Sinoboom VM04E Maintenance Manual

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Operation manual (65 pages)

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Manual No: 510002110002-EN

Manual Version: A

April 2023

Translated version

Preface to VM04E Maintenance Manual

ual

Maintenance

Manual

产品说明书

PRODU

C T MAN U AL

VM04E/VM120E

0608E (2132E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

G T JZ

0808E (2732E)

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Summary of Contents for Sinoboom VM04E

Page 1 Maintenance Manual No: 510002110002-EN Manual Version: A April 2023 Manual 产品说明书 Translated version Preface to VM04E Maintenance Manual PRODU C T MAN U AL VM04E/VM120E 0608E (2132E) G T JZ 0808E (2732E) G T JZ 0808E (2732E) G T JZ...
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 and 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 hands...
Page 4 Sales Tel:+86 400-601-5828/+86-0731-87116222 Service Tel:+86 400-608-1289/+86-0731-87116333 E-mail:info@sinoboom.com/sales@sinoboom.com Address: No.128, East Jinzhou Avenue, Ningxiang High-tech Industrial Park, Changsha, Hunan, China Postal code:410600 Copyright©Hunan Sinoboom Intelligent Equipment Co., Ltd. Hunan Sinoboom Intelligent Equipment Co., Ltd. retains the right of final interpretation of the manual.
Page 5 To Users Thank you for choosing and using the machinery of Hunan Sinoboom In- telligent Equipment Co., Ltd. Use this machine only to transport tools to work locations and for performing tasks on the work platform. Only authorized personnel who have received appropriate MEWP training may operate this machine.
Page 6: Manual Revision History
Manual Revision History: Manual Date Description Version April 2023 Original issue...
Page 7: Applicable Models
The manual applies to the following models and serial numbers: Imperial Trade ID Model Metric Trade ID Serial No. 1000200100 to present VM04E VM04E VM120E NOTICE: • Check the machine model and serial number on the machine nameplate. The location of the name- plate can be found in the Diagram of Decal Positions section of the Operation Manual.
Page 10 8.1 Power Unit ..... . . 39 11.1 Sinoboom Main Control System 63 Function valves ..... . 40 System Interface.
Page 11: Safety Warning Symbols And Signs
Indicates an imminently hazardous situation that, if not avoided, could result in death or serious injury. Indicates an imminently hazardous situation that, if not avoided, could result in minor or moderate injury. NOTICE Indicates information directly or indirectly related to personal safety, machine damage, or property loss. © April 2023 VM04E Maintenance Manual...
Page 13 No smoking or open Lifting point Lashing point Tire ground pressure Hydraulic oil filler flames/sparks Platform load capacity Do not use damaged Tool or weight Fast/high speed Slow/low speed power cords © April 2023 VM04E Maintenance Manual...
Page 15: Maintenance Safety Precautions
Before and during inspection and maintenance proce- without the written permission of Hunan dures personnel shall use caution and take measures to Sinoboom Intelligent Equipment Co., Ltd. avoid dangerous situations. Those measures include, but are not limited to, the following: 1.
Page 16: Maintenance Safety
The above listed requirements must be adhered to strictly during maintenance/inspection work. In addition, all other appropriate measures must be taken to ensure safety during maintenance work, taking account of the working environment. VM04E Maintenance Manual © April 2023...
Page 17 Do not direct water or steam ejected from the flushing equip- ment at electrical components, as this may cause short-circuits or electrical shocks. • After maintenance is completed, thoroughly clean up any spilled © April 2023 VM04E Maintenance Manual...
Page 18: Fire And Explosion Hazards
If treatment is not carried out im- can generate sparks. mediately, serious complications • Only approved non-flammable may result. cleaning solutions should be used on the machine. VM04E Maintenance Manual © April 2023...
