LGMG A45JE Service Manual
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LGMG A45JE Service Manual

Articulated boom mobile elevating work platform
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Service Manual
A14JE
Articulated Boom Mobile
Elevating Work Platform
△
WARNING
!
Before operation and maintenance, the drivers and
maintenance personnel are required to read this manual
thoroughly. Otherwise, fatal accident may occur. This
manual shall be kept properly for future reference by the
personnel concerned.
LINGONG HEAVY MACHINERY CO.，LTD.

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Summary of Contents for LGMG A45JE

  • Page 1 Service Manual A14JE Articulated Boom Mobile Elevating Work Platform △ WARNING Before operation and maintenance, the drivers and maintenance personnel are required to read this manual thoroughly. Otherwise, fatal accident may occur. This manual shall be kept properly for future reference by the personnel concerned.
  • Page 2 L I N G O N G H E A V Y M A C H I N E R Y C O . , L T D . Add.: 12F, Building 3, Lushang Olympic City, No. 9777, Jingshi Road, Lixia District, Jinan City, Shandong Province, China Tel: 86-0531-67605017 Technical service: 86-4009666569 Web: www.LGMG.com.cn Sales of accessories: 86-0531-67605016...

  • Page 3: Table Of Contents

    1.5 Intended purpose .......................... 5 1.6 Compliance ........................... 5 1.7 Description ............................ 5 Product introduction ........................7 2.1 A45JE（A1408JDTAE30）Machine parameters ................. 9 2.2 Lift platform torque specification ....................10 2.3 Key component moment table ....................13 Service ........................... 15 3.1 Platform assembly ........................17 Assembling the file box .....................
  • Page 4 Service manual of Articulated Boom Mobile Elevating Work Platform Removing the jib assembly ....................23 Removing the fly jib cylinder ..................... 23 Assembling the swing cylinder, the fly jib cylinder and the jib ......... 24 3.4 Cable carrier assembly ....................... 27 Removing the cable carrier ....................
  • Page 5 Service manual of Articulated Boom Mobile Elevating Work Platform Bleeding steering cylinder ....................52 Bleeding folding jib luffing cylinder ................. 52 Bleeding main boom luffing cylinder and lower leveling cylinder ........53 Bleeding main boom telescopic cylinder ................ 53 Bleeding fly jib luffing cylinder and upper leveling cylinder ..........53 Bleeding platform swing cylinder ..................
  • Page 6 Service manual of Articulated Boom Mobile Elevating Work Platform Drive speed limit test ......................80 Braking distance test (at slow speed)................81 Drive enable system test ....................81 Gradeability test（30%） ....................81 Operation time test ......................82 Lifting height test ......................83 Load test (1.1 times) .......................

  • Page 7: Foreword

    Service manual of Articulated Boom Mobile Elevating Work Platform Foreword You are welcome to purchase and use the products produced by Lingong Heavy Machinery Co., Ltd. This manual introduces the technical parameters and maintenance adjustment data of Articulated Boom elevating work platform, and explains the troubleshooting and maintenance process for reference by qualified professional maintenance professionals.

  • Page 8: Safety Notices

    Service manual of Articulated Boom Mobile Elevating Work Platform Safety Notices The operator shall understand and abide by the current national and local safety regulations. If such regulations are not available, the safety instructions in this manual shall prevail. Most of the accidents are caused by failure to comply with the regulations on the operation and maintenance of the machine.

  • Page 9: Safety And Environment

    Service manual of Articulated Boom Mobile Elevating Work Platform Safety and Environment...
  • Page 10 Service manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 11: Terms And Definitions

    Service manual of Articulated Boom Mobile Elevating Work Platform 1.1 Terms and definitions Administrator: The entity or individual that directly controls the use and application of the lifting platform, which usually refers to the owner, the renter or the authorized personnel of owner who obtains the control right of the lifting platform;...

  • Page 12: Maintenance And Repair Safety Specification

    Service manual of Articulated Boom Mobile Elevating Work Platform Please ensure that the forklift, crane or other lifting or supporting equipment are strong enough to support and stabilize the weight to be lifted. During repair, please do not reuse disposal fastener (such as cotter pin and self-locking nut), so as to avoid abnormal functioning due to reuse of such parts.

