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Essentials Before any maintenance of this machine, you should read

1. Result The power supply indicator will light up and the chassis control will become invalid 4 Turn the switch to the neutral position 15 GTJZ0408S amp GTJZ0608S Service Manual OFF Result All actions do not function B 4 Test the emergency stop button The function of the emergency stop button is crucial for safe operation of the machine If the emergency stop button has failed you can not shut down the hydraulic pump and stop the machine functions in case of emergency which will then endanger the platform and ground crew Selection and operation of the controller is prior to the platform controller ground including the emergency stop button the and chassis emergency stop switch and switch the 1 Release platform key switch to the position for ground control 2 Press the emergency stop switch on the ground operation panel Result Any action of the machine cannot be carried out chassis the and emergency stop switch and switch the 3 Release platform key switch to the position for platform control 4 Press the emergency stop switch on the platform Result Any action of the machine cannot be SINDBDOM carried out The ground and platform emergency stop switch can stop all actions of the machine even 1f the key switch 1s turned to the platform controller B 5 Test the horn The horn function 1s crucial for safe operation of the machine Pre
2. SINDBDOM Essentials Before any maintenance of this machine you should read understand and comply with these safety rules operation instructions and maintenance instructions Only trained and authorized personnel can be allowed to repair this machine Do keep this Manual as part of this machine and always keep it together with this machine If in doubt please contact Hunan Sinoboom Heavy Industry Co Ltd by phone Table of Content BON 3 e e ET E a sala aa alla 2 Product specifications nn 4 Working erter 4 Regular maintenance procedures 5 ee oer aesenanseesenatonteenaronda antenne 10 A 1 Check each manual 10 A 2 Check each label 10 A 3 Check the damaged loose or missing parts annae 11 A 4 Check the hydraulic ol level 11 A 5 Check the hydraulic oil eebe 11 A 6 Function test 12 A 7 Perform maintenance in 30 days 12 A 8 Check the battery 13 ee EN baa 14 RI Check the electric wire 14 B 2 Check the wheel rims and tires including mounting nuts 14 B 3 Test the key switch 15 B 4 Test the emergency stop button 15 B 5 Test the horn 16 B 6 Test the brake devices 16 B 7 Test the driving speed with the platform lifted 16 B 8 Test the driving speed with the platform fully stowed 18 B 9 Test the lifting or falling GTJZ0408S am
3. g Parameter Max platform height Max working height Extension outreach R ON oo oo Load Capacity 280 230 Wheel base A oa ek LA LA Turning radius inside 1 48 400 Outside 1 48 R gt Manual force KR KR Voltage Platform size Tire Dimension 305 Width 115 Hydraulic volume Hydraulic tank volume 1 Hydraulic system volume 1 Hydraulic system pressure bar 240 240 Aerial noise radiance maximum 72 noise level Driving Speed stowed km h 0 4 ralsed km h 0 0 8 Gradeability Lift Down speed idling 18 27 Max allowable wind speed ms oO Max allowable slope LA Nn 115 LA LA l SJ N F N B A N i o o front and rear Nn o Nn o left and right Hydraulic system descriptions Hydraulic oil L HM46 Hydraulic pump Type Gear pump Flow 3000r min 12 min Maximum driving pressure 248bar Drive motor Cycloid Type motor Displacement 230cc r Functional valve Pressure of functional main 248bar safety valve Pressure of lifting relief valve 172bar Pressure of steering relief 150bar valve Pressure of walking relief 248bar valve Walking drive Brake opening pressure 28 bar Auxiliary pump None Hydraulic filter Return Oil filter of hydraulic SP 06x10 oil tank Return oil filter bypass 2 5bar pressure SINDBDOM Hydraulic hose and pipe joint installation i
4. temperature and you should check the battery subject to battery use and working once every few weeks to determine the frequency to add water Usually the longer the battery is used the more frequently it should be added with water e Please have the battery fully charged before water is added If any plate electrode is exposed only the discharged or partially charged battery can be added with water in this case please add the water only just to have the plate electrode flooded then charge the battery and continue to add more water as follows e Remove the ventilation cap and have it upside down to prevent dust entering the check the electrolyte level if it is much higher than ventilation cap downside the plate electrode it means no additional water is required and if the electrolyte level has not yet flooded the plate electrode add deionized water please some distilled water or e For standard batteries please add water to 37 GTJZ0408S amp GTJZ0608S Service Manual the place 3mm lower the exhaust shaft referring to the plastic cover in the vent hole Please fix the vent cap on the battery again after water has been added e Charge Proper charging is a prerequisite for maximum battery performance Both undercharge and overcharge can greatly shorten the battery life Most preprogrammed and some chargers allow users chargers are automatic and to set the voltage and current values with the
5. It indicates that the hydraulic motor must be started before performing this operation It indicates that the implementation of this operation must be subject to the supplier s approval GTJZ0408S amp GTJZ0608S Service Manual Maintenance schedule There are five types of inspection and maintenance compulsorily subject to the schedule daily quarterly semi annual annual and biennial Considering the repeated procedures the part of regular maintenance procedures and maintenance inspection report can be divided into five sections A B C D and E Follow the table below to determine the required procedure combinations for performance of regular inspection Inspection interval Inspection procedure Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Biennially or every 2000 hours A B C D E Maintenance inspection report The maintenance inspection report contains the check list of each periodic inspection Replicate the maintenance inspection report for each test later on The completed check lists shall be kept more than three years SINDBDOM Pre delivery inspection It is quite necessary to carry out preparatory work before delivery Before each delivery this step must be performed in order to discover whether there is any obvious mistake of the machine before use Damaged or faulty machines should n
6. information related to correct charging as follows e This equipment charger is automatic and preprogrammed so users do not need to intervene in the charging process e The battery should be fully charged once used The lead acid battery has no memory effect so it does need to be completely discharged before recharging e Please check the electrolyte level to ensure that the positive and negative electrode plates have been flooded in water before charging e Please check whether all vent caps have been correctly fixed on the battery before charging e The battery can only be charged in a well ventilated area e The battery will discharge gas bubble when it is going to be fully charged to ensure that the electrolyte could be fully mixed e Avoid recharging in any environment more than 49 C Here follows the diagram for state of the battery charging process ZE SINDBDOM GTJZ0408S amp GTJZ0608S Service Manual we Percentag geg Open circuit voltage Schematic diagram for recommended liquid rich wet battery charging Citrien e Voltage each cell Charging current Amperes B attery 6V 1 2V SE l Charging modul E Er Con total charge input c d 100 50 1 172 2 017 5 Charging voltage Charging status Note The charging time varies according to the battery size charger output and depth of discharge f Equilibrium Equilibrium refers to excessive charging of the fully charged liquid r
7. procedure includes descriptions safety warnings and procedure instructions Symbol legends Safety warning sign used to indicate the presence of potential personal injury All safety messages after this sign shall be followed to avoid personal injuries or death Red sign used to indicate the presence of emergency situations Any disobedience will result in death or serious injuries Orange sign used to indicate the presence of potential hazardous situations Any disobedience will result in death or serious injuries A Warning Yellow sign followed by a safety warning sign used to indicate the presence of potential hazardous situation Any disobedience will result in slight or moderate personnel injuries A Caution Yellow sign not followed by a safety warning sign used to indicate the presence of potential hazardous situation Any disobedience will result in damage to properties Caution Green sign used to prompt operation or maintenance information SINDBDOM Maintain symbol legends The following symbols in this Manual are used to help understand the manual intentions When one or more symbols appear before the maintenance procedure it means as follows It indicates that tools are needed for performing this operation It indicates that new parts are needed for performing this operation It indicates that the hydraulic motor must be stopped before performing this operation
8. you should first confirm that the hydraulic oil has cooled Note While mounting the hoses and pipe should follow the prescribed torque referring to Chapter 2 joints removed you Specifications of hose and joint torques 1 Open the revolving door at the chassis left 2 Remove the oil drain plug from the hydraulic oil tank and discharge all the oil into a suitable container 3 Label disconnect and plug the hose and pipe joints on the hydraulic oil tank 4 Unscrew the fastening bolts mounted at the bottom of the hydraulic oil tank 5 Remove the fastening bolts 6 Remove the hydraulic oil tank SINDBOOM 3 7 How to remove the front wheel steering cylinder Note While mounting the hoses and pipe should follow the prescribed torque referring to Chapter 2 joints removed you Specifications of hose and joint torques 1 Label disconnect and plug the hose and pipe joints on the steering cylinder 2 Remove the nuts and gaskets to connect the steering connecting rod and the front wheel bracket 3 Unscrew the fastening bolts at the upper part of the steering cylinder 4 Remove the steering cylinder 29 GTJZ0408S amp GTJZ0608S Service Manual 3 8 How to remove the front wheel bracket Note While mounting the hoses and pipe should follow the prescribed torque referring to Chapter 2 joints removed you Specifications of hose and joint torques Before dismounting the fron
