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Operation and Maintenance Manual

Second Edition

24

Maxiton GTJZ

Fundamentals

It is the responsibility of the Niuli Machiner to perform

delivery prepare.

The inspection is designed to discover before deliver

the machine.

If damage or any unauthorized variation from factory

delivered condition is discovered, the machine must
be tagged and removed from service.

Scheduled maintenance inspections shall be

completed by qualified service technicians,
according to the manufacturer's specifications and
the requirements specified in the responsibilities
manual.

Enchiridion

Use the operator manual when operate the machine.

Delivery prepare contain Pre-operation Inspection,

Maintenance Procedures, Function Tests.

Use the following chart to note result.

Place a check in the appropriate box after each

inspection procedure is completed.

If any inspection receives an “N”, tag and remove the

machine from service, repair and re-inspect it. After
repair, place a check in the “R” box.

Legend
Y = yes, acceptable
N = no, remove from service
R = repaired

Procedure

Y

N

R

Pre-operation
Inspection

Maintenance
Procedures

Function Tests

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Содержание Maxiton GTJZ Series

Страница 1: ...12 14 models This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these i...

Страница 2: ... future printings of this and other manuals If you have any questions please contact Niuli Tel 0086 750 8311618 Fax 0086 750 8382148 E mail niuli chinaniuli com Website www chinaniuli com ADD 33 Nandong Industrical 3rd Park Heshan city Guangdong Province China Contents Important Information 1 Operation of Safety Rules 2 Maintenance of Safety Rules 7 Diagrams 8 Pre operation Inspection 10 Maintenan...

Страница 3: ...derstand and obey all applicable governmental regulations You are properly trained to safely operate the machine Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the followin...

Страница 4: ...the platform is raised use extreme caution to lower the platform Do not alter or disable the limit switches Do not drive over 0 8km h with the platform raised Do not operate the machine in strong or gusty winds Do not increase the surface area of the platform or the load Increasing the area exposed to the wind will decrease machine stability Do not drive the machine on or near uneven terrain unsta...

Страница 5: ...the platform perimeter Do not operate the machine with the chassis trays open Do not use the platform controls to free a platform that is caught snagged or otherwise prevented from normal motion by an adjacent structure All personnel must be removed from the platform before attempting to free the platform using the ground controls Fall Hazards Occupants should wear a safety belt or harness and com...

Страница 6: ...ne in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough per operation inspection of the machine and test all functions before each work shift Immediately tag and remove from service a damaged or malfunctioning machine Be sure all maintenance has been p...

Страница 7: ...ry terminals or the cable clamps with tools that may cause sparks Component Damage Hazard Do not use any battery charger greater than 24V to charge the batteries Electrocution Hazards Connect the battery charger to a grounded AC 3 wire electrical outlet only Inspect daily for damaged cord cables and wires Replace damaged items before operating Avoid electrical shock from contact with battery termi...

Страница 8: ...or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Green used to indicate operation or maintenance information Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging...

Страница 9: ...form entrance door 2 Platform entrance bar 3 Platform of fence 4 Safety belt anchorage 5 Platform extension part 6 Platform extension part release the pedal 7 Steering wheel 8 The ground operation panel 9 Power unit box 10 Fixed the brake wheel 11 Entrance to the stairs 12 Scissor stack ...

Страница 10: ...Change switch Platform control box 1 Emergency stop button 2 Fast and low speed conversion 3 Switch to walk 4 Refer to manuals 5 Display screen 6 Tilt instructions marked 7 Manipulation of the handle 8 Turn Right switch 9 Turn left to the switch 10 Overweight instructions marked 11 Power indicator label 12 Lifting switch 13 The horn switch ...

Страница 11: ...gged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specif...

Страница 12: ...ools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper levels is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydra...

Страница 13: ...Stop button to the on position Test the Up Down Functions The audible warnings on this machine and the standard horn all come from the same central alarm The horn is a constant tone The descent alarm sounds at 60 beeps per minute And the descent alarm sounds at 120 beeps per minute when the platform bellow 3 5m 8 Activate the up function Result The platform should raise 9 Activate the down functio...