  • Page 13: Intended Purpose

    Service manual of Articulated Boom Mobile Elevating Work Platform Protect the vehicle body to prevent splashing and fire; Operate in strict accordance with the welding process; Precautions of the battery maintenance Battery run-out is strictly prohibited during storage. It is strictly prohibited to keep the battery in the run-out status during storage.
  • Page 14 Service manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 15: Product Introduction

    Service manual of Articulated Boom Mobile Elevating Work Platform Product introduction...
  • Page 16 Service manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 17: A45Je（A1408Jdtae30）Machine Parameters

    Service manual of Articulated Boom Mobile Elevating Work Platform 2.1 A45JE（A1408JDTAE30）Machine parameters Machine performance parameters Parameter/de Parameter/d Item Item scription escription Rotary table rotation time per circle Rated load (kg/lbs) 230/510 95-125 (stowed) (s) Rotary table rotation time per circle...

  • Page 18: Lift Platform Torque Specification

    Service manual of Articulated Boom Mobile Elevating Work Platform Rated power（KW） 3.56 Rated speed（r/min） 3400 Rated voltage (V) Rated current (A) 71.32 Functional motor Rated power（KW） Rated speed（r/min） 2650 Output voltage (V) Battery Capacity (Ah) 390 (20-hour discharge rate) Nominal AC input voltage (V) 100-240AC Maximum AC input current (A) Charger...
  • Page 19 Service manual of Articulated Boom Mobile Elevating Work Platform 1-1/16-12 UN(F) 1-5/16-12 UN(F) 1-5/8-12 UN(F) 1-7/8-12 UN(F) 7/16-20 UN(F) 1/2-20 UN(F) 9/16-18 UN(F) 3/4-16 UN(F) 7/8-14 UN(F) EO-S 1-1/16-12 UN(F) 1-5/16-12 UN(F) 1-5/16-12 UN(F) 1-5/8-12 UN(F) 1-7/8-12 UN(F) Description: Table 1 gives the torques for metric-threaded joints and inch-threaded joints, and Table 2 gives the torques for UN-threaded joints, and for those torques, an error of 10% is allowed;...
  • Page 20 Service manual of Articulated Boom Mobile Elevating Work Platform Description: For torques given in Table 3, an error of 10% is allowed; The torque values given in Table 4 are based on the condition that the connected part is made of steel, and for connected part made of aluminum, the tightening torque equal to 60% of the corresponding torque in Table 3 shall apply and shall be rounded to the nearest integer after calculation;...

  • Page 21: Key Component Moment Table

    Service manual of Articulated Boom Mobile Elevating Work Platform Tightening torque N· m 928～ 450～530 540～680 670～880 900～1100 1237 1160～ 550～700 680～850 825～1100 1120～1400 1546 1559～ 714～952 969～1293 1319～1759 1694～2259 2079 2923～ 952～1269 1293～1723 1759～2345 2259～3012 3898 4111～ 10.9 1400～1650 1700～2000 2473～3298 2800～3350...
  • Page 22 Service manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 23: Service

    Service manual of Articulated Boom Mobile Elevating Work Platform Service...
  • Page 24 Service manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 25: Platform Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform Assembling the foot switch 3.1 Platform assembly Assembling the file box 1. Foot switch 2. Screw 3. Nut 4. Washer 1) Assemble part 1 with part 2/3/4 to the 1. Platform frame 2. File box 3. Bolt 4. Washer 5. assembling position at the bottom of the platform frame, and tighten the screws.

  • Page 26: Assembling The Arc Shield

    Service manual of Articulated Boom Mobile Elevating Work Platform 1) Install part 1 with part 2 (from top to bottom) Assembling platform 3/4 to the mounting position on the platform assembly control unit of the platform frame assembly. Note: The protective mount opening is towards the inside of the platform frame.