Page 20: Considerations After
2.4 CONSIDERATIONS AFTER MAINTENANCE 1. Check the machine functions so that faults such as oil leakage or poor operation can be detected as early as possible. VM04E Maintenance Manual © April 2023...
Page 21: Technical Characteristics
Maximum allowable tilt angle (front- 3°/1.5° rear/left-right) Turning radius (inside/outside) 0.14 m/1.34 m 5.5 in/4 ft 5 in Φ305×100 mm/solid Φ12×4 in/solid Tire (spec/type) Φ305×114 mm/solid Φ12×4.5 in/solid Maximum operating noise level 72dB IP rating IP54 © April 2023 VM04E Maintenance Manual...
Page 22 Maximum allowable altitude 1000 m 3280.8 ft Allowable ambient temperature -10℃ to 40℃ 14℉ to 104℉ (lead-acid battery) Allowable ambient temperature -20℃ to 40℃ -4℉ to 104℉ range (lithium battery) Maximum allowable relative humidity © April 2023 VM04E Maintenance Manual...
Page 23: Specifications Of Major
Rated voltage 12 V Reducer Maximum b48 (Longsheng 350Nm (258 ft-lb) charger) Torque Charging curve code 203 (Tuobang charger) Continuous 125 Nm (92 ft-lb) 12 (Yiyuan charger) torque Maximum rpm 5000 rpm Reduction ratio 50：1 © April 2023 VM04E Maintenance Manual...
Page 24: Movement Speed
(from fully raised position to fully retracted position) twice. Table 3-6 Component Metric (kg) Imperial (lb) Chassis assembly 1146 Travel Reducer Steering cylinder Wheel carrier Front wheel Rear wheel Left box Right box Battery Power Unit VM04E Maintenance Manual © April 2023...
Page 25: Pressure Limits
• The oil recommendations in this manual are for general operating conditions. For special environ- ments or special operating requirements please contact Sinoboom for special oil. © April 2023 VM04E Maintenance Manual...
Page 26: Torque Specifications
105 Nm (77 ft-lb) 135 Nm (100 ft-lb) 160 Nm (118 ft-lb) 1.25 150 Nm (110 ft-lb) 200 Nm (148 ft-lb) 230 Nm (170 ft-lb) 165 Nm (122 ft-lb) 210 Nm (155 ft-lb) 250 Nm (184 ft-lb) VM04E Maintenance Manual © April 2023...
Page 27 ( ( i i n n ) ) 11.5 Nm (8 ft-lb) 16 Nm (11 ft-lb) 1/4-28 7/16" 23 Nm (17 ft-lb) 32 Nm (24 ft-lb) 5/16-24 1/2" 41 Nm (30 ft-lb) 58 Nm (43 ft-lb) 3/8-24 9/16" © April 2023 VM04E Maintenance Manual...
Page 28: Hydraulic Hose Torque
ED, O-ring + Circlip O-ring seal L (light-duty) 18±1 Nm (13±1 ft-lb) 20±2 Nm (15±2 ft-lb) 18±1 Nm (13±1 ft-lb) M10×1 30±2 Nm (22±2 ft-lb) 35±2 Nm (26±2 ft-lb) 30±2 Nm (22±2 ft-lb) M12×1.5 VM04E Maintenance Manual © April 2023...
Page 29 185±12 Nm (136±9 ft-lb) G3/4A 180±10 Nm (133±7 ft-lb) 320±20 Nm (236±15 ft-lb) 240±15 Nm (177±11 ft-lb) 450 ± 25 Nm (332 ± 18 ft-lb) G1-1/4A 280±20 Nm (207±15 ft-lb) 540±30 Nm (398±22 ft-lb) G1-1/2A © April 2023 VM04E Maintenance Manual...
Page 30 50±3 Nm (37±2 ft-lb) 80±6 Nm (59±4 ft-lb) 3/4-16 75±5 Nm (55±4 ft-lb) 125±10 Nm (92±7 ft-lb) 7/8-14 110±8 Nm (81±6 ft-lb) 185±15 Nm (136±11 ft-lb) 1-1/16-12 160±10 Nm (118±7 ft-lb) 280±20 Nm (207±15 ft-lb) 1-5/16-12 © April 2023 VM04E Maintenance Manual...
Page 31: Maintenance Instructions21
The frequency formed by a factory-trained service technician, a person of the inspection and maintenance must be increased recognized by Sinoboom as one who, by qualification, as required by environmental conditions, requirements certificate and training, has successfully demonstrated and frequency of usage.
Page 32: Responsible Persons And Qualifi- Cations For Performing Inspection
Safety belt anchorage point 1, 2, 7 1, 2, 7 1, 2, 7 Boom assembly 1, 2 1, 2 1, 2 Boom weldment Wear pads 1, 2, 5, 12 1, 2, 5, 12 1, 2, 5, 12 © April 2023 VM04E Maintenance Manual...
Page 33 1, 3, 4, 7, 10 1, 3, 4, 7, 10 1, 3, 4, 7, 10 Platform controller 1, 3, 4, 7, 10 1, 3, 4, 7, 10 1, 3, 4, 7, 10 Ground controller © April 2023 VM04E Maintenance Manual...
Page 34 1, 2 1, 2 1, 2 and covers Greasing and lubricating according to specifications Functional test of all systems Paint and appearance Inspection date stamped on the chassis Notify Sinoboom of machine ownership (change) © April 2023 VM04E Maintenance Manual...
Page 35: General Maintenance Instructions