9. Pressure test port 3 Push against the two front wheels drive wheels at the ends of the steering shaft 4 Take down the platform controller from the platform and operate it on the ground Use the controller to implement platform this step on the ground but never stand on the platform 5 Turn the key switch to the platform 32 GTJZ0408S amp GTJZ0608S Service Manual controller and unscrew the emergency stop switch button for ground and platform control Hold the handle drive the control handle backward or forward keep the handle at the position of its maximum walking speed observe the pressure gauge reading and record the reading Refer to Part II Specifications 7 Shut down the machine use a wrench to lock the main relief valve and unscrew the nuts 8 Adjust its inner hexagon and rotate it increase pressure while clockwise to counterclockwise to decrease pressure Risk rollover Incorrect A Warning SS pressure adjustment may cause damages to the machine resulting in death or serious injuries Never have the adjustment pressure value higher than the specified value 9 Install the nuts in place 10 Repeat steps 5 7 to determine the pressure value SINDBOOM How to adjust the platform rise relief valve Make that the hydraulic oil level is at the Full mark on the oil tank sure 1 Adjust the system relief valve to the relief pressure as provided The
10. and replace the hydraulic ol for normal operation and longer service life of the machine Dirty hydraulic oil may have the machine unable to normally implement its actions and continuous use of such oil may cause damages to hydraulic parts Any unusually dirty working environment requires more frequent replacement of the hydraulic oil the hydraulic oil should be Before replaced tested to confirm whether it needs to be replaced The procedures for replacement refer to Procedure E 1 19 GTJZ0408S amp GTJZ0608S Service Manual B 11 Check the ventilation system of the hydraulic oil tank Good ventilation of the hydraulic oil tank cover 1s crucial for normal work and longer service life of the hydraulic pump Dirty or plugged hydraulic oil tank breather filter may have the hydraulic pump unable to work normally and continuous use may cause damages to the components Any unusually dirty working environment requires more frequent checks of the hydraulic oil tank breather filter this the Implement procedure when hydraulic motor is stopped 1 Remove the hydraulic oil vent filter 2 Check its ventilation hole Result The air should be smoothly passing through the ventilation filter If the air can not smoothly pass through the vent filter the filter should be cleaned as follows 3 Use any neutral cleaning solvent to clean the vent filter and then use an air gun to blow it dry Repeat
11. be placed underneath Use the safety bar to support the boom 3 Label disconnect and plug the hose and pipe joints on the hydraulic oil cylinder 4 Use special tools to unscrew the fastening bolts at the guide sleeve of the cylinder piston rod 5 Remove the spring washer Remove the pin shaft Take care to prevent Caution A the cylinder falling 7 Use special tools to unscrew the fastening nuts at the joint between the cylinder end and the scissor boom 8 Remove the bolts Use a brass rod or other auxiliary tools to force the pin shaft out 10 Carefully pull out the cylinder SINDBOOM Chassis parts 3 1 How to remove the arrester brake The arrester brake 1s to brake and fix the rear wheels so before dismounting the brake fix the equipment onto an appropriate bracket or place a competent jack under the chassis platform Note While mounting hoses and pipe joints removed you should follow the prescribed torque The cotter pin removed can not be used repeatedly and a new one must be used 1 Remove the rear wheel cotter pin which can not be reused 2 Remove the slotted nuts for tire fastening and dismount the rear wheel engaged onto the arrester brake 3 Label disconnect and plug the hose on the arrester brake device and plug the pipe joint on the arrester brake device Place the hose aside 5 Loosen the nuts to connect the arrester brake and the chassis Remove the nuts 7 Rem
12. into clean oil to lubricate its O seal ring 2 Screw in the cartridge valve according to the specified torque until the O seal ring contacts with the valve body 3 If necessary install the valve solenoid coil onto the valve rod mount the coil nut in place and tighten it according to the specified torque Name position function and torque specification of each valve UNT Nad Function Torque L V 2 position 4 way solenoid valve Platform Up Down 34 Nm eege 3 position 4 way solenoid Valve SIOEN R 34 Nm F 3 position 4 way solenoid valve Forward and backward 34 Nm Vs 2 position 2 way solenoid valve Brake pressure relief 34 Nm E Steering relief valve Steer pressure relief 24 Nm KV Main relief valve System relief 27Nm V bara saarken Liting elteren ladabsassh udii Lifting relief ossos 27 Nm Ge Pressure test joint Pressure test 31 SINDBOOM How to adjust the system relief valve Make that the hydraulic oil level is at the Full mark on the oil tank sure 1 Find the right place of the system relief valve on the functional valve 2 Connect a 0 35MPa pressure gauge to the pressure test point M on the main relief valve YD ANWYL Z les EA 1 Main relief valve 2
13. pressure has been well adjusted before installation of the valve block so in general it needs no adjustment 2 Place the maximum rated load on the platform and ensure that it is properly placed See Part II Specifications 3 Turn the key switch to the position for ground control and unscrew the emergency stop switch button for ground and platform control 4 Use a wrench to lock the lifting relief valve and unscrew the nuts 1 Lifting relief valve 5 Shift the platform rise selection switch and clockwise adjust the inner hexagon inside until the platform rises to the highest position 6 Let the platform fully retracted 7 Adda weight 1 2 times of the rated load onto the platform and place it properly 33 GTJZ0408S amp GTJZ0608S Service Manual 8 Try to lift platform 9 Correct result The platform cannot rise Incorrect result If the platform is still the counterclockwise until the platform cannot rising adjust inner hexagon rise 11 Install the nuts properly in place 12 Remove the weight on the platform 13 Have the platform rise to the highest position and 1f the pump sucks air or the platform has failed to reach its highest position add more hydraulic ol until the pump can work normally Don t let any oil flow out of the tank Risk of element damages If the pump sucks air don t always run the machine How to adjust the emergency fall handle How to adjust the manual fall spee
14. the fault has been detected appropriate repair procedures should be selected Symbol legend Safety warning sign used to indicate the presence of potential personal injury All safety messages after this sign shall be followed to avoid personal injuries or death Red sign used to indicate the presence of emergency situations Any disobedience will result in death or serious injuries Orange sign used to indicate the presence of potential hazardous situations Any disobedience will result in death or serious injuries A Warning Yellow sign followed by a safety warning sign used to indicate the presence of potential hazardous situation Any disobedience will result in slight or moderate personnel injuries A Caution Yellow sign not followed by a safety warning sign used to indicate the presence of potential hazardous situation Any disobedience will result in damage to properties Caution Green sign used to prompt operation or maintenance information SINDBDOM Platform components 1 1 How to remove the platform electronic control box Contact with live A Warning circuit may cause death or serious injury Remove all earrings watches and other jewelry Perform this operation only when the scissor boom has been fully retracted and lowered to its minimum height 1 Cut off the external power supply and set the emergency stop switches of the platform and ground
15. 3V larger than that of any other battery in the battery pack please apply equilibrium to this battery pack Measure the voltage of each battery again If any battery has its voltage 0 3V larger than that of any other battery in the battery pack this battery may have failed Moreover there are some other methods to test the battery for evaluation of its performance such as discharge test method and other methods Here follows no further description in detall i High frequency battery charger D Related technical parameters e Input voltage AC100 240V e Output voltage 24V 2 Notes e Input low voltage protection When the input AC voltage is lower than 85V the charger will shut down protectively and automatically recover its work after the voltage has become normal e Reverse connection protection When the battery is reversely connected the charger will cut off the connection between its internal circuit and the battery and will not start charging so there should be no damage e Output short circuit protection When the charger output happens to be shorted it will automatically cut off the output and restart charging with a 10 second delay after troubleshooting e Charging indicator The indicator turns yellow in charging green after charged and red in case of any fault e Charge braking device In time of charging the machine will have all its actions cut off 40 Fault diagnosis Deltatech sy