  • Page 27: Assembling The Load Cell

    Service manual of Articulated Boom Mobile Elevating Work Platform Assembling the load cell Assembling the swing motor mounting bracket 1. Load cell 2. Bolt 3. Washer 4. Nut 5. Triangle bracket assembly 6. Tumbler adjustment leg 1) Install part 1 with part 2/3 (nut end)/4 to part 1.

  • Page 28: Assembling The Anti-Collision Rubber Pad

    Service manual of Articulated Boom Mobile Elevating Work Platform Assemble part 1 with part 2 (from bottom to part 2), adjust the perpendicularity between top)/3/4 to the platform frame, and tighten it. the platform and the fly jib, and after the 2) Connect the PCU harness to part 1 firmly.

  • Page 29: Removing The Rear Axle Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform front axle securely. If not supported correctly by the sling, the rear axle may fall off due to the loss of △ ! CAUTION: Risk of crushing. balance. Removing the wheels With the wheels removed, the front axle Unscrew the wheel nuts, but do not remove could fall off due to the loss of balance.

  • Page 30: Removing The Motor

    Service manual of Articulated Boom Mobile Elevating Work Platform Lift the tire with the crane, and adjust the the motor may fall off due to the loss of angle of tire to make the tire bolt holes balance. coincident with the axle assembly bolts. Removing the reducer assembly 2) Push in the tire horizontally and make it fit closely.

  • Page 31: Removing The Jib Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform Sprayed hydraulic oil can penetrate and the hose and harness fixed to the jib. △ burn the skin. Therefore, please loosen the ! CAUTION: Risk of part damage hydraulic fitting connection very slowly to If being kinked or squeezed, the cable reduce the oil pressure gradually.

  • Page 32: Assembling The Swing Cylinder, The Fly Jib Cylinder And The Jib

    Service manual of Articulated Boom Mobile Elevating Work Platform Assembling the swing cylinder, hydraulic fitting connection very slowly to the fly jib cylinder and the jib reduce the oil pressure gradually. Do not spray or eject the oil. Remove fasteners lower connecting frame assembly and the lower link pin.
  • Page 33 Service manual of Articulated Boom Mobile Elevating Work Platform Tools: electric impact wrench (SATA 51082); socket wrench 1/2-10mm. 1. Cushion block 2. Bolt 3. Washer 1) Assemble the cushion block, use part 2/3 to 1. Shaft 2. Safety pin 3. Bolt 4. Washer 5. Nut install part 1 to the assembly position at front 6.Shaft 7.Bolt end of upper link, and tighten the bolt.
  • Page 34 Service manual of Articulated Boom Mobile Elevating Work Platform 4) Lift the subassembled jib assembly to the mounting position of telescopic boom, connect the telescopic boom to the lower connecting bracket assembly with part 1, and fix it with part 2/3 (coated with threadlock)/4/5. 5) Use part 6 to connect the upper leveling cylinder with the lower connecting bracket 7) Arrange the oil pipe and harness at the fly jib...

  • Page 35: Cable Carrier Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform wrench 1/2-16mm; QSP100N4; QSP25N4. △ WARNING: Risk of crushing 3.4 Cable carrier assembly Removing the cable carrier If not properly fixed, the upper and △ lower cable carriers may become CAUTION: unbalanced and fall during removal from the The O-ring (if any) of the removed fitting machine.

  • Page 36: Assembling The Cable Carrier

    Service manual of Articulated Boom Mobile Elevating Work Platform Assembling the cable carrier 1) Arrange the oil pipes and harnesses under the support plate, then install clip rubber strips (coated with threadlock) at both ends of part 1, and then fix part 1 with part 2/3/4 (the insertion direction of the bolt is shown in the figure).

  • Page 37: Boom Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform Reference tightening torque of part 5: 12± 2. The O-ring (if any) of the removed fitting 1N• m; and/or hose assembly must be replaced. Tools: open-end ratchet wrench 10 During installation, all connections must be tightened to specified torque.

  • Page 38: Assembling The Boom Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform reduce the oil pressure gradually, and do 3) Use fasteners to fix the pins on the right side of the machine (the safety pin fixing bolts are not spray or eject the oil. 9) Remove the fixing fasteners on the right side coated with AT262 threadlock).

