Elevated Access Sinoboom GTJZ0407SE Maintenance Manual Download

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GTJZ0407SE

Maintenance Manual

0800 222 111 [email protected]
021 500 486 www.elevatedaccess.co.nz

Summary of Contents for Sinoboom GTJZ0407SE

Page 1: ...GTJZ0407SE Maintenance Manual 0800 222 111 sales elevatedaccess co nz 021 500 486 www elevatedaccess co nz ...

Page 2: ...orm 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 load 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 Beari...

Page 3: ...ystem27 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 Troubleshooting39 5 4 Electrical Symbols 42 5 5 Electrical Schematic Diagram Deltatech System 43 GTJZ0407SE Maintenance Manual ...

Page 4: ... Pay attention to the unsafe operations mentioned in 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 Manufacturer s instructions and safety rules User s safety rules and workplace regulations All the applicable government regulations You ...

Page 5: ...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 condition Do not use disposable fasteners...

Page 6: ...erson 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 f...

Page 7: ...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 180bar Traveling deceleration motor Voltage 24V Speed ratio 47 1 Power 450W Valve Pressure of function main safety valve 180bar 2 GTJZ0407SE Maintenance Manual ...

Page 8: ...7 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 n...

Page 9: ...ving pump controlled DC motor and traveling drive motor controlling scissor arm up 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 ...

Page 10: ...n 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 Lock the tires Description This section provides detailed operation procedures for the regular maintenance and inspection The procedure includes description safety warning and step description...

Page 11: ... 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 Ever...

Page 12: ...or according to the provisions of this Manual 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 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 ...

Page 13: ...aired 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 ...

Page 14: ...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 9 GTJZ0407SE Maintenance Manual ...

Page 15: ...rator properly and might result in unsafe operation 1 Consult to the label section in the GTJZ0407SE Operation Manual and determine the correct 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 If needing to replace the labels please contact with Hunan SINOBOOM Heavy Industry Co Ltd A 3 ...

Page 16: ...idual marks on or around the following components Hydraulic oil tank pipe fittings oil pipe power unit All hydraulic cylinders and pumps All hydraulic valve blocks The area around the machine A 6 Functional Tests Inspect Platform and Ground Controller Testing functional switches and emergency stop buttons of machine is of great importance to the safe operation of the machine If any function could ...

Page 17: ...rrying out this operation it is necessary to charge the battery fully Description of battery level Display of electric quantity for platform Proportio n Description 90 100 The battery has been fully charged 70 70 of the battery capacity 50 50 of the battery capacity 30 30 of the battery capacity 20 The batter level is low and the battery must be re charge d 10 The battery level is very low and the...

Page 18: ... Power unit harness Ground controller junction box Platform controller junction box 2 Inspect the flexile joints and confirm that the joints have not become loosened and the sensor lines have not been damaged B 2 Inspect Rim and Tire Including Mounting Nuts Good maintenance of rims and tires is great importance to the safety The machine might tip over if the rim or the tire has problems The compon...

Page 19: ...It would put the personnel working on the ground and the platform in danger The ground controller shall precede over the platform controller including emergency stop buttons 1 Release the emergency stop button of lower and upper platforms and turn the key switch to the ground control position 2 Press the emergency stop button on the ground operation panel Result All actions of the machine become i...

Page 20: ...latform control position 3 The platform is lifted about 2m away from the ground and the pit protective device is turned on 4 Operate the control handle and drive the vehicle from start point to end point Result Run at the speed of 0 5km h 5 Move the high low speed selection switch tortoise symbol once push the control handle to the maximum position and drive the vehicle from start point to end poi...

Page 21: ...sed further It is necessary to often replace the hydraulic oil when the service environment is very dirty Before replacing the hydraulic oil it is necessary to inspect the hydraulic oil to confirm whether it needs to be replaced See Procedure E 1 for replacement steps B 11 Inspect Ventilation System of Hydraulic Oil Tank Good ventilation of hydraulic oil tank cap is of great importance to the norm...

Page 22: ...lied to the platform Result For weight is 288kg raising height of the platform is not more than 2 meters Procedure D D 1 Inspect Scissor Arm Installation Bearing Good maintenance of scissor arm installation bearing is of great importance to safe operation of the machine Sustained use of an old bearing may cause damage of parts and unsafe operation situations v The operation shall be executed when ...