16. Step 2 4 Mount the vent filter on the oil tank COVCT SINDBDOM Procedure C C 1 Replace the vent filter of the hydraulic oil tank It is very important to replace the hydraulic oil tank air filter for normal operation and longer service life of the machine A dirty or clogged filter may have the machine unable to work properly and continuous use of such filter may cause damages to components Any unusually dirty working environment requires more frequent replacement of the filter 1 Unscrew the filter 2 Install a new air filter 20 GTJZ0408S amp GTJZ0608S Service Manual C 2 Check the weighing system of the platform optional The Hunan specification of Sinoboom Heavy Industry Co Ltd requires performance of this procedure once every 500 hours or 6 months Preparations before test Park the vehicle on a flat and solid ground The lubricated bearings and slideways are well Control the platform to rise and fall for two times on the ground and there should be no obvious shaking or abnormality GTJZ0408S The scissor boom is fully retracted and lowered to the minimum height Add a load of 280 kg onto the platform Result When the weight is less than 280 kg the platform can rise to the top normally The scissor boom is fully retracted and lowered to the minimum height Add a load of 335 kg onto the platform Result When the weight is 335 kg the platform can rise no more
17. amages Never have the pressure value of the adjusting valve higher than the specified value 9 Install the nuts in place 10 Repeat steps 5 6 to confirm the pressure value Manual brake release valve The manual brake release valve is installed at the chassis rear Press the reversing valve 1 repeatedly push and pull the manual pump and 1 Steering relief valve then the brake can be relieved 2 Pressure test port Diagram for manual brake release valve 3 Take down the platform controller from the assembly Use the platform Press it for reversing platform and operate it on the ground controller to implement Manual pump Manual brake release this step on the ground but never stand on the platform 4 Turn the key switch to the platform controller and unscrew the emergency stop switch button for ground and platform control 5 Hold the handle drive the steering button 34 H GTIZ0408S amp GTJZO608S Service Manual 1 Reversing valve 2 Manual pump 35 SINDBOOM Electrical system Lead acid battery use and maintenance manual a Required equipment 5 Goggles and gloves Rubber handle wrench Baking soda Pole protector 1 e vaseline anti corrosion sprays Voltmeter special for liquid rich type wet batteries colloid and AGM batteries Distilled water and purified water 1 e Such water after deionization and reverse osmosis treatment Discharge tester if any Hydr
18. cator doesn t light up The CAN equipment has lost 1 Whether the power and communication leads are not inserted connection correctly and firmly 2 Whether the platform and chassis cables have their Deutsch plug pin wiring consistent with the drawing 3 Whether the platform plug or the plugs of the platform and chassis connecting cables are well contacted 4 The platform controller is abnormal 5 Whether the chassis controller has its Deutsch plug connected correctly and firmly Chassis operation invalid Not switched to the chassis operation 1 The key switch is not placed at the position for chassis control abnormal 2 The chassis controller is always powered on after any program is downloaded again Platform operation invalid Not switched to the platform 1 The key switch is not placed at the position for chassis control operation abnormal 2 Itis always powered on after any program is downloaded 3 The platform controller is abnormal Continuous warning of level tilt The level switch is disconnected or in 1 Whether the level switch is not inserted correctly or firmly failure 2 Whether the level switch is abnormal In case of unloading and level the chassis can t fall The falling valve is in failure 1 Whether the on off input plug is not inserted correctly or firmly 2 Whether the plug switch is wired correctly 3 The falling valve leads are wired wrongly or abnormally The platform can t fall even i
19. cement and needs z Caution risk of part A Caution damages There is no relief valve installed on the pump and if the pressure is more than 24 8MPa the pump may be damaged Start the 30 GTJZ0408S amp GTJZ0608S Service Manual pump in a very short time interval and confirm the reading Don t let the pump overloaded 5 Remove the pressure gauge and connect the hose according to the prescribed torque Risk of bodily injuries The hot hydraulic oil may penetrate or burn A Caution your skin so slowly loosen the hydraulic connections to relieve the oil pressure slowly Never have the oil spraying out 4 2 How to remove the hydraulic pump While you must replace the removing the hoses and joints O shaped ring and complete installation according to the prescribed torque Refer to Chapter 2 Specifications of hose and joint torques 1 Disconnect the power supply e Risk of electric shock A Caution Contact with live wires may cause death or serious injury Remove all earrings watches and other jewelry 2 Label and loosen the cables on the drive motor 3 Label disconnect and plug the hose on the pump and plug the connector on the pump 4 Remove the mounting bolts of the power unit and dismount the power unit 5 Remove the pump mounting bolts and carefully dismount the pump 4 3 Platform control valve block How to install the cartridge valve 1 Dip the valve
20. controllers at the OFF position 2 Find out the cable connected to the bottom of the control box 3 Disconnect the cable from the bottom of the control box and mark it 4 Remove the platform control box assembly and mounting bracket 5 Remove the platform control box assembly from the platform 24 GTJZ0408S amp GTJZ0608S Service Manual 1 2 How to remove the platform Let the platform rise about meter 2 Use appropriate support equipment to support the platform 3 Remove the catch bolts of the platform and the scissor hinged shaft and remove the catch bolts of the slider fixing shaft in the slideway at the bottom of the platform 4 Lower the platform down to its loading position cut off external power supply set the emergency stop switches of the platform and ground control panels at the OFF position and find out the cable connected to the bottom of the platform control box 5 Disconnect the cable from the bottom of the control box Dismount the platform control box assembly and the mounting bracket and remove the control cable away from the working platform 6 Pull out the four pin shafts to fix the platform and slider 7 Remove the platform 1 3 How platform Remove the platform referring to 1 2 to remove the extension 2 Loosen the fastening bolts of all guard rails remove the fence and put it aside 3 Loosen the bolts of the fastening rollers at both sides of th
21. d Lift the platform to the height of 2 1 2 4m Hold up the safety bar 3 Put down the platform and use the safety bar to support the scissor boom Risk of crush When the platform is lowering put A Warning your hands far away from scissor boom 4 Pull the emergency fall handle outward until you cannot further pull it 5 Measure the distance from the end of the handle to the mounting nut Correct result The measured distance should be no greater than 3mm If the result is correct skip to Step 8 6 Adjust the mounting nuts 7 Lift the platform and lower the safety bar 8 Pull the handle outward and release it 2 3 SINDBDOM GTJZ0408S amp GTJZ0608S Service Manual times to ensure normal action to have the wheels turn to their right limits hold the handle to see the reading and How to adjust the steering relief valve write down the pressure value See Part II Specifications 6 Operate the handle have the wheels turn to their left limits hold the handle to see readings of the pressure gauge Make sure that the 7 Shut down the machine and unscrew the hydraulic oil level is at nuts of the steering relief valve the Full mark on the oil tank 8 Adjust its inner hexagon and rotate it clockwise to increase pressure while 1 Find out the right position of the steering counterclockwise to decrease pressure relief valve on the functional valve 2 Connect a pressure gauge M Risk of element d
22. d replace the hydraulic oil It is very important to check and replace the hydraulic ol for normal operation and longer service life of the machine Dirty hydraulic oil or filter may have the machine unable to work properly and continuous use of such filter may cause damages to components Any unusually dirty working environment requires more frequent replacement of the hydraulic oil Before replaced hydraulic oil should be tested to confirm whether it needs to be replaced If unqualified after testing the hydraulic oil should be replaced this the Implement procedure when platform is in its fully retracted position 1 Open the chassis right door and remove the battery connecting wire A Warning Risk of electric shock Contact with hot or live wire may cause death or serious injury Remove all earrings watches and other jewelry 2 Remove the oil drain plug to drain the oil into an appropriate container The hydraulic oil tank is 23L A Warning Physical damage warning The spraying hydraulic oil will infiltrate or burn your skin Slowly loosen the hydraulic connection device and never let the oil spray 3 Disconnect and plug the oil suction pipe GTJZ0408S amp GTJZ0608S Service Manual 10 11 12 22 Disconnect and plug the return oil pipe at the return oll filter Remove the fastening bolts of the hydraulic oil tank Remove the oil tank from the machine Remove the return oil filt
23. e extension platform 4 Loosen the fastening bolts of the baffle on the fixed platform and dismount the baffle 5 Lift the extension platform from both ends of the extension platform and put it aside SINDBDOM Scissor boom part 2 1 How to dismount the scissor boom as a whole Perform this operation only when the scissor boom has been fully retracted and lowered to its minimum height 1 Remove the platform and its electrical equipment see the part for platform 2 Disconnect the circuit and oil tube on the chassis with the scissor boom When dismounting the hose and pipe joints you must dismount the O seal ring at the end of the hose or pipe joint and make relevant marks 3 Use a travelling crane to fix the scissor boom 4 Unscrew the fastening bolts of the fixing stop pin 5 Remove the stop pin Use a brass rod or other auxiliary tools to force the pin shaft out H Take care not to hurt Caution your hand 7 Move the travelling crane transversely to push the slider out of the slideway 8 Dismount the scissor boom as a whole GTJZ0408S amp GTJZO0608S Service Manual 2 2 How to remove the lifting cylinder Hot or spraying hydraulic oil may cause harm to human body So before dismounting the joint of the hydraulic cylinder you should first confirm that the hydraulic oil has cooled 1 Use a travelling crane to fix the scissor boom and lift it until the safety bar can