  • Page 39: Subassembling The Boom Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform Subassembling boom 5) Assemble part 4 onto the right inner side of assembly the upper pivot, and fix it with part 5/6/7/8. Note: 1. In this step, the travel switch roller faces to the right;...
  • Page 40 Service manual of Articulated Boom Mobile Elevating Work Platform 4) Remove the slider bolt, then apply 242 1) and apply 242 threadlock to the bolt ends. threadlock, and fix the slider again; Note: The bolt penetrates from the riser (part Reference tightening torque of part 4: 23±...

  • Page 41: Hydraulic Tank

    Service manual of Articulated Boom Mobile Elevating Work Platform 1. Bolt 2. Washer 3. Nut 4. Telescopic cylinder the boom after installation. 14) Clamp the front end of part 4 inside the stop block, and assemble part 3 onto the limit plate at the front end of the boom with part 1/2.

  • Page 42: Removing The Hydraulic Tank

    Service manual of Articulated Boom Mobile Elevating Work Platform performing this procedure must be clean. If 1) Assemble part 2 to the hydraulic tank debris enters the hydraulic system, serious damage may be caused to the components. weldment body. Therefore, it is recommended that this 2) Install the oil suction filter into the hydraulic service is performed by dealers.

  • Page 43: Cylinder Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform and put a label on the machine to inform 1) Lift the telescopic boom to a horizontal related personnel. position. 6) Mark, disconnect and plug the hose. 2) Lift the folding jib until the pin at the barrel 7) Remove the hydraulic tank from the machine.

  • Page 44: Assembling The Boom Luffing Cylinder

    Service manual of Articulated Boom Mobile Elevating Work Platform Assembling the boom luffing △ WARNING: Risk of crushing cylinder During removal of the boom luffing cylinder pin, the boom will be lowered if it is not supported properly. 8) Retract the link end of the boom luffing cylinder into the cylinder.

  • Page 45: Removing The Boom Telescopic Cylinder

    Service manual of Articulated Boom Mobile Elevating Work Platform 2. Pin 3. Safety pin 4. Bolt 5. Washer damage. Therefore, strongly 3) Install the link end of part 1 to the boom, tap recommended that this service is performed part 2 in, and secure it with part 3/4/5. by dealers.

  • Page 46: Removing The Lower Leveling Cylinder

    Service manual of Articulated Boom Mobile Elevating Work Platform Note: 1、 Pay attention to the length of cylinder after removal. The mounting spacing of cylinders must be the same. 2、 For the assembling method of the boom 1. Washer 2. Pin 3. Retaining ring telescopic cylinder, refer...

  • Page 47: Assembling The Lower Leveling Cylinder

    Service manual of Articulated Boom Mobile Elevating Work Platform During installation, all connections must be Assembling the lower leveling tightened to specified torque. Please refer to cylinder the specification for selection of tightening torque of the lifting platform. 1) Lift the articulated boom until it can come into contact with the link end and barrel end pivots of the lower leveling cylinder.
  • Page 48 Service manual of Articulated Boom Mobile Elevating Work Platform 2) Place the cushion block under the platform 7) Carefully pull the cylinder out of the boom. for support, and lower the boom until the platform rests cushion block supporting the platform. Note: Do not completely lower the boom on the cushion block.

  • Page 49: Articulated Boom Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform 3.8 Articulated boom assembly 1. Upper 2nd jib assembly (1# jib) 6. Articulated boom cylinder 2. Upper 1st jib assembly (2# jib) 7. Lower 2nd jib assembly (4# jib) 3. Lower 1st jib assembly (3# jib) 8.

  • Page 50: Removing The Articulated Boom Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform Removing the articulated boom pressure gradually. Do not spray or eject the assembly oil. △ ! CAUTION: Risk of personal injury 7) Remove the pin fasteners at both ends of the articulated boom lift cylinder, and do not This procedure requires specific service remove pin.
  • Page 51 Service manual of Articulated Boom Mobile Elevating Work Platform 15) Remove the 1# jib from the machine. pivot may fall off due to loss of balance when the 2# jib is removed from the machine. △ ! WARNING: Risk of part damage 23) Connect the sling from the overhead crane to the 2# jib at the upper pivot end.

