Elevated Access Sinoboom GTJZ0407SE Maintenance Manual
GTJZ0407SE
Maintenance Manual
0800 222 111 sales@elevatedaccess.co.nz
021 500 486 www.elevatedaccess.co.nz
GTJZ0407SE Maintenance Manual
Key Points
Before maintaining the machine, it is necessary to
read, understand and observe those safety rules,
operation instructions and maintenance instructions.
Only the trained and authorized personnel are allowed
to maintain the machine. It is necessary to always
keep this Manual along with the machine as a part of
it. Please contact with Hunan SINOBOOM Heavy
Industry Co., Ltd.
Table of Contents
Importance ....................................................... A
ety Rules .................................................... B
Saf
Product Performance Parameters .................... 1
Operating Procedures ...................................... 4
Regular Maintenance Procedures ................... 5
Procedure A ........................................... 10
A-1 Inspect All Manuals ............... 10
A-2 Inspect All Labels .................. 10
A-3 Inspect Damaged, Loose or
Lost Parts ....................................... 10
A-4 Inspect Hydraulic Oil Level .. 11
A-5 Inspect Hydraulic Oil Leakage
....................................................... 11
A-6 Functional Tests ..................... 11
A-7 Carry out Maintenance after 30
Days............................................... 11
A-8 Inspect Batt
ery ....................... 12
Procedure B ........................................... 13
B-1 Inspect Electric Wires ............ 13
B-2 Inspect Rim and Tire (Including
Mounting Nuts) ............................. 13
B-3 Test Key Switch ..................... 14
B-4 Test Emergency Stop Buttons 14
B-5 Test Horn................................ 14
B-6 Test Braking Device .............. 14
B-7 Testing Traveling Speed
(Platform in Lifted State) .............. 15
B-8 Testing Traveling Speed
(Platform in Fully Retracted State)
....................................................... 15
B-9 Test Full Lifting and Full
Lowering Time (no-l
oad) .............. 16
B-10 Inspect Hydraulic Oil ........... 16
B-11 Inspect Ventilation System of
Hydraulic Oil Tank ....................... 16
Procedure C ........................................... 17
C-1 Replace Air Filter of Hydraulic
Oil Tank ........................................ 17
C-2 Inspect Platform Weighing
System (Optional) ......................... 17
Procedure D ........................................... 17
D-1 Inspect Scissor Arm Installation
Bearing .......................................... 17
D-2 Inspect Base Frame Slider ..... 17
Procedure E ........................................... 18
E-1 Inspect and Replace Hydraulic
Oil .................................................. 18
tenance Procedures ............................... 18
Main
Platform Components ........................... 19
1-1 How to Remove Electric
Control Box from Platform ........... 19
1-2 How to Remove Platform ....... 20
1-3 How to Remove Extension
Platform ......................................... 20
Scissor Arm Part.................................... 20
2-1 How to Remove Scissor Arm . 20
2-2 How to Remove Lifting
Cylinder ......................................... 21
Base Frame Components ...................... 21
3-1 How to Remove Traveling
Motor ............................................. 21
3-2 How to remove the front wheel
....................................................... 21
w to Remove Storage Battery
3-3 Ho
....................................................... 22
3-4 How to Remove Hydraulic
Valve Block ................................... 22
3-5 How to dismantle the hydraulic
power unit ..................................... 22
3-6 How to Remove Hydraulic Oil
Tank ............................................... 22
3-7 How to Remove Steering Oil
Cylinder of Front Wheel ............... 23
3-8 How to dismantle the front
wheel bracket ................................ 23
Hydraulic System .................................. 23
4-1 Detection of Function Pump... 23
4-2 How to Replace Hydraulic
Pump ............................................. 24
4-3 Power Unit Control Valve Block
....................................................... 25
4-4 Symbols of Hydraulic System 27
4-5 Hydraulic Schematic Diagram28
Electrical System .......................... 29
5-1 Use and Maintenance of
Lead-Acid Storage Battery ........... 29
5-2 Trouble Diagnosis (Deltatech
System) .......................................... 33
5-3 Fundamental Troubleshooting 39
5-4 Electrical Symbols .................. 42
5-5 Electrical Schematic Diagram
(Deltatech System) ........................ 43
GTJZ0407SE Maintenance Manual
Importance
Hazard
Warning
Caution
Caution
Attention
Before maintaining GTJZ0407SE, it is necessary to
read, understand and observe corresponding safety
rules and operation instructions.