24. e pit protection device retracted 4 Operate the control handle to drive the vehicle from the starting point to the end Result Low speed driving 2km h 5 Operate the high and low speed selector switch once rabbit symbol push the control handle to its maximum position and drive the vehicle from the starting point to the end Result High speed driving 4km h 18 GTJZ0408S amp GTJZ0608S Service Manual B 9 Test the lifting or falling speed Appropriate rising or falling speed is crucial for safe operation of the machine The control and execution should be able to respond to the operator quickly and smoothly with no shaking impact or abnormal noise Choose a solid and horizontal test area free from obstructions 1 Release the emergency stop switch and switch it to the chassis control position 2 Turn the platform rise fall switch to its rise position until the platform has risen up to its maximum height Results GTJZ0408S The platform rise time should be controlled within 18s GTJZ0608S The platform rise time should be controlled within 17s 3 Turn the platform rise fall switch to its fall position until the platform has fallen down to its minimum height Results GTJZ0408S The platform fall time should be controlled within 31s GTJZO0608S The platform fall time should be controlled within 27s SINDBDOM B 10 Check the hydraulic oil It is very important to check
25. ely or not fixed weights lifting or moving Do remember to wear work shoes Gr SINDBDOM Work site safety Ensure that no spark flame or lit cigarette butt is close to any flammable or explosive material such as battery and motor fuel Qualified fire extinguishers shall be equipped around Maintain the working site and all tools for later use Ensure that the work environment is clean to prevent impurities or debris falling into the machine parts to result in damages Make sure that your working site and working area well ventilated with good lighting conditions Ensure that any forklift travelling crane or other lifting and supporting device has the capacity enough for support and lifting Make sure to use intact wire ropes or belts with enough bearing capacity Ensure that the disposable fasteners such as the cotter pins and self locking nuts are not repeatedly used Otherwise the components may fail Use qualified containers for proper treatment of the hydraulic oil and other liquid waste Please pay attention to protect environment against pollution GTJZ0408S amp GTJZ0608S Service Manual Product specifications Specifications GTJZ0408S Dimensions GTJZ0608S Overall length Overall width 1 78 0 78 1 90 1 78 0 78 Overall height 1 88 Ground clearance O J Ground clearance Pit B B protection device expanded x Overall weight 1248 1328
26. enoid coll Sensor Horn Coupler Relay Tl SSC Emergency stop switch Toggle switch GTIZO408S amp GTJZO608S Service Manual Motor controller H Button Oil pump motor Charger QF Power off switch Coulombmeter 47 Limit switch Warning lamp Buzzer Indicator Key switch Two circuits are connected Two circuits are not connected Level switch ZE SINDBDOM GTJZ0408S amp GTJZ0608S Service Manual Electrical schematic diagram Deltatech system Poner Socket Batteries anChrger Interrupt PunpEngneerControl Fuse Jegen _ key Controler Poe pnt Bon ite iti tre earning Press Seso Wang I LASA 7B HB 12C 1B DD DN NZ HAS P ce0V ee OV deier Arel Oe Socket Ar witch Horn High Low Relay Broke Roise Oo Bock Wed w i okt 48 SINDBDOM Hydraulic system symbols Filter Power unit gt a Relief valve FJ A Three position four way solenoid reversing valve Manual fall release valve Walking high low speed reversing valve 49 GTJZ0408S amp GTJZO0608S Service Manual One way throttle valve Ze r t Priority valve gt Manual brake release valve Brake Motor 6 One way valve Gr SINDBDOM Hydraulic schematic diagram 12L Min 7 e MNJ GTJZ0408S amp GTJZ0608S Serv
27. er from the hydraulic oil tank Remove the oil suction filter from the oil tank and use appropriate solvent to clean it Use appropriate solvent to rinse the oil tank inside And dry the hydraulic oil tank in the air Mount the hydraulic oil tank onto the machine Mount the fastening bolts of the oil tank Mount the return oil pipe onto the return oil filter SINDBDOM Repair procedures Observe and obey The repair procedures should be implemented by qualified personnel after professional repair training any damaged or faulty machine shall be timely labeled and removed and all faults shall be eliminated before operation of the machine Before starting any repair Read understand and observe the safety regulations and operating instructions in the GTJZ0408S amp GTJZ0608S Operating Manual Prepare all required tools and parts the instruction attachments Thoroughly read procedures and and any shortcut behavior may cause dangerous situation Unless otherwise stated the repair procedures of this shall be according to the following tips machine implemented 1 Park the machine on a flat level surface 2 Have the platform in the loading position 3 Turn the key switch to the OFF position and remove the key 4 Lock the wheels 25 GTJZ0408S amp GTJZ0608S Service Manual Instructions Most procedures in this section should only be carried out by special repair service centers After
28. eted by qualified personnel after professional training gt The regular maintenance and checks can be divided into semi annual annual and biennial regular daily quarterly maintenance The maintenance and inspection personnel must carry out inspection and maintenance according to the maintenance and inspection report and fill in the report Warning If the Warning maintenance procedures provided in this Manual are not timely or regularly implemented death serious injury or damage to the machine may happen gt Timely label and remove the damaged or faulty machine gt Before any operation the damaged or faulty machine must be repaired in advance gt All inspection records shall be kept more than three years gt The machine without maintenance more than three months must accept quarterly inspection gt Unless otherwise specified the maintenance procedures shall be implemented according to the following provisions Place the machine on a flat level surface Let the platform in its loaded conditions Turn the key switch to the OFF position and remove the key GTJZ0408S amp GTJZ0608S Service Manual Place the red emergency stop buttons on the platform controller and ground controller to the OFF position Disconnect all AC power supply on the machine Lock the tires Instructions This part provides detailed procedures for regular maintenance and inspection and each
29. f there is no alarm Limit of 1 2 meters falling Reset the handle and implement the falling operation again 44 ZE SINDBDOM GTJZ0408S amp GTJZ0608S Service Manual When the machine is unloaded and the platform is at Height calibration error rising valve 1 Whether the on off input plug is not inserted correctly or firmly its lowest level the platform can not rise failure 2 Whether the plug switch is connected correctly 3 Calibrate the height again 4 The rising valve leads are wired wrongly or abnormally In time of no load indoors it can t rise to its The height is not calibrated The x Recalibrate the height maximum height travel switch is not set correctly Change the setting calibration of the travel switch The platform can t rise any more when reaching a The travel switch is not set correctly SEN the travel switch certain position Overweight alarm in time of no load The load is not calibrated lift for the Recalibrate the loading coefficient 2 Force to lift and fall for first time several times Forward function invalid in time of no alarm The forward function is abnormal Whether the chassis controller PWM plug is not inserted correctly or firmly Whether the forward valve is connected right and normally The chassis controller is abnormal Backward function invalid in time of no alarm The backward function is abnormal Whether the chassis controller PWM plug is not inserted correctly or firmly W
30. he handle and PCU Confirm that the handle has been in its neutral position prior to power connection and if not consider replacing the handle and PCU Check whether the handle neutral parameters have been set through the LabView program If not consider replacing the handle and PCU been tightly inserted and the solenoid valve has been shorted and broken 42 ZE SINDBDOM GTJZ0408S amp GTJZ0608S Service Manual Rice solenoid valve E E Limit of lifting and Check and confirm that the wire harness connected to the solenoid valve connector has 5 walking been tightly inserted and the solenoid valve has been shorted and broken Faine sokenoid vave aiue Limit of lifting and Check and confirm that the wire harness connected to the solenoid valve connector has 8 walking been tightly inserted and the solenoid valve has been shorted and broken ing a E PEPEE E E E E E Limit of lifting and Check and confirm that the wire harness connected to the solenoid valve connector has 5 walking been tightly inserted and the solenoid valve has been shorted and broken 57 d ETE E valve in Limit of lifting and Check and confirm that the wire harness connected to the solenoid valve connector has walking been tightly inserted and the solenoid valve has been shorted and broken 58 Braking solenoid valve failure Limit of lifting and Check and confirm that the wire harness connected to the solenoid valve connector has unavailable walking been tigh
31. hether the forward valve is connected right and normally The chassis controller is abnormal It cannot walk in time of tilt alarm Tilt angle extension switch The pit protection function has been enabled No alarm when it has lowered to its minimum height Pit protection The high speed hydraulic valve is wired improperly or it can not travel at its high speed The travel switch is not installed in place abnormally The hydraulic valve is abnormal Beyond the detection angle infinite action appears The level detection is abnormal The level sensor has its parameters wrongly calibrated Whether the level sensor wiring is correct and inserted firmly Whether the analog input leads are not inserted correctly and firmly The level sensor is bad The chassis controller is abnormal 45 ZE SINDBDOM GTJZ0408S amp GTJZ0608S Service Manual Overload free warning The load is not calibrated or the height 1 The sensor is not calibrated 13 WIONS 2 The load sensor is wired improperly 3 The sensor is bad The vehicle runs and stops frequently The electric quantity is not enough 1 Recalibrate the parameters calibrated correctly 2 The battery has no electricity so the coulombmeter can only be used as reference The set parameters can not be saved after repeated The storage is abnormal 1 The parameters are beyond the limit try 2 The chassis controller is abnormal 46 SINDBOOM Electrical symbols Sol