  • Page 52: Assembling The Articulated Boom Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform 44) Remove the 2# jib from the machine. △ ! WARNING: Risk of crushing △ ! WARNING: Risk of crushing If not properly supported, the 2# jib may fall off due to loss of balance when the link is If not properly supported by the crane, removed from the 2# jib.

  • Page 53: Removing The Articulated Boom Lift Cylinder

    Service manual of Articulated Boom Mobile Elevating Work Platform sealant) on the right side of the machine to fix Reference tightening torque of part 3: 90± 9N• m; Tools: QSP100N4; open-end ratchet wrench 10; socket wrench 1/2-18mm. Note: 1. Confirm visually instead of by hands whether the mounting holes are aligned, and do not stand in front of the boom;...

  • Page 54: Assembling The Articulated Boom Lift Cylinder

    Service manual of Articulated Boom Mobile Elevating Work Platform with a copper hammer. △ ! WARNING: Risk of personal injury 7) Remove the articulated boom lift cylinder from the machine. Removal requires specific maintenance 8) Remove the cylinder on the other side in skills, lifting equipment and a suitable the same way.

  • Page 55: Rotary Table Swing Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform cylinders are at the outside, and should be removed hose assembly and/or fitting must be passed from back to front. replaced. During installation, all connections Reference tightening torque of part 3: 52± must be tightened to the specified torque.

  • Page 56: Assembling The Slewing Drive Assembly

    Service manual of Articulated Boom Mobile Elevating Work Platform 3) Remove slewing drive assembly Lowering the rotary table mounting fastener 2. 4) Carefully remove the slewing drive assembly from the machine. △ ! WARNING: Risk of crushing properly supported overhead crane, the rotary table rotation assembly may fall off due to loss of balance 1.

  • Page 57: Assembling The Horn

    Service manual of Articulated Boom Mobile Elevating Work Platform the battery box assemblies, and secure the cover with butterfly nuts. Assembling the horn 1. Nut 2. Mono cone horn 1) Turn off the power of the whole machine, open the hood on the right side of the machine, assemble part 2 with part 1 to the horn fixing plate and tighten it, and connect part 2 to the harness plug.

  • Page 58: Valve Group

    Service manual of Articulated Boom Mobile Elevating Work Platform 3.11 Valve group Installing the spool 1. Immerse the spool in clean oil to lubricate the O-ring. 2. Manually screw in the spool until it reaches the top of the O-ring, and then adjust the torque to meet specification requirements.
  • Page 59 Service manual of Articulated Boom Mobile Elevating Work Platform Description Function of valve spool Torque (Nm) Solenoid valve Controlling oil circuit connection 27.1 Solenoid valve Controlling oil circuit connection 27.1 Maintaining back pressure to prevent the load from free Balance valve 40-45 fall Solenoid valve...

  • Page 60: Bleeding Cylinder

    Service manual of Articulated Boom Mobile Elevating Work Platform 3.12 Bleeding cylinder slowly 5 times in area A; Step 2: Operate the machine so that the Bleeding function pump piston rod of the steering cylinder moves 1. After each cylinder is replaced, it is necessary slowly twice in the minimum (C) and to carry out bleeding.

  • Page 61: Bleeding Main Boom Luffing Cylinder And Lower Leveling Cylinder

    Service manual of Articulated Boom Mobile Elevating Work Platform Bleeding folding jib luffing cylinder Bleeding main boom luffing cylinder and lower leveling cylinder Bleeding main boom telescopic cylinder Bleeding fly jib luffing cylinder 1. Activate the main boom luffing lifting button to bleed the main boom luffing cylinder and and upper leveling cylinder lower leveling cylinder;...
  • Page 62 Service manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 63: Maintenance

    Service manual of Articulated Boom Mobile Elevating Work Platform Maintenance...
  • Page 64 Service manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 65: Compliance And Obedience

    Service manual of Articulated Boom Mobile Elevating Work Platform Check that each page of the manual is 4.1 Compliance and Obedience identifiable and in good condition. The operator can only perform routine Put the manual in the storage file box after maintenance items as specified in this use.