Operation Manual start up of the machine and tag the machine and this manual. accordingly. 2. All controls should be turned off to avoid accidental actuation of the control system. © April 2023 VM04E Maintenance Manual...
Page 36 7. High-strength bolts should be tightened in strict ac- cordance with the requirements of this manual. 8. Requirements for the acceptance of onsite machine installation work: © April 2023 VM04E Maintenance Manual...
Page 37 Application of Insulating Silicone Grease to Electrical Connections Insulating silicone grease should be applied to all elec- trical connections for the purpose of: © April 2023 VM04E Maintenance Manual...
Page 39: Major Modification And Repair
• Clean the bearing and pivot pin with a cleaning agent to remove all grease and oil. The compo- site bearing uses dry coupling which does not re- quire lubrication. © April 2023 VM04E Maintenance Manual...
Page 41: Platform Components
5. Remove the fastening nuts and bolts from the boom and the side of the platform. 6. Slowly remove the platform assembly with the aid of the lifting equipment. Installation For installation, follow the disassembly procedure in re- verse order. © April 2023 VM04E Maintenance Manual...
Page 43: Boom Components
Table 6-1 Boom Components Description 1. Fasteners, boom assembly and frame 2. Fasteners, lift cylinder and boom base 3\4\5. Fasteners, lift cylinder and boom assembly A. Lift Cylinder B. Safety strut C. Boom Assembly © April 2023 VM04E Maintenance Manual...
Page 44: Disassembly And Installation
1. Start the machine from the ground and raise the platform so that the safety strut can be fully erected. 2. Erect the safety strut and lower the platform as to ensure that the safety strut provides effective support. © April 2023 VM04E Maintenance Manual...
Page 45: Chassis Component
For installation, follow the disassembly procedure in re- side to be worked on, and support the chassis. verse order. 4. Remove the tire and wheel assembly. 5. Mark and disconnect the harness connections on the drive motor and reducer. © April 2023 VM04E Maintenance Manual...
Page 46: Tire Assembly
Parts Manual of the corresponding machine. If you choose not to use the replacement tires recommended 7. Remove the jack as needed after installation. by Hunan Sinoboom Intelligent Equipment Co., Ltd., the following specifications should be adhered to: • The ply rating/rated load capacity and size should be the same as the original tire or superior to it.
Page 48 CHASSIS COMPONENT 4. After securing the battery with slings, remove the battery from the machine using suitable lifting equipment. © April 2023 VM04E Maintenance Manual...
Page 49: Hydraulic System
9. 2-Position 2-Way Solenoid Valve 10. Overflow valve 11. Oil Port Drain 12. Hydraulic Tank Fasteners 13. Clamp 14. Oil Suction Tube 15. Oil Return Tube 16. Hydraulic Pump Mounting 17. Pressure Measuring Port Screws and Washers © April 2023 VM04E Maintenance Manual...
Page 50: Function Valves
Extra care should be taken during disassembly to avoid damaging component surfaces. It is recommended to replace the suction filter screen every year or after 1000 hours of operation. The re- Installation placement interval should be shorter in harsh operating environments. VM04E Maintenance Manual © April 2023...
Page 51: Checking The Cleanliness Of The Hydraulic Oil
The hydraulic oil is milky white and cloudy. • The hydraulic oil is black. • Check a small sample of the hydraulic oil using a bright source of light to see if there are reflections of © April 2023 VM04E Maintenance Manual...
Page 52: Adjusting Emergency Lowering
If the platform drifts down 16.0000 16.0000 more than 50 mm (1.97 in) in 10 minutes, perform a cyl- inder drift inspection as per the following procedures. 1. Place the machine in an environment with stable ambient temperature. © April 2023 VM04E Maintenance Manual...
Page 53 32.0000 directional valve 32.0000 28.5682 32.0000 16.0000 Directional valve for 28.5682 traveling at high and low 28.5682 16.0000 speed 16.0000 棕兰黑 Priority flow valve 17.4787 Check valve 46.7096 34.4087 32.0000 28.5682 16.0000 © April 2023 VM04E Maintenance Manual...