32. hine is provided by four 6V batteries in series Any contact with the battery charger wire may result in death or serious injury Remove all earrings watches and other jewelry A Warning The battery contains acidic liquid so you should avoid acidic liquid leakage and contact Use soda water to neutralize the spilled acid liquid Before this operation is performed the battery must be charged at first In order to judge the battery status more accurately please fully charge the battery and keep it idle for 24 hours 1 Do wear protective protective goggles clothing and 2 Ensure that the battery cable connectors are not corroded 3 Ensure that the battery is firmly installed with its cables reliably connected 4 Open the exhaust covers of the two groups of batteries and use a fluid densimeter to check the electrolyte density of each group of batteries Result If any group of battery has its electrolyte density less than 1 026 it must be replaced GTJZ0408S amp GTJZ0608S Service Manual 5 Check the electrolyte level If necessary add distilled water from the water inlet at the top of the battery Take care not to spill any water 6 Install the battery drain cover in place 7 Check the battery line connection and ensure the lines are properly connected 8 Connect the charging plug to a 220V socket Result The battery can be normally charged with the charging indicator light up Whe
33. his Chapter to familiarize the inspection procedures Record the inspection results and if any inspection result is N stop using the machine repair and check the machine again and mark it with R Notes Y Yes the machine is intact N No the machine is faulty R Repaired the machine has been repaired GTJZ0408S amp GTJZ0608S Service Manual Record form A YIN R A 1 Check each manual BER A 2 Check each label A 2 Check each label A 3 Check the damaged loose or missing parts A 4 Check the hydraulic oil level Il A 5 Check the hydraulic oil meen A A 6 Check the functions Check the functions Check after 40 hours work of a new vehicle A 7 Perform maintenance in 30 days Perform inspection in 125 hours A 8 Check the battery ER Record form B Ku B 1 Check the electric wire Il B 2 Check the wheel rims and tires including mounting nuts B 3 Test the key switch Il B 4 Test the emergency stop button B B STestthehom Test the horn B 5Testthehom III B 6 Test the brake devices Il B 7 Test the driving speed with the platform lifted B 8 Test the driving speed with the platform fully stowed B 9 Test the lifting or falling speed B 10 Check the hydraulic oil B 11 Check the ventilation system of the hydraulic oil tank Record form C Ku C 1 Replace the vent filter of the hydraulic oil tank C 2 Check the weighing system of the platform optional Record fo
34. ice Manual Lifting Cylinder _ Brake Manifold Kdl ESE vu um zent D M Steer ylinder l E CSE AS RE ee BK O 3 207bar F g Se e ord do og e br y1 Q d O TT za age cital Am SR sl H 91 0 Lee Y6 C l A Ge 1 A 50
35. ich wet batteries It is recommended that only when the fully charged battery features a low proportion lower than 1 25 or a large proportion range larger than 0 030 can equilibrium be applied Never perform equilibrium on any other battery The conditions for equilibrium implementation are as follows e Confirm it is a liquid rich wet battery e Check the electrolyte level to ensure that the positive and negative electrode plates are flooded in water before charging e Before charging confirm all vent caps have been properly fixed on the battery e Set the charger as its equilibrium model e The battery will discharge gas during the process of equilibrium e Measure its proportion once every hour and stop the equalization charging when the proportion is no longer increasing g Storage e Charge the battery before battery storage e Store the battery in a cool and dry place subject to no weather impact e Disconnect the power plug to eliminate the potential spurious load because of battery leakage e The stored battery needs a quick charge The battery will gradually discharge itself when only 70 or less electricity is left l Monitor the opoe OF e The battery should be recharged before use voltage once every 4 6 weeks with the when removed from where it is kept e Storage in a thermal environment higher than 32 C Never have the battery directly exposed to charging state proportion and open ci
36. ifferent movements and adjust the speed In order to protect the related parts and avoid overload of the system pressure the valve block is provided with a relief valve Electrical system In the system 4 separate 6V batteries are used to drive the hydraulic pump and the controller to control the lifting function of the scissor boom The batteries are charged through the external power supply Machine control This system controls the machine functions by means of a controller installed in the ground control box The controller completes data exchange through a high speed data bus Safety measures A series of angle sensors and limit switches provide signals to the controller The level sensor measures the angle of the body X axis and Y axis when the X axis angle is greater than 1 5 degrees or the Y axis angle greater than 3 degrees it will give alarms and can t GTJZ0408S amp GTJZ0608S Service Manual rise walk or steer The height potentiometer is used to measure the platform height and mainly restrict the driving speed The travel switch is used to confirm whether the pit protection mechanism is extended in place if the platform rises to about 1 5 meters from the ground the pit protection plate is not expanded and the sensor does not detect any relevant signal the platform will stop rising SINDBDOM Regular maintenance procedures Observe and obey gt The maintenance and checks shall be compl
37. lic system nanne 30 4 1 Functional pump detection30 4 2 How to remove the hydraulic pump 30 4 3 Platform control valve block 31 Electrical system aaaaassscccsasaaaaannnni 36 Lead acid battery use and maintenance manual 36 Fault diagnosis Deltatech system Troubleshooting of basic failures 44 Electrical schematic diagram Deltatech SYS RE 48 Hydraulic schematic diagram 50 Please contact us Website www sinoboom com E mail overseas sinoboom com cn Service hotline 400 601 5828 Fax 0086 731 87116516 All rights reserved by Hunan Sinoboom Heavy Industry Co Ltd The First Edition Nov 2013 GTJZ0408S amp GTJZ0608S Service Manual SINDBDOM Importance Before any attempt to maintenance or repair of the GTJZO408S and GTJZO608S products please carefully read understand and comply with the relevant safety regulations and operating instructions This Manual provides product owners and operators with detailed information for maintenance and provides qualified professional maintenance personnel with methods and procedures for inspection maintenance and troubleshooting To perform any maintenance procedure you must know about mechanical hydraulic electrical and other basic knowledge and at the same time some maintenance procedures require specialized skills tools lifting equipment and proper working site Therefore we s
38. n the battery is in its charging state please measure its voltage If any battery has its voltage lower than the following values 7V for any 6V battery the voltage difference between the battery and any other one in the battery pack is more than 0 5V 14V for any 12V battery the voltage 39 GTJZ0408S amp GTJZ0608S Service Manual difference between the battery and any other one in the battery pack is more than 1 0V then it indicates that this battery may have failed Proportion test Please fill and drain the hydrometer two or three times and then take one sample from the battery Measure the proportion readings of all battery modules When it is above 27 C add 0 004 once 5 C higher to correct the proportion readings and when below 27 C deduct 0 004 once 5 C readings lower to correct the proportion If each battery module in the battery pack is lower than 1 250 this battery pack may be insufficiently charged and it needs recharging If the proportion difference between any two battery modules in the battery pack is more than 0 050 please apply equilibrium to this battery pack If the difference still exists the battery in the pack may have failed Open circuit voltage test this method is not used commonly To obtain accurate voltage readings the battery must remain idle for at least 6 hours but the best for up to 24 hours Measure the voltage of each battery If any battery has its voltage 0
39. n the level is about 20 the battery must be charged Never have the battery exhausted before charged Ur SO Charger QF Power off switch OQ Charging indicator SINDBDOM GTJZ0408S amp GTJZO0608S Service Manual Wire Description of battery power M Full power 90 100 2 70 power L 70 Battery wiring harness Charger wire harness Scissor boom wiring harness Power unit wire harness Ground controller wiring box Platform controller wiring box Check whether any movable Joint 1s loose and confirm whether there 1s any sensor circuit damaged 30 power 30 Battery in low power must charge 10 7 IN Procedure B immediately Battery in low power will slow the machine s movements B 1 Check the electric wire The electric wire maintenance is very important for normal and safe operation of electrical machines If any burned abraded corroded or broken wire is not timely found and replaced unsafe operation or serious injury may occur i Contact with live wires Warning may cause death or serious injury Remove all earrings watches and other jewelry 1 Check the following areas to see 1f there 1s any burned abraded corroded or loose 50 power 50 14 B 2 Check the wheel rims and tires including mounting nuts Good maintenance of the wheel rims and tires is crucial for n
