... 3-1 Application of Insulating Silicone Machine Control System ....3-1 Grease to Electrical Connections ..4-6 GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 10 Filter .......5-18 Charger Troubleshooting ..6-17 Sinoboom Control System ..6-17 © Mar. 2022...
  • Page 11 Electrical Schematic Diagram ..6-43 Appendix 1: Prepare the Work Record Before Delivery ..A-1 Appendix 2：Repair & Inspection Report ......A-3 Appendix 3: Major Modification and Repair Record ..... A-7 GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 12 © Mar. 2022 GTJZ0612E&0812E&1012E&1212E 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.. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 14 This Page Intentionally Left Blank © Mar. 2022 GTJZ0612E&0812E&1012E&1212E 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

    Table 1-1 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) © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 17 • Do not put a load outside the GTJZ1212E: 400N (90 lbf) indoor/ 200 N (45 lbf) platform. outdoor • Do not operate the machine when the chassis doors are open. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...

  • Page 18: Work Environment Hazards

    If the machine is to be used in any other appli- cations, or by any other means, other than those © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 19: Unsafe Operation Hazards

    SAFETY specified by Sinoboom, it must be approved or guided by the manufacturer. Table 1-3 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.

  • Page 20: Fall Hazards

    (60kg [132lb]). Do not use a battery that weighs less than the original lead acid battery (40kg [88lb]) or lithium battery (60kg [132lb]) about GTJZ1212E. The battery not only provides power, but also serves as a © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 21: Collision 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. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...

  • Page 22: Crush Hazards

    Maintain good judgment and plan- maintenance requirements in the Operation Manual ning when using the controller on and the Maintenance Manual. the ground to operate the ma- chine. Maintain proper distance between operator, machine and fixed object. © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 23: Bodily Injury 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. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 24 • Never store the battery in water or humid atomosphere. • Daily check the battery cable for damage, and replace any damaged parts before operating the machine. © Mar. 2022 1-10 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 25: Hydraulic Systems Hazard

    Maintenance Manual. 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. GTJZ0612E&0812E&1012E&1212E Maintenance Manual 1-11 © Mar. 2022...
  • Page 26 SAFETY This Page Intentionally Left Blank © Mar. 2022 1-12 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 27: Specifications

    SPECIFICATIONS PERFORMANCE PARAMETERS Table 2-1 GTJZ0612E Specifications 0612E (METRIC) 2146E (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...
  • Page 28 Stored at -20℃ to 50℃ (-4℉ to 122℉) in a well-ventilated environ- Storage condition ment with 90% relative humidity (20℃ [68℉]), and away from rain, sun, corrosive gas and inflammables and explosives. WEIGHT Weight (in a no-load state) (indoor/ 2455kg 5412 lb outdoor) © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 29 Max. allowable inclination (front to back/left 3°/1.5° to right) Turning radius (inside) Turning radius (outside) 2.35m 7ft 8.5in Max. allowable manual force (indoor/ 400N 90 lbf outdoor) Max. noise 72dB POWER PARAMETERS Drive×Steer 2 WD×2 WS GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 30 Weight (in a no-load state) (indoor/ 2715kg 5985lb outdoor) Table 2-3 GTJZ1012E Specifications 1012E (METRIC) 3346E (IMPERIAL) MEASURE DIMENSION PARAMETERS Max. platform height 32ft 10in Max. working height 39ft 4.5in Max. horizontal reach 0.9m Length 2.45m © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 31 Hydraulic system pressure 3046 psi 21MPa Battery specification (voltage, capacity, 24 V, 220 Ah, 20 hr rate of discharge)-lead-acid battery Battery specification (voltage, capacity, 25.6 V, 200 Ah, 1 hr rate of discharge)-lithium battery GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 32 Max. horizontal reach 0.9m Length 2.45m Width 1.17m 3ft 10in Height (stowed, rails folded) 1.98m 6ft 6in Height (stowed, rails up) 2.6m 8ft 6in Wheel base 1.88m 6ft 2in Wheel span 1.025m 3ft 4.4in © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 33 25.6 V, 200 Ah, 1 hr rate of discharge)-lithium battery Power system voltage 24VDC System control voltage 24VDC Charger (input voltage/output current) 100～240 V AC/30 A Drive motor (voltage/power) 24 V /0.85 kW GROUND BEARING DATA GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...