Страница 14: ... control handle in the direction identified by the yellow triangle on the control panel Result The steer wheels should turn in the direction that the yellow triangle points on the control panel 26 Depress the thumb rocker switch in the direction identified by the red triangle on the control panel Result The steer wheels should turn in the direction that the yellow triangle points on the control pa...

Страница 15: ...nder a pothole guard Raise the platform Result Before the platform is raised 3 5 m from the ground an alarm should sound and the drive function should not work 42 Lower the platform and remove the 2x4 Workplace Place Inspection You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection...

Страница 16: ...h to ground control 2 Pull out both ground and platform red Emergency Stop buttons to the on position 3 Be sure the battery pack is connected before operating the machine To Position Platform 1 Move the up down toggle switch according to the markings on the control panel Drive and steer functions are not available from the ground controls Operation From Platform 1 Turn the key switch to platform c...

Страница 17: ...dels without chassis counterweight The platform extension limit switch will disable the drive function when the platform is extended and the platform is raised above 26 ft 7 9 m Lower the platform or retract the platform extension to drive the machine Operation From Ground with Controller Maintain safe distances between the operator machine and fixed objects Be aware of the direction the machine w...

Страница 18: ...nt rolling while the machine is being loaded Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight See the serial plate for the machine weight The machine must be on a level surface or secured before releasing the brakes Securing to Truck or Trailer for Transit Always chock the machine wheels in preparation for transport Use the tie down ...

Страница 19: ...repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injur...

Страница 20: ...er pipe and connect the join move the pipe joints and all the wires 4 Arms frame in the whole discharge level 5 Dismantling the lifting oil cylinder then moved away 6 From up to down in each arm between frame removed connecting shaft according to the order put them in order 7 Remove the arm of the frame on the last shock the slider Chassis parts 3 1 Drive Pump Drive pump is a long working power un...

Страница 21: ... hose or at the end of the pipe joints of the O rings 1 Labeling Disconnect and plug for hydraulic hoses hose clipsfittings hydraulic braking device 2 Loosen tire nut 3 The drive speed reducer telescopic shaft placed below a enough ability of jack Don t jacked up machine 4 In the direction of the steel placed at the end of a machine 5 Jacked up machine about 15 cm Will put below support at the ste...

Страница 22: ...ifications hose end Install Size Nm 4 24 4 6 36 6 8 54 2 10 85 4 12 122 16 162 7 20 190 24 223 7 Torque Procedure 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properl...

Страница 23: ...achine damage or malfunction before operating the machine Keep records on all inspections for three years Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the machine in the following configuration 1 Machine parked on a flat level surface 2 Boom in stowed position 3 Ext...

Страница 24: ...livery Prepare Report The delivery prepare report contains checklists for each type of scheduled inspection Make copies of the delivery prepare report to use for each inspection Store completed forms as requested Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual and two year The Scheduled Maintenanc...

Страница 25: ...ding to the manufacturer s specifications and the requirements specified in the responsibilities manual Enchiridion Use the operator manual when operate the machine Delivery prepare contain Pre operation Inspection Maintenance Procedures Function Tests Use the following chart to note result Place a check in the appropriate box after each inspection procedure is completed If any inspection receives...

Страница 26: ...r place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist A Y N R A 1 Manuals A 2 Decals and placards A 3 Damage and loose or missing parts A 4 Hydraulic oil level A 5 Hydraulic leaks A 6 Hydraulic filter condition indicators B 1 Hydraulic tank return filters B 2 Hydraulic tank intake filters B 3 Electrical wiring B 4 Brake configuration B 5 Tires and wheel...

Страница 27: ...gible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Niuli distributor or Niuli if replacement manuals are needed A 2 Inspect the Decals and Placards Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible haza...

Страница 28: ...c oil level should be on the same level of returning oil inlet A 5 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components 1 Inspect for hydraulic oil puddles dripping or residue on or around the following areas Hydraulic ...