40. nals damaged melted or burned Tightening torque of the cable fastening nuts 9 11 Nm for M8 bolts 18 23 Nm for M10 bolts Too tight connection with the terminals may lead to terminal damages while too loose connection may have the terminals melted or burned A Warning A rubber handle wrench should be used to connect batteries amp Terminal protection If the terminal 1s not kept clean and dry it may be corroded continuously so we can coat it with a thin layer of vaseline or apply a terminal protector to prevent corrosion Preventive maintenance Check Check the battery appearance and keep the battery top and terminal connection clean and dry free of dust and corrosion SINDBOOM e If there is any liquid at the top of the battery too much water may have been added in the battery e Check the connection of the battery cables and other sleeves and tighten any loose connecter e Replace any damaged cable e Check whether all ventilation caps are correctly fixed on the battery Clean e Use cloth or a brush as well as baking soda and water mixture to clean the battery top terminals and connections but never have any cleaning solution into the battery e Clean it with water and dry it with cloth and have it coated with a thin layer of vaseline or apply a terminal protector e Keep the battery peripherals clean and dry 3 Add water The battery needs additional water regularly the
41. nd controllers 1 Switch the key switch to its ground control 2 Turn all functional switches on the ground control panel Result All the functions should be normally For the instructions refer to the Operation Manual executed specific function Detect the platform controller 1 Switch the key switch to its platform control 2 Ty to press all functional control handles of the machine and turn the switch or button Result All the functions should be normally For the instructions refer to the Operation Manual executed specifie function 12 GTJZ0408S amp GTJZ0608S Service Manual A 7 Perform maintenance in 30 days The 30 days maintenance refers to the one time maintenance performed after the new equipment has been used for 30 days or 40 hours After completion of the maintenance the should be implemented in accordance with the normal relevant maintenance interval of time Implement according to the following procedures B 1 Replace the element of the return oll filter B 3 Check the tightening torque of the tire fastening nuts Gr SINDBDOM A 8 Check the battery This procedure shall be implemented once every 125 hours Good battery conditions are very important for equipment normal and safe operation Inappropriate electrolyte level cable damage and loose connection may result in equipment damage and dangerous situations The 24V working voltage of the mac
42. ns 1 Refer to the labels in GTJZO408S amp GTJZ0608S Operation Manual and use the label list and chart to correctly locate each label 2 Check whether all labels are clear with no damage and timely replace any damaged or illegible label If any label needs to be replaced please contact Hunan Sinoboom Heavy Industry Co ltd SINDBDOM A 3 Check the damaged loose or missing parts Daily checks of the machine conditions are crucial to safe and reliable operation of the machine If any damaged loose or missing part 1s not found or maintained in time unsafe operation may occur Observe the whole machine to see 1f there 1s any part damaged missing or improperly installed with check contents included as follows lt gt Electrical components wiring and cables lt gt Hydraulic power unit oil tank joint hose hydraulic cylinder and valve block Batteries and connections Drive motor and brake devices Non slip paste Tires Power unit Limit switch and horn Alarm and indicator lamp if equipped Nuts bolts and other fasteners Platform access middle hurdle or door Platform access chains Pit protection device Platform extensions oo oo ooo Scissor boom pin shaft and fixed fasteners lt gt Platform control lever 11 GTJZ0408S amp GTJZ0608S Service Manual A 4 Check the hydraulic oil level It is very important for normal operation of the machine to have the hyd
43. nstructions When removing or installing any hydraulic hose or pipe Joint with O seal rings do follow the torques as specified in the specification E M18 X 1 5 M22 X 1 5 GTJZ0408S amp GTJZ0608S Service Manual Tightening procedure Replace the O seal ring When the seal 1s damaged the O seal ring must be replaced If the pipe joint or hose is tightened the O seal ring can not be reused Lubricate the O seal ring before installation Make sure that the sealing O seal ring 1s properly placed and fixed Align the hose nuts to the pipe joint and tighten the nuts Tighten the nuts or pipe joint according to the torque as provided in the table above Implement all machine functions and check the hose pipe joint and related components to ensure no leakage SINDBDOM Working principle Power source 4 lead acid batteries 6V each in series are adopted to drive a 24V DC motor The gear pump and the motor output shaft are connected through a spline to power the system Hydraulic system All machine functions are driven by the hydraulic system and the whole hydraulic system can be divided into two parts one part for walking and steering functions and the other for the lifting function of the platform When the motor works the hydraulic pump will send pressure oil to each functional valve block on which the direction valve and the flow regulating valve are arranged and used to accomplish d
44. ols lifting equipment and appropriate working site GTJZ0408S amp GTJZ0608S Service Manual Personal safety Anyone working on or around the machine must be aware of the potential safety hazards Personal safety as well as sustainable and safe operation of the machine is of greatest importance Read the procedures carefully The labels used in this manual and on the machine mean as follows Safety warning sign used to indicate the presence of potential personal injury All safety messages after this sign shall be followed to avoid personal injuries or death Red sign used to indicate the presence of emergency situations Any disobedience will result in death or serious injuries Orange sign used to indicate the presence of potential hazardous situations Any disobedience will result in death or serious injuries A Warning Yellow sign followed by a safety warning sign used to indicate the presence of potential hazardous situation Any disobedience will result in slight or moderate personnel injuries A Caution Yellow sign not followed by a safety warning sign used to indicate the presence of potential hazardous situation Any disobedience will result in damage to properties Caution Green sign used to prompt operation or maintenance information You need to wear protective glasses and working clothes Potential hazards such as moving parts components able to rotate fre
45. ometer special for liquid rich type wet batteries Notice to battery installation safety When dealing with any battery do always wear goggles Never smoke near any battery Do keep the protective clothing gloves and battery far from sparks flames and metal objects When connecting batteries do use rubber handle wrenches The electrolyte is the solution mixed with acid and water so we should prevent it contaminating your skin If your skin or eyes are contaminated with acid immediately wash with clean water Check whether the cables are firmly connected with the terminals and too tight or too loose connection may have the pole damaged melted or burned To prevent short circuits please do not put any object on the battery The wet lead acid batteries will release a small amount of gas during use and especially in the process of charging so the battery must be charged at a well ventilated place 36 GTJZ0408S amp GTJZ0608S Service Manual Never add any acid to the battery Please always have the battery vertically kept and if it is placed sidelong or obliquely the liquid in the battery may overflow Notice to battery connection Battery cable and torque value The battery cable can connect the battery electric equipment and charging system We should use a soft cable to connect the battery charging system and electric equipment Incorrect connection may lead to poor performance or have the termi
46. ormal and safe performance If any wheel rim or tire has failed it may result in overturning of the machine and if it is not timely detected or maintained damages to components may happen The machine uses solid tires with no inflation needed 1 Check to make sure that all tires are free of cuts cracks punctures and other abnormal wears 2 Check whether any rim is suffering from amp SINDBDOM damages buckling deformation and welding cracks 3 Remove the cotter pin and check whether the mounting nuts are tightened at a correct tightening torque While fastening the you checking nuts often need to change the cotter pin 4 Replace the cotter pin and bend it to the locking position B 3 Test the key switch Flexible use of the key switch is very important for safety operation of the machine The key switch failure may cause dangerous situations The ground control panel of the machine is equipped with a key switch used to control the power on off and achieve control options of the platform and chassis To perform this check please operate on the ground but never stand on the platform 1 Release the emergency stop switch for the platform and chassis 2 Switch the key switch to the position for chassis control Result The power supply indicator will light up and the platform control will become invalid 3 Switch the key switch to the position for platform control
47. ot be used If any machine is found damaged or abnormal label and remove it immediately The machine must be repaired by qualified maintenance personnel in strict accordance GTJZ0408S amp GTJZ0608S Service Manual Instructions Use the operation manual of this machine The preparation work before delivery includes inspections maintenance procedures and function tests before delivery Record the inspection results if any inspection result is N stop using the machine repair and check the machine again and mark it with R Notes Y Yes the machine is intact N No the machine is faulty R Repaired the machine has been repaired Preparation before delivery _ Y N R inspection before delivery with the maintenance manual Routine maintenance should be done by qualified operators according to the provisions of this Manual Maintenance procedures M Function checks Model S N Date User Verifier s signature Verifier s post Verifier s unit SINDBDOM Maintenance log Model S N Date User Verifier s signature Verifier s post Verifier s unit Instructions Each inspection result should be recorded Inspection interval Inspection procedure Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 A B C hours Annually or every 1000 hours A B C D Biennially or every 2000 hours A B C D E Check according to the steps in t
