This document is a Maintenance Manual for Sinoboom GTJZ0408S, GTJZ0608S, GTJZ0408M, and GTJZ0608M series machines, which are likely mobile elevating work platforms (MEWPs) or scissor lifts, given the references to platforms, scissor arms, and lifting functions. The manual provides detailed information for operating, servicing, and maintaining these machines, emphasizing safety and proper procedures.
Function Description:
The machines are designed for transporting tools to work locations and performing tasks on a work platform. They are powered by either four 6V batteries in series or a 24V lithium battery, driving a 24V DC motor. A gear pump and motor output shaft provide power to the hydraulic system. The hydraulic system is divided into two parts: one for driving and steering, and the other for platform lifting. When activated, the hydraulic pump sends pressure oil to a function manifold equipped with directional valves for various actions and flow regulating valves for speed adjustment. A relief valve protects components from pressure overload. The electrical system controls machine functions via two controllers: one on the right door of the machine for platform up/down functions, and another on the platform for lift and drive functions. These controllers exchange data through a high-speed data bus. Safety measures include angle sensors and limit switches, with a level sensor measuring the machine's angle on X and Y axes. An alarm triggers and lift/drive/steer functions are limited if the X-axis angle exceeds 1.5 degrees or the Y-axis angle exceeds 3 degrees. A pothole limit switch ensures pothole guards are deployed when the platform rises above approximately 1.5m (4ft 11in); otherwise, the platform stops rising. An optional platform weighing system detects load capacity, triggering an alarm and stopping movement if the load exceeds the rated capacity or a certain height threshold (more than 39 in. (1 m) or 10% of the height that can be lifted).
Important Technical Specifications (for GTJZ0408S/1530S and GTJZ0608S/1930S models, with variations for M models):
Dimension Parameters:
- Max. platform height: 4.6m (15ft 1in) for GTJZ0408S/M, 5.8m (19ft) for GTJZ0608S/M.
- Max. working height: 6.6m (21ft 8in) for GTJZ0408S/M, 7.8m (25ft 7in) for GTJZ0608S/M.
- Max. horizontal extension: 0.9m (3ft) for all models.
- Length: 1.78m (5ft 10.1in) for all models.
- Width: 0.76m (2ft 6in) for S models, 0.81m (2ft 8in) for M models.
- Height (stowed, rails folded): 1.84m (6ft 0.4in) for GTJZ0408S/M, 1.86m (6ft 1.2in) for GTJZ0608S/M.
- Height (stowed, rails up): 2.1m (6ft 10.7in) for GTJZ0408S/M, 2.12m (6ft 11.5in) for GTJZ0608S/M.
- Wheel base: 1.325m (4ft 4.2in) for all models.
- Wheel span: 0.65m (2.14ft) for S models, 0.695m (2.28ft) for M models.
- Ground clearance (pothole guards retracted): 0.07mm (28in) for all models.
- Ground clearance (pothole guards deployed): 24mm (0.95in) for all models.
- Tire size: Φ305×115mm/Solid (Φ12×4.5in./Solid) for all models.
- Platform dimension (Length x Width x height): 1.64m×0.76m×1.1m (5ft 4.6in.×2ft 6in.x3ft 7in) for all models.
- Rated load capacity of platform: 280kg (617 lb) for GTJZ0408S/M, 230kg (507 lb) for GTJZ0608S/M.
- Max. load capability of extended platform: 120kg (265 lb) for all models.
- Max. platform occupancy: 2 persons (indoor only) for S models, 2 persons (indoor)/1 person (outdoor) for M models.
- Drive speed (stowed): 0~3 km/h (0~1.86 mph) for all models.
- Drive speed (raised): 0~0.8 km/h (0~0.5 mph) for all models.
- Uptime (in a no-load state): 15~20 s for all models.
- Downtime (in a no-load state): 28~33 s for GTJZ0408S/M, 25~30 s for GTJZ0608S/M.
- Gradeability: 30% for GTJZ0408S/M, 25% for GTJZ0608S/M.
- Max. allowable inclination: 3°(Front to back)/1.5°(Left to right) for all models.
- Turning radius (inside): 0m (0 ft) for all models.
- Turning radius (outside): 1.49m (4ft 10.7in) for all models.
- Rated load capacity of a single tire: 550kg (1213 lb) for all models.
- Max. allowable manual force: 400N (90 lbf) indoor for S models, 400N (90 lbf) indoor/200N (45 lbf) outdoor for M models.
- Max. noise: 72dB for all models.
Power Parameters:
- Hydraulic tank capacity: 14L (3.1 gal(imperial)/3.7 gal(US)) for all models.
- Hydraulic system capacity (including tank): 14L (3.1 gal(imperial)/3.7 gal(US)) for all models.
- Hydraulic system pressure: 24MPa (3481 psi) for all models.
- Battery specification: 4×6V, 225Ah for all models.
- System voltage: 24VDC for all models.
- Control voltage: 24VDC for all models.
- Drive Hydraulic Motor: Gerotor motor, 300cc/r.
- Functional Valves: Lift relief valve pressure 21MPa (3045Psi), Steer relief valve pressure 12MPa (1740Psi).
- Hydraulic Return Filter: Bypass pressure 0.17MPa (24.56Psi).