  • Page 34: Major Component Weights

    The hydraulic tank capacity is the maximum volume in the hydraulic tank. MAJOR COMPONENT WEIGHTS UNSAFE OPERATION HAZARD • Do not move heavy components without mechanical assistance. • Do not place heavy components upon instable surface. © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 35 SPECIFICATIONS Table 2-5 GTJZ0612E major component weights Component Metric (kg) Imperial (lb) Chassis assembly 1441 3178 Drive reducer Steer cylinder Wheel carrier 48.5 Tire Left box (lead-acid battery) Left box (lithium battery) Right box Lead-acid battery Lithium battery Power unit...
  • Page 36 Drive reducer Steer cylinder Wheel carrier 48.5 Tire Left box (lead-acid battery) Left box (lithium battery) Right box Lead-acid battery Lithium battery Power unit Scissor assembly 1206 2659 Upper lift cylinder Lower lift cylinder © Mar. 2022 2-10 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 37: Power System Specifications

    Steer relief valve pressure 15 MPa (2176 Psi) HYDRAULIC RETURN FILTER Bypass pressure 0.17 MPa (25 Psi) NOTICE Different hydraulic oils can be added according to customer requirements upon factory delivery, but cannot be mixed. GTJZ0612E&0812E&1012E&1212E Maintenance Manual 2-11 © Mar. 2022...

  • Page 38: Hydraulic Hose And Fitting

    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 © Mar. 2022 2-12 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 39 180 ± 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) GTJZ0612E&0812E&1012E&1212E Maintenance Manual 2-13 © Mar. 2022...
  • Page 40 110 ± 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) © Mar. 2022 2-14 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 41: Hydraulic Hose And Fitting Tight

    450 Nm (332 ft-lb) 600 Nm (443 ft-lb) 700 Nm (516 ft-lb) 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) GTJZ0612E&0812E&1012E&1212E Maintenance Manual 2-15 © Mar. 2022...
  • Page 42 92 Nm (68 ft-lb) 7/16-20 5/8" 100 Nm (74 ft-lb) 145 Nm (107 ft-lb) 1/2-20 3/4" 145 Nm (107 ft-lb) 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" © Mar. 2022 2-16 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 43 SPECIFICATIONS NOMINAL OPPOSITE NUT SIZE (S) CLASS 5 CLASS 8 DIAMETER (IN) 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 GTJZ0612E&0812E&1012E&1212E Maintenance Manual 2-17 © Mar. 2022...
  • Page 44 SPECIFICATIONS This Page Intentionally Left Blank © Mar. 2022 2-18 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 45: System Descriptions

    The other controller is located on the platform and controls lift and drive functions. The controller exchanges data through a high-speed data GTJZ0612E&0812E&1012E machines are powered by bus. four 6V batteries in series or a 24V lithium battery to drive a 24V DC motor, which drives the gear pump to provide power for the system.
  • Page 46 SYSTEM DESCRIPTIONS This Page Intentionally Left Blank © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 47: 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 48: Preventive Maintenance

    Procedures in appropriate areas 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 49: Storage

    Never attempt to move heavy parts without the aid of a this manual. mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...

  • Page 50: Cleanliness

    • The static and dynamic load tests of the machine suggest a compliance with the relevant standard. © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 51: Pressure-Fit Parts

    2. Unless specific torque requirements are given • Excessive sloppiness in joints. within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in • Noise originating from the joint during operation. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...

  • Page 52: Application Of Insulating Silicone Grease To Electrical Connections

    1. Prior to the machine assembling, apply silicone grease around the male pins and female pins inside the connectors to prevent oxidization. An injector may be used for the convenience of operation. © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 53: Maintenance

    • Conduct quarterly inspection on machines that have been out of service for a period longer than three 2. Follow this procedure each time before delivery. months. Performing a pre-delivery inspection could reveal GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...