48. ove the fastening bolts of the arrester brake 8 Remove the arrester brake 26 GTJZ0408S amp GTJZ0608S Service Manual 3 2 How to remove the drive motor The drive motor is to drive and fix the front wheels so before dismounting the motor fix the equipment onto an appropriate bracket or place a competent jack under the chassis platform Note While mounting hoses and pipe joints removed you should follow the prescribed torque The cotter pin removed can not be used repeatedly and a new one must be used 1 Remove the front wheel cotter pin which can not be reused 2 Remove the slotted nuts for tire fastening and dismount the front wheel engaged onto the drive motor shaft 3 Label disconnect and plug the hose on the arrester brake device and plug the pipe joint on the drive motor Place the hose aside 5 Loosen the nuts to connect the drive motor and the chassis 6 Remove the nuts Remove the fastening bolts of the drive motor 8 Remove the drive motor SINDBOOM 3 3 How to remove the battery Before removing the battery you must cut off the charger power supply and the complete vehicle power supply Open the right door 2 Label and disconnect the electric wires connected to the battery 3 Remove the battery 217 GTJZ0408S amp GTJZ0608S Service Manual 3 4 How to remove the hydraulic valve block A Caution Hot or spraying hydraulic oil may cause harm to human bod
49. p GTJZ0608S Service Manual speed 18 B 10 Check the hydraulic oil 19 B 11 Check the system of the hydraulic oil tank 19 ventilation Procedure WE 20 C 1 Replace the vent filter of the hydraulic oil tank 20 C 2 Check the weighing system of the platform optional 20 Procedure Doonside 21 D 1 Check the mounting bearings of the scissor DOOM 21 D 2 Check the chassis sliders 21 D 3 Replace the return oil filter of the hydraulic oil tank 21 PILI EEEE 22 E l Check and replace the hydrau EOL EE 22 Repair procedures 23 Platform components 24 1 1 How to remove the platform electronic control box 24 1 2 How to remove the platform 24 1 3 Howto remove the extension Pla OCA eede 24 Scissor boom part 25 2 1 How to dismount the scissor boom as a whole 25 2 2 How to remove the lifting Cy NC a 25 Chassis PariS coeocccaescaindaracssscrancosncocnececss 26 3 1 How to remove the arrester brake 26 3 2 How to remove the drive motor 26 3 3 How to remove the battery27 3 4 How to remove the hydraulic valve block cccceececccceceeeeeeeeeees 27 3 5 How to remove the hydraulic DOWEL E 28 3 6 How to remove the hydraulic On 28 3 7 How to remove the front SINDBDOM wheel steering cylinder 29 3 8 How to remove the front WHEEL M 116216 2 asnersamsarsernenssonntuen 29 Hydrau
50. raulic oil kept at an appropriate level Inappropriate hydraulic oil level may damage the hydraulic components Daily check can make the observer understand the oil level changes and find the hydraulic system problems Note Open the revolving door on the chassis left to execute this procedure Observe the liquidometer on the side panel of the hydraulic oil tank The hydraulic oil level should be up to the FULL level at the top of the liquidometer A 5 Check the hydraulic oil leakage It is very important for safe operation and normal work of the machine to prevent leakage of the hydraulic oil If any existing leakage is not found dangerous situations may occur to weaken the machine performance and damage its parts Observe whether there is any hydraulic oil spill drop or residue on or around the following parts Hydraulic oil tank filter pipe joint oil tube power unit All hydraulic cylinders pumps and manual release valves All hydraulic valve blocks The machine around SINDBDOM A 6 Function test Check the platform and ground controllers It 1s very Important for safe operation of the the emergency stop switch If any function can not machine to test its functions and work properly or the emergency stop switch can not stop all functions unsafe conditions may happen Any function should be working stably and reliably with no shake violent and abnormal noise Detect the grou
51. rcuit voltage as compared in the table below 38 SINDBOOM h heat source during its storage period because the battery itself will discharge the environment and if the battery is stored in the hot proportion or voltage faster under high temperature summer please monitor its more frequently about once every 2 4 weeks Storage in a cold environment lower than OC Never have the battery stored wherever the temperature is expected to reach the freezing point The battery may be frozen at a low temperature if not fully charged It is very important to fully charge the battery if it is stored in the cold winter Troubleshooting The following battery test steps are only used as the guidelines to determine whether the battery needs replacing D Voltage test in time of charging Disconnect and reconnect the DC plug to restart the charger When charging the battery please record the current during the last half hour s charging if possible and measure the battery pack voltage If the current is below 5A at the end of charging and the battery pack voltage is higher than the following values 56V for any 48V system 28V for any 24V system 14V for any 12V battery 7V for any 6V battery then please continue to charge the charger output is correct and recharge the Otherwise please check whether battery as required If the battery pack voltage is still low then the battery may have failed Whe
52. rm D D 1 Check the mounting bearings of the scissor boom D 2 Check the chassis sliders D 3 Replace the return oll filter of the hydraulic oil Record form E E l Check and replace the hydraulic oil SINDBDOM Procedure A A 1 Check each manual It is very important for safe operation to keep the operation manual and maintenance manual at a proper place so such manuals should be stored in the box on the platform special for manual storage Illegible or defective manuals cannot provide and necessary security operation information for safe operation 1 Check and confirm that the storage box is appropriately mounted on the platform 2 Check and confirm that the operation manual and maintenance manual are kept intact in the storage box on the platform 3 Check the manual pages and confirm that the words are clear and intact 4 Put the manual back into the storage box after use If any manual needs to be contact Hunan Sinoboom Heavy Industry Co Itd replaced please 10 GTJZ0408S amp GTJZ0608S Service Manual A 2 Check each label That all security and suggestive labels are well maintained is crucial to the safe operation of the machine The labels will remind the operator of possible dangers during operations and at the same time they will provide users with information about operation and maintenance Illegible labels cannot correctly instruct operators and may cause unsafe operatio
53. sensor and its wiring harness At the same time check and 32 Angle sensor failure All actions l confirm that the correct machine mode has been selected Prior to power connection it prompts Only the failure Confirm that the left turn button has been pressed prior to power connection and 1f not that the platform left turn button has information 1S P P P consider replacing the handle and PCU been pressed Prior to power connection it prompts that the platform right turn button has been pressed LA Prior to power connection it prompts that the platform handle enabled button has been pressed A N Prior to power connection 1t prompts that the handle is no longer in its neutral position displayed Only the failure information 1S displayed Limit the platform action Slow lifting speed 52 Forward solenoid EEN Limit of lifting and Check and confirm that the wire harness connected to the solenoid valve connector has walking been tightly inserted and the solenoid valve has been shorted and broken and Check and confirm that the wire harness connected to the solenoid valve connector has 53 Backward solenoid valve failure Lamit of lifting walking Confirm that the right turn button has been pressed prior to power connection and if not consider replacing the handle and PCU Confirm that the handle enabled button has been pressed prior to power connection and if not consider replacing t
54. speed is very important for safe operation of the machine The driving function should be able to respond to the with no operator quickly and smoothly shaking impact or abnormal noise The machine is parked on a flat and horizontal solid ground free of obstacles 1 Mark two lines on the ground about 12 meters each from the starting point to the end point 2 Switch the key switch to the platform control 3 Have the platform rising about 2m above the ground with the pit protection device enabled 4 Operate the control handle to drive the vehicle from the starting point to the end Result Driving speed of the vehicle 0 8km h 5 Operate the high and low speed selector switch once rabbit symbol push the control handle to its maximum position and drive the vehicle from the starting point to the end Result Low speed driving 0 8km h 17 SINDBDOM B 8 Test the driving speed with the platform fully stowed Reasonable driving speed is very important for safe operation of the machine The driving function should be able to respond to the with no operator quickly and smoothly shaking impact or abnormal noise The machine is parked on a flat and horizontal solid ground free of obstacles 1 Mark two lines on the ground about 12 meters each from the starting point to the end point 2 Switch the key switch to the platform control 3 Have the platform fully contracted with th