This Manual provides detailed maintenance
information for the owner and the operator, and
specifies inspection, maintenance and troubleshooting
methods and procedures for the competent
professional maintenance personnel.
The execution of maintenance procedures requires
basic knowledge
on machinery, hydraulic and
electrical aspects. Some maintenance procedures need
special skills, tools, lifting equipment and appropriate
work place. Therefore, it is strongly recommended to
maintain and repair at the designated service center of
the SINOBOOM.
Hunan SINOBOOM Heavy Industry Co., Ltd. will
provide accurate information and quality services.
However, the products will be improved continuously
and technical specification of pr
oduct may be
modified without advance notice. We suggest the
users to update latest product maintenance
specifications regularly.
We will appreciate if the customers could inform us
the deficiencies of the products and propose
improvement measures. We will consider all
suggestions carefully and use them as the reference
for the preparation of maintenance specification and
other specifications. Please contact us by E-mail or
fax.
Safety Rules
Hazard
Failure to observe the instructions in this Manual and
corresponding operation manual would cause death or
serious injury accident.
Pay attention to the unsafe operations mentioned in
GTJZ0407SE Maintenance Manual
the operation manual when carrying out maintenance
procedures.
Do not operate, unless:
You have understood and observed the safe
operation rules in the operation manual.
You shall have read, understood and observed
—Manufactu
rer’s instructions and safety rules
—User’s safety rules and workplace regulations
—All the applicable government regulations
You must use appropriate tools, lifting
equipment and work place.
Personal safety
All working staff on or around the machine must be
aware of any possible safety hazards. The personal
safety and the continuous and safe operation are the
most important.
Read the procedures carefully. The marks used in the
l
abels in this manual and on the machine are defined
as follows:
Safety warning mark- It is used to prompt
potential personal injuries. Observe all
safety prompts behind this mark for the
purpose of avoiding personal injuries or
death.
Red mark- It is used to prompt the urgent
hazardous cases; if not avoided, it would
lead to death or serious injuries.
Orange mark- It is used to prompt
potential hazardo
it would lead to death or serious injuries.
Orange mark with safety warning- It is
used to prompt potential hazardous case;
if not avoided, it might lead to mild or
moderate personal injury.
Orange mark without safety warning- It is
used to prompt potential hazardous case;
if not avoided, it might lead to property
losses.
Green mark- It is used to prompt
operation or maintenance in
It is necessary to wear protective goggles,
and work clothes.
us cases; if not avoided,
formation.
A
GTJZ0407SE Maintenance Manual
With potential hazards such as movable
parts, components which could rotate
freely or have not been fixed, lifting or
moving weight. Be sure to wear work boots.
Safety in Work Place
Keep sparks, flame and lit cigarette end
away from flammable and explosive
materials such as storage battery and
engine fuel. Equip qualified fire extinguisher nearby.
Maintain all tools and work place
properly for futu
working environment to be clean and
prevent the sundries or fragment dropping into the
machine components, resulting in damages.
Ensure good ventilation and illumination
conditions in the work place and working
area.
Ensure any forklift, traveling crane or
other lifting/supporting equipment to
have sufficient bearing and lifting
capacity. Ensure to use steel wire rope or belt with
sufficient bearing capacity and in good
Do not use disposable fasteners (such as
split pins and self-locking nuts)
repeatedly. The components might
become invalid if they are used again.
Dispose the used hydraulic oil and other
fluid appropriately. Use appropriate
container. Protect the environment from
being polluted.
re use. Ensure the
condition.