  • Page 54: Following Amaintenance Schedule

    Every day or every 8 hours maintenance procedure requirements. Every quarter or every 250 hours 2. The Repair & Inspection Report shall include the inspection form of each regular inspection. © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 55 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 Air Filter B-6 Inspect Brake Manual Release Function B-7 Inspect Emergency Lowering GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 56 Description Been Repaired Condition Malfunction D-1 Inspect Scissor Arm Installation Bearing D-2 Inspect Chassis Slider D-3 Replace Return Oil Filter Element D-4 Replace Hydraulic Oil User Inspector Signature Inspection Date Inspector Title Inspector Company © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 57: Major Modification And Repair Record

    “Good” condition before company. continuing to use the machine. Table 5-4 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 GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...

  • Page 58: Checklist Aprocedures

    If any part is found damaged, missing, or improperly boom Intelligent Equipment Co., Ltd.. installed, please immediately replace it with a new one and install it correctly; if any fastener is found detached or loose, please tighten it immediately. © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 59: Inspect Hydraulic Oil Level

    Function Testsection in the Operation Manual. Extremely cold region Special programmes Before peforming the function test, be sure to read less than -30°C (-22°F) need to be identified. through and understand the safety rules in the Operation Manual. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 60 MAINTENANCE Figure 5-3 Ground controller 9. Back key 1.Fuse Figure 5-4 Platform controller (SINOBOOM) 2. Emergency stop button 10.Page up key 3. Off position 11. Enable switch 8. Emergency stop 1. Steer right button 12. Platform down 4. Platform control switch 9.

  • Page 61: Inspect The Battery Level

    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. The battery is at 30% of its capacity. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...

  • Page 62: Perform Maintenance After

    ELECTRICAL SHOCK HAZARD Be sure to disconnect the battery from the machine and the charger from the AC outlet before inspecting electrical wires. Contacting live wire conductors could result in death or serious injury. © Mar. 2022 5-10 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 63: Inspect Battery

    B-3 Inspect Battery The battery condition will affect the machine performance and operation. Improper battery electrolyte level or damaged cable and wiring may damage battery parts and may lead to dangerous conditions. GTJZ0612E&0812E&1012E&1212E Maintenance Manual 5-11 © Mar. 2022...

  • Page 64: Inspect Hydraulic Oil

    D-4 Replace Hydraulic Oil, page 5-21 for replace- gravity reading for every 5℃ (40°F) lower; ment steps. • Result 1: if the gravity readings of all battery cells are 1.250 or higher, and the difference of © Mar. 2022 5-12 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 65: Inspect Air Filter Of Hydraulic

    5. Use neutral solvent to clean the air filter, then dry it up using an air gun, and check the air filter again to ensure air can go through smoothly. 6. Install the clean or new air filter to the hydraulic tank. GTJZ0612E&0812E&1012E&1212E Maintenance Manual 5-13 © Mar. 2022...

  • Page 66: Inspect Emergency Lowering

    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. © Mar. 2022 5-14 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 67: Test Braking Device

    (4 in). the controllable speed range, The machine should be free of shaking, shock or unusual noise. 1. Pull out the emergency stop buttons on the ground and platform controls to ON position. GTJZ0612E&0812E&1012E&1212E Maintenance Manual 5-15 © Mar. 2022...

  • Page 68: Inspect The Tilt Protection

    Low speed testing： button should be lit. 3. —SINOBOOM system：Move upwards the lift func- tion enable switch on the platform controller, the in- dicator light should be on. —DTC system：Press the lift function enable 8.

  • Page 69: Inspect Pothole Guards

    11. When the machine tilt alarm sounds, the display shows “LL” • GTJZ0612E：Change from the drive function to lift function, and raise the platform by approx. 2 ±0.3m（6ft 7in±10in), the machine cannot be operated to raise further or drive, but the lower- ing is allowed.

  • Page 70: Checklist Cprocedures

    When the platform load exceeds 540kg (1190 lb), the overload indicator lamp will illuminate, an alarm will sound, and all functions will be restricted from use. Once the excess weight is re- moved, the work platform will be able to move again. © Mar. 2022 5-18 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 71: Inspect Up Limit Switch

    NOTICE Weight calibration must be performed by qualified 1. Park the machine on flat, level and firm ground. personnel trained by Sinoboom. 2. Operate on the platform controller and raise the platform to the highest position. 3. Then Lower the machine with platform controller to C-3 Inspect Up Limit Switch a height as listed in the Table below.