55. ss the horn button on the platform controller and it will sound on the chassis to warn the ground staff If the horn has failed the operator will not be able to warn the ground crew of dangers 1 Release the chassis emergency stop switch and switch the platform and key switch to the position for platform control 2 Press the horn button on the platform controller Result The horn will sound B 6 Test the brake devices The correct brake devices are crucial for normal and safe operation of the machine It requires that the brakes should be smooth with no impact or noise This machine brakes by means of its rear wheel brakes The vehicle is idling to stop 1 _ Switch the key switch to the position for platform control 2 Operate the handle to have the vehicle GTJZ0408S amp GTJZ0608S Service Manual running at its maximum speed on an allowable maximum slope 30 and then release the handle as quickly as possible 3 Measure the vehicle braking distance The braking distance should be less than 0 6 meters as required The vehicle must be able to stop on the maximum slope it can climb up 30 and not to fall 4 Let the vehicle fully rising with load and driving on a flat surface at its allowable maximum speed then quickly release the handle and the vehicle stopping distance should be less than 0 2 meters B 7 Test the driving speed with the platform lifted Reasonable driving
56. stance between each slider bottom surface and the mounting shaft center 2 Measure the distance between the fixed end pivot and the bottom mounting plate 3 Compare the difference between the two measurement values of distance 21 GTJZ0408S amp GTJZ0608S Service Manual Result When the thickness difference is greater than 2mm the slider should be replaced D 3 Replace the return oil filter of the hydraulic oil tank It is very important to replace the return oil filter of the hydraulic oil tank for normal operation and longer service life of the machine A dirty or clogged filter may have the machine unable to work properly and continuous use of such filter may cause damages to components Any unusually dirty working environment requires more frequent replacement of the filter A Caution Take care of the hot oil Any contact with the hot oil may cause severe burns this the Implement procedure when hydraulic pump has been shut down 1 Open the chassis left side door and find the return oil filter 2 Place a suitable container under the return oil filter of the hydraulic oil tank 3 Use a special tool to unscrew the return oil filter 4 Coat the new return oil filter gasket with a thin layer of oil film 5 Install the new return oil filter and use a special tool to tighten it 6 Check the filter and related components to ensure no leakage SINDBDOM Procedure E E 1 Check an
57. stem The machine equipped with this system has two display screens located on the chassis ECU control box and the platform control box respectively and used to display the machine parameter data and fault types Display screen of the platform control box 41 GTJZ0408S amp GTJZ0608S Service Manual ZE SINDBDOM GTJZ0408S amp GTJZ0608S Service Manual Fault description and inspection Deltatech system Failure description Action limit Failure inspection Display 01 System initialization failure All actions ECU may have failed and then should be replaced 02 TEE inte All E Check whether the communication cables are well connected If the cables are well y connected replace the ECU and PCU 03 Invalid mode setting failure All actions Set correct machine configuration parameters Prior to power connection the chassis Limit the chassis 12 P e Check whether the chassis swing switch and its wire harness are stuck switch acts earlier actions Limit of lifting and Check whether the pit protection is enabled and check the pit protection switch Check the 18 Pit protection failure M walking pit protection wiring harness and the lower in place detection switch Check the failure of the pressure sensor and its wiring harness At the same time check 31 Pressure sensor failure All actions and confirm that the correct machine mode has been selected Check the failure of the angle
58. t wheel bracket fix the equipment onto an appropriate bracket or place a competent jack under the chassis platform 1 Label disconnect and plug the hose and pipe joints on the hydraulic motor 2 Remove the nuts and gaskets connected with the front wheel steering connecting rod 3 Unscrew the fastening bolts of the front wheel bracket 4 Remove the front wheel bracket Gr SINDBDOM Hydraulic system 4 1 Functional pump detection The pump and motor are connected to form a hydraulic power unit How to check the hydraulic pump The hoses and joints be installed according to the prescribed torque removed must Refer to Chapter 2 Specifications of hose and Joint torques 1 Label and plug the oil outlet hose disconnected from the hydraulic pump e Risk of bodily injuries A Caution The spraying oil may penetrate or burn your skin so slowly loosen the hydraulic connections to relieve the oil pressure slowly Never have the oil spraying out 2 Connect a 0 35MPa pressure gauge to the hydraulic pump outlet 3 Turn the key switch to its ground control position and screw out the emergency stop switch for ground and platform control 4 Let the ground controller drive the Scissor Fork Up button Correct result The pressure gauge reading is 24 8MPa with normal emergency stop and pump functions Incorrect result The pressure value is less than 24 8MPa the pump maintenance or repla
59. than 2 meters GTJZGTJZ0608S The scissor boom is fully retracted and lowered to the minimum height Add a load of 230 kg onto the platform Result When the weight is less than 230 kg the platform can rise to the top normally The scissor boom is fully retracted and lowered to the minimum height Add a load of 275 kg onto the platform Result When the weight is 275 kg the platform can rise no more than 2 8 meters SINDBDOM Procedure D D 1 Check the mounting bearings of the scissor boom Good maintenance of the scissor boom mounting bearings is crucial to safe operation of the machine Continuous use of any old bearing may cause damages to components and unsafe operation This not be shall implemented operation before the scissor boom is fully retracted and lowered to its minimum height 1 Use a plug gauge to measure the shaft and sleeve clearance 2 The sleeve must be replaced if its measurement clearance is greater than 0 1mm or it is damaged D 2 Check the chassis sliders Good maintenance of the sliders is crucial to safe operation of the machine The chassis sliders are located at the friction pairs formed on the U bar surface Inappropriate sliders or use of old sliders continuous may cause damages to components and unsafe operation This operation shall not be implemented before the scissor boom is fully retracted and lowered to its minimum height 1 Measure the di
60. tly inserted and the solenoid valve has been shorted and broken o Eege Check the battery voltage and have it charged Check whether the battery cables are tightly connected D Weight 80 alarm Only alarm deeg load is close to its rated weight and it is recommended that no load could be Weight 90 alarm Only alarm The platform load is rather close to its rated weight and it is recommended that no load could be added The platform load has reached its rated weight and it is recommended that no load could be added Platform overload failure Limit all actions If the platform is overloaded remove the overloaded weight If the machine is tilted never operate before it is leveled If it 1s level check whether the level switch has had its wiring harness reliably connected and confirm whether it has any failure Weight 99 alarm Only alarm Limit of lifting and walking Tilt safety limit failure 43 ZE SINDBDOM GTJZ0408S amp GTJZ0608S Service Manual Troubleshooting of basic failures Failure symptom Failure cause Failure coverage The power indicator doesn t light up The device is not powered on 1 The key switch 1s right in its neutral position 2 The platform or chassis emergency stop switch is in the state of being pressed 3 The platform controller is abnormal or always powered on after any program is downloaded 4 The chassis controller is abnormal or always powered on after any program is downloaded The power indi
61. trongly recommend that maintenance and repair be made in our designated service center Hunan Sinoboom Heavy Industry Co Ltd will make greatest effort to provide you with accurate information and excellent services but continuous improvement on our products should be the policy of Sinoboom so any change of the product technical specifications shall be subject to no early notice Please regularly update your product maintenance manual Hunan Sinoboom Heavy Industry Co Ltd encourages customers to point out the inadequacies of our products and put forward the measures of improvement we will seriously consider all opinions and use as reference for preparation of maintenance manual and other manuals Please contact us by E mail or fax GTJZ0408S amp GTJZ0608S Service Manual SINDBDOM Safety Rules Danger Any disobedience to this Manual and the corresponding operation manual instructions will result in death or serious injuries During implementation of maintenance and repair procedures equal attention shall be paid to the unsafe operations mentioned in the operation manual Do not operate unless gt You understand and follow the safety operation rules in this operation manual gt You should read understand and follow Manufacturer s instructions and safety rules User s safety rules and work site regulations All regulations applicable governmental gt You must have proper to
62. y So before dismounting the hydraulic valve block you should first confirm that the hydraulic oil has cooled Note While mounting the hoses and pipe should follow the prescribed torque referring to Chapter 2 joints removed you Specifications of hose and joint torques 1 Open the door at the side with the valve block mounted 2 Label disconnect and plug the hose and pipe joints on the valve block 3 Unscrew the fastening screws mounted at the bottom of the valve block 4 Remove the valve block Gr SINDBDOM 3 5 How to remove the hydraulic power unit MN E Caution or spraying v oil may cause harm to human body So before dismounting the hydraulic pump you should first confirm that the hydraulic oil has cooled Note While mounting the hoses and pipe should follow the prescribed torque referring to Chapter 2 joints removed you Specifications of hose and joint torques 1 Open the chassis left door at the side with the power unit mounted 2 Label and disconnect the cables on the power unit 3 Label disconnect and plug the hose and pipe joints on the hydraulic pump 4 Unscrew the fastening bolts mounted at the bottom of the power unit 5 Remove the power unit 28 GTJZ0408S amp GTJZ0608S Service Manual 3 6 How to remove the hydraulic oil tank cd IN L Caution or spraying g f oil may cause harm to human body So before dismounting the hydraulic ol tank

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