B
Width
Height
GTJZ0407SE Maintenance Manual
Product Performance Parameters
Parameter items Unit GTJZ0407SE
Outline dimension
Length
Ground clearance mm 65
Ground clearance (pithole protective device stretches) mm 15
Total weight kg 880
Design dimension
Maximum platform height
Maximum working height
Maximum horizontal extension
Maximum bearing capacity kg 240
Maximum load bearing capability of extended platform kg 100
Allowable quantity of people working on the platform Person 2 (indoor)
Wheel base m 1.11
Wheel span m 0.68
Turning radius
Internal wheel m 0.3
External wheel m 1.35
Maximum allowable yawing force (indoor) N 400
Control voltage (DC) V 24
Platform dimensions
Length*Width m* m 1.34*0.7
Tire size
Diameter mm 230
Width mm 80
Oil volume
Hydraulic oil tank L 4
Hydraulic system L 5 (Oil tank)
Pressure of hydraulic system bar 180
System voltage (DC) V 24
Maximum noise for normal working dB 72
Traveling speed
Off-running status km/h 0～4
Lifting status km/h 0～0.5
Gradeability % 25
Lifting/lowering time s 30s /25s (No load)
Maximum allowable wind speed m/s 0
Maximum allowed inclined angle
Frong and rear/Left and right 3°/1.5°
m 1.42
m 0.76
m 1.97
m 3.8
m 5.8
m 0.6
1
Description of Hydraulic System
Hydraulic oil Normal temperature region (-10℃ to 40℃):
L-HM46;
Cold region (-30℃ to -10℃): L-HV32;
Hot region (＞40℃): L-HM68;
Extremely cold region (＜-30℃＝: Special
scheme to be determined;
Different hydraulic oil may be filled in
according to the requirements of the
customer upon delivery.
Hydraulic pump
Type Gear pump
Flow rate (at 3000r/min) 3.3L/min
Maximum driving
pressure
Traveling deceleration motor
Voltage 24V
Speed ratio 47.1
Power 450W
Valve
Pressure of function
main safety valve
180bar
180bar
GTJZ0407SE Maintenance Manual
2
GTJZ0407SE Maintenance Manual
Installation Instructions for Hydraulic Hoses and
Fittings
When removing or installing the hydraulic hoses and
fittings with O-ring, it is necessary to operate as per
the torque specified in the following table.
Hose fittings
Thread Torque Nm
M10×1 15
M12×1.5 25
M14×1.5 35
M16×1.5 50
M18×1.5 70
M22×1.5 125
M27×2 145
M33×2 210
Hoses
Thread Torque Nm
M12×1.5 15～17
M14×1.5 18～21
M16×1.5 25～28
M18×1.5 35～39
M22×1.5 45～50
M27×1.5 85～94
M30×2 110～121
M36×2 130～143
Tightening Procedures
1. Replace the O-ring. It is necessary to replace the
O-ring if the seal has been damaged. The O-ring
shall not be reused if the pipe fitting or the hose
has between tightened.
2. Lubricate the O-ring before installation.
3. Ensure to place and fix the O-ring properly.
4. Align the hose nut to the pipe fitting, and tighten
the nut.
5. Tighten the nut or the pipe fitting as per the
torque spec
6. Perform all machine functions and inspect hoses,
hose fittings and relevant components to confirm
that no leakage occurs.
ified in the above table.
3
Operating Procedures
Energy
Two 12V lead-acid storage battery are connected in
series and drive one 24V DC motor. The gear pump is
connected to the output shaft of the motor with the
spline to provide power for the system.
Hydraulic System
The entire hydraulic system of the machine is divided
into two parts: one is for steering function and the
other is for platform up and down functions.
When the motor works, the hydraulic pump
deliver the pressure oil to the functional valve block
on which the directional valve is installed and is used
to complete different actions. For protecting relevant
components, and prevent the system overloading, the
valve block is fitted with overflow valve.
Electrical System
2 separated batteries (12V) are used in the system,
which are used for driving pump controlled DC motor
and traveling drive motor, controlling sciss
and down, traveling and other functions. Batteries are
charged by external power.
Machine Control
The functions of the machine are controlled with one
controller in this system. This controller is installed in
the ground control box. The controller exchanges data
through a high-speed data bus.
Safety Measures
A series of angle sensors and limit switches provides
signals to the controllers. The level sensor measures
the angle of vehicle body on axis X and axis Y; when
the angle on axis X exceeds 1.5° or the angle on axis
Y exceeds 3°, the alarm will be triggered, and the
machine could not lift, travel or turn.
The stroke switch is used for confirming whether the
pit protection mechanism is turned on into position.
The platform will stop ascending if it is about 2m
away from the ground, the pit protective plate fails to
be spread and th
e sensor fails to detect any signal.
will
or arm up
GTJZ0407SE Maintenance Manual
4
Regular Maintenance Procedures
Warning
Hazard
Warning
Caution
Caution
Attention
Compliance
The maintenance and inspection should be
completed by trained and competent personnel.
The regular maintenance inspection consists of
daily, quarterly, semiannual, annual and biennial
maintenance. The maintenance and inspection
personnel must inspect and maintain according
to the maintenance and inspection reports, and
fill in maintenance and inspection reports in
details.