Environmental Requirement:
- Max. allowable wind speed: 0m/s (0mph) indoor for S models, 0m/s (0mph) indoor/12.5m/s (28 mph) outdoor for M models.
- Max. allowable altitude: 1000m (3280.8ft) for all models.
- Allowable ambient temperature (lead-acid batteries): -10°C to 40°C (14°F to 104°F) for all models.
- Allowable ambient temperature (lithium batteries): -20°C to 40°C (-4°F to 104°F) for all models.
- Max. allowable ambient relative humidity: 90% for all models.
- Storage condition: Stored at -20°C to 50°C (-4°F to 122°F) in a well-ventilated environment with 90% relative humidity (20°C [68°F]), away from rain, sun, corrosive gas, and inflammable explosive.
- Weight (in a no-load state): 1330kg (2932.5 lb) for GTJZ0408S/M, 1526kg (3365 lb) for GTJZ0608S/M.
Power System Specifications:
- Hydraulic Oil: L-HM46 (Normal temperature region), L-HV32 (Cold region), L-HM68 (Hot region), Special scheme for extremely cold region.
- Hydraulic Pumps: Gear pump, 12 L/min flow rate, 31MPa (4495Psi) maximum driving pressure.
Usage Features:
The manual emphasizes the importance of reading, understanding, and complying with all operation and safety requirements. Only trained and authorized personnel should operate the machine. It is designed for specific tasks and not for general transport or as a crane. Operators must be aware of jobsite conditions, including potential hazards like uneven terrain, strong winds, and live conductors. The machine is not insulated and lacks electric shock protection. Specific warnings are provided for tipping hazards, crush hazards, electrocution hazards, explosion and fire hazards, damaged machine hazards, bodily injury hazards, and battery hazards. Detailed instructions are given for using the ground and platform controllers, including emergency stop functions, lifting/lowering, steering, and driving/braking.
Maintenance Features:
The manual outlines a comprehensive maintenance schedule, including daily, quarterly (every 250 hours), biannual (every 500 hours), and annual (every 1000 hours) inspections. A "Repair & Inspection Report" is provided for documenting maintenance activities.
Key maintenance procedures include:
- Pre-delivery inspection: To identify potential problems before the machine is put into service.
- Inspecting manuals and decals: Ensuring they are legible and present for safe operation.
- Inspecting damaged, loose, or lost parts: Checking electrical components, hydraulic power unit, battery pack, drive motor, brake release valve, tires, limit switches, horn, alarms, fasteners, platform door, pothole guard, pin shafts, and platform sliding block bolts.
- Inspecting hydraulic oil level and leakage: Checking for proper oil levels and any signs of leaks.
- Functional tests: Verifying the proper operation of all switches, emergency stop buttons, lifting/lowering, steering, driving, braking, emergency lowering, tilt protection, and pothole guard.
- Platform weighing system inspection (optional): Checking its functionality if equipped.
- Raised and lowered limit function inspection: Ensuring the platform stops at the correct limits.
- Battery level inspection: Monitoring battery charge using the display indicator and recharging when necessary.
- 30-day maintenance: Specific procedures for new machines after initial operation.
- Inspecting electric wires: Checking for damage or corrosion in various harnesses and junction boxes.
- Inspecting rim, tire, and fasteners: Checking for wear, damage, and proper torque.
- Inspecting battery: Checking connections, electrolyte level (for lead-acid), and charge status. Warnings are provided for electrical shock and bodily injury due to battery acid.
- Inspecting hydraulic oil tank ventilation system: Checking the air filter for cleanliness and proper airflow.
- Inspecting brake manual release function: Verifying proper operation of the manual brake release.
- Replacing hydraulic oil tank air filter: Detailed steps for replacing the air filter.
- Inspecting scissor arm installation bearing: Measuring clearance and replacing if necessary.
- Inspecting chassis slider: Measuring wear and replacing if necessary.
- Replacing hydraulic oil tank return oil filter element: Detailed steps for replacing the filter element.
- Inspecting and replacing hydraulic oil: Procedures for checking oil condition and replacing it.
- Inspecting key structural parts: Checking platform, scissor arm, lift cylinder, chassis, and pothole guard for deformation, cracks, or damage.
- Removing components: Detailed instructions for removing the platform controller, platform, extension platform, scissor arm, lifting oil cylinder, drive motor, front wheel bracket, steering cylinder, brake, and battery.
- Testing and adjusting hydraulic system components: Procedures for testing the function pump, removing the hydraulic power unit and pump, removing the hydraulic oil tank and valve block, installing cartridge valves, and regulating platform lifting and steering overflow valves.
- Trouble Diagnosis (Deltatech System): A comprehensive table of error codes, problems, action limits, and solutions for various system faults, including battery, sensor, motor controller, and load-related issues.
- Electrical Symbols: A list of standard electrical symbols used in the schematic diagrams.
- Battery Use and Maintenance: Detailed guidelines for lead-acid and lithium batteries, including charging, cleaning, filling with distilled water, equalization, storage, and troubleshooting. Specific precautions for high-frequency battery chargers are also included.
The manual emphasizes that all maintenance procedures must be performed by qualified, trained, and competent personnel in a properly equipped workshop. It also stresses the importance of replacing damaged components immediately and never operating a machine with known defects.
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