Страница 29: ... Result all functions can be operated smoothly 4 Pull out the red Emergency Stop button to the OFF position Result all functions can not be operated As a security feature please give priority to ground control for operation A 8 Test the Tilt Sensor and Alarm The tilt sensor sounds an alarm located in the platform when the incline of the turntable exceeds 3 degree Taking the test at the ground by p...

Страница 30: ...the battery vent caps from both batteries and check the specific gravity of each battery with a hydrometer Result If any battery cell displays a specific gravity of less than 1 086 the battery must be replaced 6 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 7 Install the vent caps Table B Procedures B 1 Replace the Hydr...

Страница 31: ... by hand 4 Inspect the filters and related components to be sure that there are no leaks B 3 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Contact with hot or live ci...

Страница 32: ...from the ground or platform controls 1 Pull out the Emergency Stop button to the ON position at both the ground and platform controls 2 At the ground controls turn the optional switch to the ground position 3 Check any machine function from the ground controls Result The machine functions should operate 4 Check any machine function from the platform controls Result The machine functions should not...

Страница 33: ...n it is working Not before the ground into arms frame to pack up B 10 Test the Horn A functional horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform ...

Страница 34: ... and slowly move the joystick away from the center Result The drive function is executed B 14 Test the drive brake Proper brake function is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range The drive gears o...

Страница 35: ...speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart and two lines on the ground 10 feet 3 m apart 2 Start the machine from the platform controls 3 Press the machine idle select button until the foot switch activated high idle rabbit and foot switch symbol is selected 4 Raise the boom unti...

Страница 36: ...rm over the entire range of motion and check the key parts that may lead to the extended platform jammed Table E Procedures E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty co...

Страница 37: ...urn filter 14 Install the suction tube onto the hydraulic oil tank 15 Fuel to the hydraulic tank to the level of 1 4 every movement of the machine for a cycle then drain the hydraulic oil 16 Fuel to hydraulic tank to the level of 3 4 then cove the cap of the oil tank 17 Close the ground control box at the bottom ...

Страница 38: ...1 Warning 1 2 Model 2 3 Company logo 2 4 Rated load 2 5 Notice be careful foot 4 6 Notice be careful line 2 7 Maintenance schedule 1 8 Warning banned climb 2 9 Maximum pressure heavy 4 10 Notice prevent slipping 1 11 Battery weight 1 12 Notice lock door lock 1 13 Warning no smoking 1 14 Notice handling 4 15 Warning be careful electricity 1 16 Notice pay attention to close to the personnel 1 17 War...

Страница 39: ...d 1800mm 1800mm 2160mm 2285mm 2410mm 2535mm 2895mm Platform L W 1150 600m m 1150 600m m 2260 800m m 2260 800m m 2260 1130m m 2260 1130m m 2930 1650m m Ground clearance 100 20mm 100 20mm 100 20mm 100 20mm 100 20mm 100 20mm 200mm Tires size Φ250 80m m Φ250 80 mm φ381 125 mm φ381 125 mm φ381 127 mm φ381 127 mm φ590 190 mm Weight 540kg 540kg 1900kg 2010kg 2450kg 2580kg 3350kg Motor 24 0 8 V kW 24 0 8 ...

Страница 40: ...Operation and Maintenance Manual Second Edition 39 Maxiton GTJZ Hydraulic and electric layout ...

Страница 41: ...Operation and Maintenance Manual Second Edition 40 Maxiton GTJZ ...

Страница 42: ... Road Blok D2 Ds Banjarsari Buduran Sidoarjo 61252 Indonesia Email salessub01 newleadeng com Tel 6231 990 31338 31 990 31349 Fax 6285 1030 66500 Operation mode Sales Repair Warehousing After Sales MALAYSIA OFFICE Maxiton M Engineering Sdn Bhd Add 18 Persiaran Perusahaan Kledang Utara 1 1 Kawasan Perindustrian Chandan Raya 31450 Ipoh Perak Darul Ridzuan Malaysia Email salesmsia01 newleadeng com Tel...

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