  • Page 72: Inspect Carbon Brush Of Motor5-20

    Use sand paper to clean the slide ring so that less material will be removed. 3. If the slide ring is deeply dented, replace with a new one instead of cleaning. © Mar. 2022 5-20 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 73: Element

    Performance Parameters, 6. Clean all oil spills during the replacement process. page 2-1. 7. Start the machine from the ground 8. Check the filter and associated parts are free of leakage. GTJZ0612E&0812E&1012E&1212E Maintenance Manual 5-21 © Mar. 2022...
  • Page 74 7. Secure the oil tank to the inside of the right chassis door with retaining screws. 8. Install the suction and return pipes. 9. Add new hydraulic oil. © Mar. 2022 5-22 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 75: Repair

    4. Lift and push the platform to reach the wear pad to from the AC outlet before performing the notch. this procedure. Contact with live 5. Slowing lift the platform away. conductors could result in death or serious injury. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...

  • Page 76: Extension Platform

    1. Remove the platform assembly. Refer to Platform, block out of the slide chute. page 6-1. 7. Remove the scissor arm assembly. 2. Disconnect the hydraulic system and electric sys- tem connecting the scissor arm with the chassis. © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 77: Lift Cylinder

    Tires and Rims Replacing tires and rims Hunan Sinoboom Intelligent Equipment Co., Ltd. recommends the replacement tires be of the same size, ply rating and brand as the original tires. For the part number of a specific machine model, please reference the Part Manual.If the replacement tires are not...

  • Page 78: Reducer & Drive Motor

    & drive motor #3. reducer, and apply threadlocker Loctite 272 to the Installation of reducer and drive motor wheel bolts and install in sequence. Rear wheels： align the mounting holes of the new wheel or the © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 79: Front Wheel Bracket

    3. Remove the fixing bolts and gaskets at position 2# of the front wheel bracket. 2. Label and disconnect the wires connected to the battery. 4. Remove the front wheel bracket. 3. Use the appropriate lifting equipment to remove the battery. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...

  • Page 80: Hydraulic System

    Layout of Hydraulic Elements Figure 6-9 Table 6-1 1.Platform control valve 2.Filter 3. Gear pump 4.Hydraulic tank 5. DC motor 6. Upper lift control valve 7.Lower lift control valve Hydraulic Valves Figure 6-10 Upper lift control valve © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 81 Check valve To prevent backward flow 27.2Nm (20ft-lb) of fluids Relief valve Safety valve to protect the 40～50Nm (29.5～37ft-lb) system Solenoid valve (with To control the lowering 27.2Nm (20ft-lb) screen) electrically Throttle screw 4Nm (3ft-lb) GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 82 When re-installing the hoses & fittngs, torque to the lift control valve. specifications as listed in Hydraulic Hose and Fit- 5. Remove the screws securing the lift control valve to ting Specifications, page 2-12. cylinder. 6. Remove the lift control valve. © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 83 To limit the steer pressure 40Nm (29.5ft-lb) Throttle sleeve Throttle screw 2Nm (1.5ft-lb) Limit block With channels inside, as a Main valve block carrier for valve spool or other elements Removing the platform control valve GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...

  • Page 84: Regulating Hydraulic Valve

    The relief valves of all machines UNSAFE OPERATION HAZARD have been well regulated before delivery, never modify unless This procedure must be performed authorized. using the platform controller on the ground, never stand on the platform to operate. © Mar. 2022 6-10 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 85: Adjusting The Emergency Lowering

    页 safety arm to fully set up. 2. Properly lower the platform to ensure the safety arm 46.7096 46.7096 supports the scissor arm effectively. Filter 34.4087 34.4087 32.0000 32.0000 Power unit 16.0000 16.0000 GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-11 © Mar. 2022...
  • Page 86 16.0000 32.0000 directional valve 32.0000 28.5682 32.0000 16.0000 Running high and low 28.5682 28.5682 16.0000 speed reversing valve 16.0000 棕 兰 黑 Flow regulator valve 17.4787 Check valve 46.7096 34.4087 32.0000 28.5682 16.0000 © Mar. 2022 6-12 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 87: Hydraulic Schematic Diagram