Page 23: ... suction pipe 4 Disconnect and plug the return oil pipe 5 Remove the fastening bolt from the hydraulic oil tank 6 Remove the oil tank from the machine 7 Remove the oil suction filter from oil tank and clean with appropriate detergent 8 Wash the inside of the oil tank with appropriate detergent and dry the hydraulic oil tank in the air 9 Install the hydraulic oil tank on the machine 10 Install the ...

Page 24: ... 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 information Platform Components 1 1 How to Remove Electric Control Box from Platform Touching live line might lead to death or serious injuries Take down all ear rings wrist wat...

Page 25: ...re located on both sides of the extended platform to fasten the idler wheels 4 Loosen the fixing bolts from the baffle plate on the fixed platform and remove the baffle plate 5 Uplift the extended platform from the front end and the rear end Put it aside Scissor Arm Part 2 1 How to Remove Scissor Arm The operation shall be executed when the scissor arm is in fully retracted state 1 Remove platform...

Page 26: ...ability shall be placed below the chassis platform before removing the traveling motor Attention When installing the removed rear wheel the rear wheel must contact well with the joint key on the traveling motor shaft The key must be replaced if it is damaged 1 Remove the cover plate of the rear wheel 2 Remove self locking nuts for fixing the tire and the rear wheel on the traveling motor 3 Remove ...

Page 27: ...pump it is necessary to confirm that the hydraulic oil has cooled down When installing the previously removed hoses and fittings it is necessary to tighten with specified torque Refer to Page 6 Installation Instructions for Hydraulic Hoses and Fittings 1 Open the right door of the chassis on the side of installing the power unit 2 Label and disconnect the cables on the power unit 3 Label disconnec...

Page 28: ...ions for the Installation of Hydraulic Hose and Hose Nippler Risk of physical injury The oil that is jetted out will penetrate or burn the skin Loosen the hydraulic connector slowly to drain off the oil pressure slowly and prevent the oil from jetting out 1 One 0 35MPa pressure gauge is installed on the port M of pressure measuring point of power unit 2 Turn the key switch to the position of platf...

Page 29: ...clamp for oil tank seam allowance and protect the oil tank 5 Remove the screws on oil tank and avoid scratching the oil tank 6 Level and remove the plastic oil tank and protect the inner wall of oil tank seam allowance from being damaged 7 Remove the oil return pipe 8 Remove the oil inlet pipe assembly with filter screen of gear pump 9 Remove the gear pump two screws with flat washers on opposite ...

Page 30: ...tall the solenoid coil of the valve on the valve rod install the coil nut properly and tighten as per specified torque if necessary Name Position Function and Tightening Torque of Valves No Name Function Tightening Torque 1 3 position 4 way solenoid valve Left right turn 9Nm 2 2 position 2 way solenoid valve Lifting 34 Nm 3 Pressure measuring connector Measuring pressure 4 Main overflow valve Syst...

Page 31: ...be damaged and lead to death or serious injury Do not adjust the pressure value to be higher than the specified value 6 Repeat steps 4 5 to determine the pressure values How to regulate the emergency descent lever How to regulate the descending speed manually 1 Lift the platform for 2 1 2 8m 2 Erect the safety rod 3 Descend the platform and support the scissors fork arm with the safety rod Risk of...

Page 32: ...s of Hydraulic System Filter Power unit Overflow valve Three position four way solenoid directional valve Manual lowering release valve Directional valve for lifting One way valve 27 GTJZ0407SE Maintenance Manual ...

Page 33: ...4 5 Hydraulic Schematic Diagram GTJZ0407SE Hydraulic Schematic Diagram Optional Overweight sensor Lifting cylinder Overweight sensor Steering cylinder 28 GTJZ0407SE Maintenance Manual ...

Page 34: ...iably the terminal posts may get damaged molten or catch fire if the connection is too tight or too low Do not put any object on the battery for avoiding short circuit The wet lead acid battery will release little gas in the process of use particularly in the charging process thus it is necessary to charge the battery in a well ventilated place Always keep the battery vertical The electrolyte in t...

Page 35: ...ixed solution of sodium bicarbonate and water Do not let the cleaning solution enter the battery Clean with water and wipe dry with cloth Apply a thin layer of petroleum jelly or use terminal protector Keep the area around the battery clean and dry e Battery Charging Proper charging is the prerequisite for maximizing the battery performance Insufficient or excessive charging may shorten the servic...