Page 54: Hydraulic Schematic Diagram
HYDRAULIC SYSTEM 8.6 HYDRAULIC SCHEMATIC DIAGRAM Lift cylinder 40/30-3*1086 Steer cylinder DT302 50/25-76 DT303 DT304 DT301 95 bar Fig. 2 Hydraulic Schematic Diagram VM04E Maintenance Manual © April 2023...
Page 55: Electrical System
If the readings match Result 1 pro- battery box shows any damage. If any damage is ceed to the next step. found, repair the paint immediately to protect the out- er box insulation and to prevent corrosion. © April 2023 VM04E Maintenance Manual...
Page 56: Adding Fluid
(1-2 cm above the mini- mal level of the water filler plug). Wear gloves during the process. Never add any acid solution. VM04E Maintenance Manual © April 2023...
Page 57: Changing The Charging Curve
Capacity indicator light teries does not require any settings, so the following in- structions apply to the charger for lead-acid batteries Charging voltage indicator only. Charging current indicator Battery voltage indicator Change the curve: © April 2023 VM04E Maintenance Manual...
Page 58: Fault Code Description
Machine Faults and Solutions The machine has a display screen at the ground controller and platform controller respectively for displaying machine parameter information and fault types. Table 9-3 Machine Faults and Solutions (Sinoboom Control System) Restricted Description Recommended solution...
Page 59 ELECTRICAL SYSTEM Table 9-3 Machine Faults and Solutions (Sinoboom Control System) (continued) Restricted Description Code Recommended solution functions Check whether any ECU buttons have been pressed Limits all Power-up ECU Key Fault or pushed-down. If this does not solve the problem, operations on the please try to replace the ECU.
Page 60 ELECTRICAL SYSTEM Table 9-3 Machine Faults and Solutions (Sinoboom Control System) (continued) Restricted Description Code Recommended solution functions Check whether the sensor and its wiring are in normal operating state. Check that the ECU sensor Angle Sensor Fault All functions configuration options are correct.
Page 61 ELECTRICAL SYSTEM Table 9-3 Machine Faults and Solutions (Sinoboom Control System) (continued) Restricted Description Code Recommended solution functions still does not solve the problem, please try replacing the solenoid valve. Check whether the wiring of the solenoid valve is correct. If this does not solve the problem, please...
Page 62 ELECTRICAL SYSTEM Table 9-3 Machine Faults and Solutions (Sinoboom Control System) (continued) Restricted Description Code Recommended solution functions does not solve the problem, please try restarting the machine. If this does not solve the problem, please try replacing the motor controller.
Page 63: Charging Faults And Solutions
ELECTRICAL SYSTEM Table 9-3 Machine Faults and Solutions (Sinoboom Control System) (continued) Restricted Description Code Recommended solution functions occurs if the foot pedal is depressed while operating the handle, please check whether there is a problem with the foot pedal switch.
Page 64: Basic Troubleshooting
Check whether the wiring of the plug switch is Lowering valve malfunction cannot be lowered malfunctioning using the ground • Check whether the lowering valve is malfunctioning controls. or whether the lead is connected properly. VM04E Maintenance Manual © April 2023...
Page 65 Perform pressure sensor calibration The machine is • Check the wiring of the pressure sensor for any overloaded but no Pressure sensor malfunction abnormalities. overload alarm is present. • Check whether the pressure sensor is malfunctioning. © April 2023 VM04E Maintenance Manual...
Page 66: Electrical Symbols
黑棕兰黑 28.5682 16.0000 46.8000 黑兰棕黑 17.4787 兰棕 17.4787 28.5682 VM04E Maintenance Manual © April 2023 46.7096 黑 46.8000 46.8000 46.7096 34.4087 28.5682 46.8000 17.4787 + Li 46.7096 28.5682 34.4087 + Li + Li...
Page 67 黑 28.5682 28.5682 兰 16.0000 棕 28.5682 16.0000 黑 46.8000 17.4787 46.7096 28.5682 46.7096 AGM battery Lithium battery 46.8000 46.8000 34.4087 28.5682 棕兰黑 28.5682 16.0000 Fuse 17.4787 46.7096 34.4087 32.0000 28.5682 16.0000 © April 2023 VM04E Maintenance Manual...