    REPAIR Hydraulic Schematic Diagram GTJZ0612E&0812E hydraulic schematic diagram Lift cylinder 75/50-1210 Load sensor (options) ∅ 0.9 Lift control manifold ∅ 1.0 Steer cylinder 50/35-2×71 210bar Platform control manifold Ø1.0 Ø1.0 DT2b DT2a 2.8L/Min ∅ 0.6 ∅ 1.0 150bar GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-13 ©...
  • Page 88 Load sensor (options) Upper lift control manifold ∅ 0.9 80bar ∅ 1.2 Lower lift control manifold ∅ 1.6 Steer cylinder 50/35-2×86 210bar Platform control manifold Ø1.0 Ø1.0 DT2a DT2b 2.8L/Min ∅ 0.6 ∅ 1.0 150bar © Mar. 2022 6-14 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 89: Electrical System

    If the battery acid escapes, please petroleum jelly to the terminals or use terminal use baking soda to neutralize the protector. acid. 3. Keep the area around the battery clean and dry. Charging GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-15 © Mar. 2022...
  • Page 90 The self-discharge process will accelerate in warmer temperatures. If storing the battery in hot temperatures or during hot weather, monitor the specific gravity or the voltage more frequently (about every 2 - 4 weeks). © Mar. 2022 6-16 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 91: Charger Troubleshooting

    • All operations in this section must guaranteed. be performed by qualified personnel who have been This section is applicable to Sinoboom system. professionally trained and authorized by Sinoboom, ECU main interface otherwise the consequences will be at your own risk.
  • Page 92 Enter key on the main interface of the ground controller to enter the ECU menu selection mode. Select and enter different function interfaces through the PgUp key and PgDn key. The system interface is described in the figure below: Figure 6-14 © Mar. 2022 6-18 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 93 No of discharge Controller_Temperature cycles Leftmotor_Temperature Rightmotor_Temperature Leftmotor_actualspeed Rightmotor_actualspeed Receive_liftcode Left motor brake state Right motor brake state Left motor error Right motor error Left Ver Right Ver Figure 6-15 System interface description GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-19 © Mar. 2022...
  • Page 94 Single pressure Curtis_TWO_AC Calibrate joystick lower end Calibrate X-axis Double pressure Curtis_DC_CAN Calibrate joystick Foot switch Calibrate Y-axis upper end QianTuo_DCCAM Calibrate joystick Anti-collision switch middle end Figure 6-16 System interface description (continued) © Mar. 2022 6-20 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 95 USB flash disk: ECU_MAIN.bin. limit, pump motor current limit, deceleration time 1 and deceleration time 2 can be set. Note: please contact Sinoboom after-sales personnel to get the program. Note: 3. Turn off the machine, and insert the USB flash disk •...
  • Page 96 Calibrate joystick Height calibration middle end done Figure 6-18 Figure 6-21 4. Calibrate joystick lower end: push the joystick to the lowermost end and hold it, select and enter the © Mar. 2022 6-22 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 97 1. Place heavy objects with the same weight as the rated load of the machine on the platform. 2. Select and enter Full-load calibration interface, and press the Enter key to start automatic calibration. GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-23 © Mar. 2022...

  • Page 98: 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 99 Pressure Sesnor Mode Voltage Output Current Output Pothole Guard Descent Delay Motion Alarm Load Sensing High Torque Limit Drive Drain Alarm Time Drain Shut Time Foot Pedal Collision BMS Function Figure 6-29 System interface description GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-25 © Mar. 2022...
  • Page 100 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 101 Set OL Descent Height 1. Ensure that the space above the platform allows the platform to be safely lifted to the maximum height Figure 6-40 and the machine is horizontally positioned. GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-27 © Mar. 2022...