Page 36: ...lowing table for the charging state specific gravity and open circuit voltage Percentage Charging Specific Gravity Open circuit Voltage Battery Cell 6V 12V 100 1 277 2 122 6 37 12 73 90 1 258 2 103 6 31 12 62 80 1 238 2 083 6 25 12 50 70 1 217 2 062 6 19 12 37 60 1 195 2 040 6 12 12 24 50 1 172 2 017 6 05 12 10 40 1 148 1 993 5 98 11 96 30 1 124 1 969 5 91 11 81 20 1 098 1 943 5 83 11 66 10 1 073 ...

Page 37: ... system 14V for 12V system or 7V for 6V system proceed to the next step Otherwise inspect whether the output of the charger is correct and re charge the battery as required If the voltage of the battery rack is still very low the battery may have troubles Measure the voltage of individual battery when the battery is in charging state If the voltage of any battery is lower than the following value ...

Page 38: ...he charger output is subjected to unexpected short circuit the charger will turn off the output automatically after the trouble has been eliminated the charger will re start charging with 10s delay Charging indication The yellow indicator lamp will be lit up when charging the green indicator lamp will be lit up after charging and the red indicator lamp will be lit up if the battery has trouble Cha...

Page 39: ...ECU control box Display screen of the control box on the upper platform 34 GTJZ0407SE Maintenance Manual ...

Page 40: ...machine mode has been selected 32 Angle sensor trouble All actions Inspect the harness of the angle sensor and the angle sensor Meanwhile check to verify whether correct machine mode has been selected 42 Left turn button of platform has been pressed before powering on Only displaying trouble information Confirm whether the turn left button is pressed down before energizing if not please consider r...

Page 41: ...tor has been inserted tightly and meanwhile inspect whether the solenoid valve is short circuited or open circuited 57 The left turning solenoid valve breaks down Lifting and traveling Inspect whether the harness connected to the solenoid valve connector has been inserted tightly and meanwhile inspect whether the solenoid valve is short circuited or open circuited 61 Current sensor error of motor ...

Page 42: ...eck the wiring of the main contactor If the wiring is correct replace the contactor Replace the motor controller if necessary 72 Over voltage error of motor controller All actions Check the battery voltage and whether the battery charger is charging Then restart the machine If the issue fails to be solved try to replace the motor controller 73 Reduced heat error of motor controller All actions The...

Page 43: ...inal and make sure they are tightened If they are check the coil itself for open or short circuit 83 Coil error of right brake Lifting and traveling Check the wiring of the coil terminal and make sure they are tightened Check the coil itself for open or short circuit 90 Alarm of weight 90 Only alarming The platform load is very close to the rated weight It is recommended not to increase the load 9...

Page 44: ...the drawing 3 Inspect whether the upper platform plug or the plug of connecting cable between upper and lower platforms is in good contact 4 Inspect whether the upper platform controller is abnormal 5 Inspect whether the Deltatech plug of lower platform controller is firm or correct Operation of lower platform is invalid The key switch has not been turned to the operation of lower platform 1 The k...

Page 45: ... firmly 2 Inspect whether the wiring of plug switch is abnormal 3 Re calibrate the height 4 Inspect whether the connection of the lead of lifting valve is wrong and whether the lifting valve is abnormal The platform could not be lifted to the maximum position when it is no load indoors The height has not been calibrated the travel switch is incorrect 1 Re calibrate the height 2 Change the setting ...

Page 46: ...ning The level switch is abnormal 1 The level switch air bubble is not in the middle position 2 The level switch is connected in properly or is not inserted firmly 3 The lower platform controller is abnormal No overload warning The load has not been calibrated or the height is incorrect 1 The sensor has not been calibrated 2 The wiring of load sensor is wrong 3 The sensor is not in good condition ...

Page 47: ...orage battery Toggle switch Fuse Pump controlled motor Charger Power off switch Hour meter Limit switch Buzzer Warning lamp Key switch Two circuits are connected Two circuits are not connected Level switch 2 12V Battery Pump controlled motor Blue Brown Black 42 GTJZ0407SE Maintenance Manual ...

Page 48: ...High status Left brake Low status Travelling activation Fault Indicator Speed reduction 1 Speed reduction 2 Bus connector Enable Lifting speed Travelling speed Travelling activation Forward Reverse External power source socket Charger plug Leakage switch Warning light Relay Electric meter Rising to proper place Loweri ng to proper place Implem entation of testing Up Down Blue Black Brown Red Red Y...

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