Warning: Fai
maintenance procedures
specified herein timely and regularly may lead to
death, serious injury or machine damages.
The damaged or troubled machine must be
labeled and moved away timely.
The damaged or troubled machine must be
repaired before operation.
All records shall be stored for at least three
years.
The machine which has not been maintained by
over three months must be subjected to quarterly
ins
pection.
Unless otherwise specified, the maintenance
procedures shall be carried out according to the
following precautions:
Park the vehicle on level firm ground
Engage the platform in loaded state
Turn the key switch to the position “OFF” and
take down the key
Turn the red emergency stop buttons on
platform controller and ground controller to the
position “OFF”
Disconnect all DC power supplies on the
machine
lure to carry out
GTJZ0407SE Maintenance Manual
Lock the tires
D
escription
This section provides detailed operation procedures
for the regular maintenance and inspection
The procedure includes description, safety warning
and step description.
Symbol Definition
Safety warning mark- It is used to prompt
potential personal injuries. Observe all
safety prompts behind this mark for the
purpose of avoiding personal injuries or
death.
Red mark- It is used to prompt the urgent
hazardo
us cases; if not avoided, it would
lead to death or serious injuries.
Orange mark- It is used to prompt
potential hazardous cases; if not avoided,
it would lead to death or serious injuries.
Orange mark with safety warning- It is
used to prompt potential hazardous case; if
not avoided, it might lead to mild or
moderate personal injury.
Orange mark without safety warning- It is
used to prompt potential hazar
not avoided, it might lead to property
losses.
Green mark- It is used to prompt operation
or maintenance information.
dous case; if
5
Attention
GTJZ0407SE Maintenance Manual
Maintenance Symbol Definition
The following symbols are
used in this manual for
helping the reader understand the intent of this
specification. If one or several symbols are marked in
front of the maintenance procedure, it is defined as
follows:
Indicate the tools for carrying out this
operation
Indicate new parts for carrying out this
operation
Indicate the motor must be stopped before
carrying out the operation
Indicate the mo
tor must be started before
carrying out the operation
Indicate that this operation must be carried
out by the supplier
Maintenance Schedule
There are five types of repair & inspection to be
carried out according to the schedule: Every day,
every quarter, every six months, every year and every
two years. With consideration to the repeated
procedures, the “Regular Repair Procedure Section”
and the “Repair
& Inspection Report” shall be
classified into five sections- A, B, C, D and E. The
necessary procedure combination for regular
inspection shall be determined according to the
following table.
Inspection Interval Inspection Procedures
Every day or every 8 hours A
Every quarter or every 250 hours A+B
Every half a year or every 500 hours A+B+C
Every year or every 1,000 hours A+B+C
Every two years or every 2,000 hours A+B+C+D+E
+D
Repair & Inspection Report
The repair & inspection report shall include the
inspection table of each regular inspection.
Duplicate the repair & inspection report for each
inspection. Store the completed tables by over three
years.
6
Attention
GTJZ0407SE Maintenance Manual
Pre-delivery Inspection:
It is quite necessary to carry out the preparation before
delivery.
Carry out this procedure each time before delivery for
the convenience of finding before putting the machine
into service whether there are any obvious errors.
Damaged or troubled machine shall not be used. It is
necessary to label and move away the machine if
finding damaged or abnormal machine.
The machine repair must be completed
competent repair personnel strictly according to the
repair manual.
Daily maintenance must be completed by the
competent operator according to the provisions of this
Manual.
by the
Description:
Use the operation manual for this machine.
The preparation before delivery includes inspection
before delivery, maintenance procedures and
functional inspections.
Record the inspection results. If any inspe
is N, it is necessary to stop the machine, repair the
machine and then re-inspect the machine, and mark R.
Notes:
Y—Yes, the machine is in good condition.
N—No, the machine has trouble.
R—Repaired, the machine has been repaired.
Record Form of Preparation before Delivery
Items Y N R
Inspection before
Delivery
Maintenance Procedures
Functional Inspections
ction result
Model
Serial No.
Date
User
Signature of Inspector
Position of Inspector
Organization of Inspector
7
GTJZ0407SE Maintenance Manual
Maintenance Record Form:
Model
Serial No.
Date
User
Signature of Inspector
Position of Inspector
Organization of Inspector
Description:
Record the following results after inspection on each
step.