  • Page 102: Trouble Diagnosis

    For the causes and solutions of fault codes, please refer to Trouble Diagnosis , page 6- 28). Table 6-7 Trouble Description and Inspection (SINOBOOM System) Cod- Problem Action Limit Solution System Initialization Fault: ECU may be...
  • Page 103 Discharge Temperature Fault 2 and Driving factory to check battery. Alarm only GPS Lock Ⅰ Contact SINOBOOM after-sales staff. Pressure Sensor 1 Fault: Check the wiring to the sensor and then the sensor itself. Also check to Disable All Pressure Sensor 1 Fault...
  • Page 104 ECU and Driving controller to quit the mode. GPS Lock Ⅱ pre-warning Alarm only Contact SINOBOOM after-sales staff. Disable Lifting GPS Lock Ⅱ Contact SINOBOOM after-sales staff. GPS Lock Ⅲ pre-warning Alarm only Contact SINOBOOM after-sales staff.
  • Page 105 Motor controller. If that doesn’t resolve the issue, replace the Motor Controller. Disable Lifting Motor Controller Motor Fault: Check connections Motor Controller Over Heat Fault and Driving to the motors. Cycle power to the lift and if that GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-31 © Mar. 2022...
  • Page 106 Foot pedal no action: when operate the joystick to Disable Platform Foot pedal no action drive and lift, there is no action on foot pedal, so Control please check the switch of foot pedal. © Mar. 2022 6-32 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 107 Cell Voltage Low Fault 2: Inform BMS factory to Cell Voltage Low Disable Lifting and Driving check battery. Fault 2 Sharp Difference in Sharp Difference in Voltage: Inform BMS factory to Disable Lifting and Driving Voltage check battery. GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-33 © Mar. 2022...
  • Page 108 Reverse Coil Fault: Check the connections to the Disable Lifting and Driving Coil’s terminals and make sure they are tight. If so, Reverse Coil Fault check the coil itself to see if it is open or shorted. © Mar. 2022 6-34 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 109 Make sure other Motor Controller Fault parameters are properly selected. Total Voltage Low Fault 2: Check battery voltage Total Voltage Low Disable All Motion and charge if necessary. Check the battery Fault 2 GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-35 © Mar. 2022...
  • Page 110 Motor Controller. Left Drive Motor Short Fault: Check the Motor Left Drive Motor Short Disable All Motion connections and make sure they are tight. Check Fault the Motor for a short. © Mar. 2022 6-36 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 111 If the Disable Lifting and Driving Machine Tilted machine is level, check the wiring to the tilt sensor and then the sensor itself. GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-37 © Mar. 2022...

  • Page 112: Fundamental Troubleshooting

    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. © Mar. 2022 6-38 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 113 Inspect whether the lower platform controller is malfunctioning. There is no warning • The high-speed hydraulic valve is connected after descending to the Pothole protector incorrectly. minimum limiting position • The installation of the travel switch is abnormal. GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-39 © Mar. 2022...
  • Page 114 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. © Mar. 2022 6-40 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 115: 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 GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-41 © Mar. 2022 46.7096 28.5682 46.7096 46.8000 46.7096 46.8000 34.4087...
  • Page 116 46.7096 46.7096 46.8000 34.4087 34.4087 REPAIR 32.0000 28.5682 Symbol Description Symbol Description 28.5682 16.0000 Storage battery Lithium battery 46.8000 Fuse © Mar. 2022 6-42 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 117: Electrical Schematic Diagram

    REPAIR Electrical Schematic Diagram GTJZ0612E&0812E&1012E&1212E Maintenance Manual 6-43 © Mar. 2022...
  • Page 118 REPAIR This Page Intentionally Left Blank © Mar. 2022 6-44 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 119: Appendix 1: Prepare The Work

    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 the box marked "inspection" must be checked. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 120 REPAIR This Page Intentionally Left Blank © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 121: Appendix 2：Repair & Inspection Report

    B-2 Inspect Rim, Tire and Fasteners B-3 Inspect Battery B-4 Inspect Hydraulic Oil B-5 Inspect Air Filter of Hydraulic Oil Tank B-6 Inspect Brake Manual Release Function B-7 Inspect Emergency Lowering B-8 Inspect Brake Device GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 122 Damage or Description Been Repaired Condition Malfunction D-1 Inspect Scissor Arm Installation Bearing D-2 Inspect Chassis Slider D-3 Replace Return Oil Filter Element D-4 Replace Hydraulic Oil User Inspector Signature Inspection Date Inspector Title © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...
  • Page 123 4. Record the inspection results. If any inspection item is marked as "NO", the machine must be stopped and re- inspected after repair is completed, and the box marked “REPAIRED” shall be checked. Select the appropriate inspection procedure based on the inspection type. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 124 REPAIR This Page Intentionally Left Blank © Mar. 2022 GTJZ0612E&0812E&1012E&1212E Maintenance Manual...

  • Page 125: Appendix 3: 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. GTJZ0612E&0812E&1012E&1212E Maintenance Manual © Mar. 2022...
  • Page 126 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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