Page 68: Electrical Schematic Diagram
ELECTRICAL SYSTEM 9.6 ELECTRICAL SCHEMATIC DIAGRAM Fig. 2 Electrical Schematic Diagram VM04E Maintenance Manual © April 2023...
Page 69: Functions And Controls
6. Calculate the travel speed using the measured data, and compare it with the specified maximum travel speed in stowed position. © April 2023 VM04E Maintenance Manual...
Page 70: Pothole Protection Device
3 months no obvious vibration or abnormalities, and is prop- or after 250 hours of operation. erly lubricated. VM04E Maintenance Manual © April 2023...
Page 71: Staged Lowering Function
The platform will lower. 3. Once the platform is lowered to the non-operating position, the machine will stop lowering automatically. 4. Release the joystick to the neutral position. © April 2023 VM04E Maintenance Manual...
Page 73: Control System
This section is applicable to machines configured with ware without authorization from Sinoboom main control system and right chassis door Sinoboom. with wide panel. Due to different machine configu- rations, certain descriptions be-...
Page 74 Navigation 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 Fig. 1 System interface VM04E Maintenance Manual © April 2023...
Page 75 Calibrate Joystick gauge Single pressure Calibrate joystick Calibrate X-axis lower end Double pressure Calibrate joystick Calibrate Y-axis upper end Foot switch Calibrate joystick middle end Anti-collision switch Car tilt detection Fig. 2 System interface (continued) © April 2023 VM04E Maintenance Manual...
Page 76: Updating The Program
Enter key for 5 sec. Brake release Updating the program will restore the system parameters set by the original owner/user/ Sinoboom to the original parameters set by the control system manufacturer. Updating the Fig. 3 program without prior authorization from Sinoboom is strictly forbidden.
Page 77 2. Make sure that no heavy objects are placed on the platform. No-load calibration 3. Enter the ECU menu selection mode, then select and enter the Calibrate Height interface and press the Enter key. © April 2023 VM04E Maintenance Manual...
Page 78: User Selection Setting
(including alarm parameters, functional configurations, speed parameters, and alarm settings, etc.)) must be carried out only by authorized and qualified personnel who have undergone professional training by Sinoboom. Not meeting this requirement bears significant risks. Warning Parameters In the Warning Parameters menu of Parameter Debug-...
Page 79: Appendix
APPENDIX 12.1 MAJOR MODIFICATION AND REPAIR RECORD Major Modification and Repair Record Model Serial No. Machine Status Modified/Repaired Item Date Technician after Change © April 2023 VM04E Maintenance Manual...
Page 80: Inspection And Preven- Tive Maintenance Schedule
1, 2, 5, 12 1, 2 1, 2 1, 2 Fasteners Chassis assembly Chassis 1, 2 1, 2 1, 2 Tires Wheel nuts Traveling and steering components 1, 2, 5 1, 2, 5 1, 2, 5 VM04E Maintenance Manual © April 2023...
Page 81 1, 3, 10 1, 3, 10 1, 3, 10 Tilt alarm Pothole protection device 1, 3, 10 1, 3, 10 1, 3, 10 Emergency lowering device 1, 3, 10 1, 3, 10 1, 3, 10 © April 2023 VM04E Maintenance Manual...
Page 82 1, 2 1, 2 1, 2 and covers Greasing and lubricating according to specifications Functional test of all systems Paint and appearance Inspection date stamped on the chassis Notify Sinoboom of machine ownership (change) © April 2023 VM04E Maintenance Manual...
Page 83 6. Check for correct level, sealing and leaks 7. Labels complete, clear and secure 8. Check for appropriate tolerances 9. Fully charged 10. Verify/perform 11. Replace the oil or filter element 12. Correctly lubricated © April 2023 VM04E Maintenance Manual...
Page 85 For B et t er A ccess Solution s Alw ays For B et t er A ccess Solution s ess Solution s Always for Better Access Solutions Hunan Sinoboom Intelligent Equipment Co., Ltd. AS/N ZS 长沙市宁乡高新技术产业园区金洲大道东 128 号...

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