Time Interval Inspection Procedures
Every day or every 8 hours A
Every quarter or every 250 hours A+B
Every half a year or every 500 hours A+B+C
Every year or every 1,000 hours A+B+C+D
Every two years or every 2,000 hours A+B+C+D+E
Inspect according to the steps in this section to get
acquainted with the inspection procedures.
Record the inspection results. If any inspection result
is N, it is necessary to stop the machine, repair the
machine and then re-inspect the machine, and mark R.
Notes:
Y—Yes, the machine is in good condition.
N—No, the machine has trouble.
R—Repaired, the machine has been repaired.
Record Form A
Items Y N R
A-1 Inspect All Manuals
A-2 Inspect All Labels
A-3 Inspect Damaged, Loose or Lost
Parts
A-4 Inspect Hydraulic Oil Level
A-5 Inspect Hydraulic Oil Leakage
A-6 Functional Inspections
Carry out Inspections of New Vehicle after 40
Working Hours
A-7 Carry out Maintenance after 30
Days
Carry out Inspections Every 125 Hours
A-8 Inspect Battery
Record Form B
Items Y N R
B-1 Items
B-2 Inspect Rim and Tire (Including
Mounting Nuts)
B-3 Test Key Switch
B-4 Test Emergency Stop Buttons
B-5 Test Horn
B-6 Test Braking Device
B-7 Test Traveling Speed (Platform in
Lifted State)
B-8 Test Traveling Speed (Platform in
Fully Retracted State)
B-9 Test Full Lifting and Full Lowering
Time
B-10 Inspect Hydraulic Oil
B-11 Inspect Ventilation System of
Hydraulic Oil Tank
Record Form C
Items Y N R
C-1 Replace Air Filter of Hydraulic
Oil Tank
C-2 Inspect Platform Weighing
System (Optional)
8
Record Form D
Items Y N R
D-1 Inspect Scissor Arm Installation
Bearing
D-2 Inspect Base Frame Slider
Record Form E
Items Y N R
E-1 Inspect and Replace Hydraulic
Oil
GTJZ0407SE Maintenance Manual
9
Procedure A
Attention
Attention
A-1 Inspect All Manuals
Storing the operation manual and the maintenance
manual in appropriate place is of great importance to
the safe operation of the machine. The manuals shall
be stored in the dedicated storage box on the platform.
The illegible or damaged manuals could not provide
necessary safety and operation information for safe
operation.
1. Inspect and confirm that the document box is
placed on appropriate po
2. Inspect and confirm that the operation manual
and the maintenance manual are stored in the
storage box on the platform properly.
3. Inspect the pages of the manuals and confirm that
they are legible and intact.
4. Return the manual into the storage box after use.
with Hunan SINOBOOM Heavy Industry Co., Ltd.
A-2 Inspect All Labels
Maintaining all saf
great importance to the safe operation of the machine.
The labels are used to prompt the operator the
potential risks in the operation process, and
meanwhile provide operation and maintenance
information to the user. The illegible labels could not
guide the operator properly, and might result in unsafe
operation.
1. Consult to the label section in the “GTJZ0407SE
Operation Manual” and determine
positions of the labels according to the label list
and chart.
2. Inspect whether all labels are legible and intact;
replace the damaged and illegible labels timely.
Hunan SINOBOOM Heavy Industry Co., Ltd.
ety and prompt labels properly is of
sition of the platform.
If needing to replace the
manual, please contact
the correct
If needing to replace the
labels, please contact with
GTJZ0407SE Maintenance Manual
A-3 Inspect Damaged, Loose or Lost Parts
Inspecting the condition of the machine daily is of
great importance to the safe and reliable operation of
the machin
damaged, loose or lost parts have not been found and
repaired timely.
Observe the entire machine and check whether any
parts are damaged, installed improperly or lost,
including:
Electrical components, wirings and cables
Oil tank, fittings, hoses, hydraulic cylinders and
Storage battery pack and its connection
Connection between the drive motor and the
Tire
Power unit
Limit switch and horn
Alarms and indicator lamps
Nuts, bolts and other fasteners
Intermediate hurdles of entrance or door for
Pit-hole protector
Extended zone of platform
Pivot of scissors arm and fastener
Platform joystick
Fastening bolts on the sliding block of the
e. It would lead to unsafe operation if the
valve blocks
rear wheel
s and its fastening nuts
platform
platform
10
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