  • Page 66: Check The Hydraulic Oil Level And Leakage

    Service manual of Articulated Boom Mobile Elevating Work Platform platform, and check for incorrect installation performed when the platform is in the retracted state or missing parts and components, including:  Park the vehicle on the flat site.  Fully retract the boom. and hydraulic cylinders -resistant pads and wheels...

  • Page 67: Checking The Battery

    Service manual of Articulated Boom Mobile Elevating Work Platform the swing gearbox at intervals of 100 hours. It is fully charge the battery and stay the battery necessary for maintaining performance and still for at least 6h (preferably 24h). maintenance life to lubricate the turntable △...

  • Page 68: Check The Wires

    Service manual of Articulated Boom Mobile Elevating Work Platform Result: the specific liquid gravity of each Under the rear cover of chassis: motor battery is greater than 1.277 after the control unit, main contactors adjustment. Fully charge the battery and turn to Step 9.

  • Page 69: Check The Tires And Wheels

    Service manual of Articulated Boom Mobile Elevating Work Platform Remove all rings, watches or other accessories. △ Caution: In the event of any damage, the contactor should be replaced. Figure 1-1 Traveling slowdown 1. Oil filler 2. Viewing port 4.10 Check the Tires and ...

  • Page 70: Visual Inspection Of The Hydraulic Oil

    Service manual of Articulated Boom Mobile Elevating Work Platform ③ Carefully clean the tank exhaust cover with 4.14 Platform weighing structure mild solvent and dry it with low pressure lubrication compressed air. Repeat Step 2. Install the exhaust cover of the hydraulic oil tank. This operation is performed every 500 hours or 4.13 Visual Inspection of the every six months, whichever comes first.

  • Page 71: Replace The Reducer Gear Oil

    Service manual of Articulated Boom Mobile Elevating Work Platform component damage. The filter should long service life. Failure to change the gear oil each year result performance replaced more frequently degradation and continuous operation may extremely dirty working conditions. result in component damage. △...

  • Page 72: Regular Maintenance

    Service manual of Articulated Boom Mobile Elevating Work Platform service life of the machine. Dirt or a clogged filter cause performance degradation hydraulic components, and continuous use will cause damage to components. In dirty work environments it is necessary to increase the change intervals.

  • Page 73: Fault Code Of Li-Battery

    Service manual of Articulated Boom Mobile Elevating Work Platform 4.20 Fault code of Li-battery Displayed Troubleshooting Fault code Fault description Restricted actions information suggestions BMS FLT=1/10 BMS FLT=1/10 Low SOC 1 The buzzer sounds Charge The buzzer sounds, boom BMS FLT=2/11 BMS FLT=2/11 Low SOC 2 lifting is restricted, but...
  • Page 74 Service manual of Articulated Boom Mobile Elevating Work Platform The buzzer sounds, boom Stop charging, BMS FLT=2/32 BMS FLT=2/32 Charge overcurrent 2 lifting is restricted, but charge again lowering is allowed The buzzer sounds, and all Stop charging, BMS FLT=3/33 BMS FLT=3/33 Charge overcurrent 3 actions are restricted...
  • Page 75 Service manual of Articulated Boom Mobile Elevating Work Platform Stop charging period of time, and wait The buzzer sounds, boom until temperature High charge BMS FLT=2/55 BMS FLT=2/55 lifting is restricted, but drops to a reasonable temperature 2 lowering is allowed temperature, such 25°...

  • Page 76: Routine Inspection And Maintenance Intervals

    Service manual of Articulated Boom Mobile Elevating Work Platform manufacturer Stop discharging The buzzer sounds, boom Large discharge charge, and if there is BMS FLT=2/77 BMS FLT=2/77 lifting is restricted, but voltage difference 2 any fault, contact the lowering is allowed manufacturer Stop discharging...
  • Page 77 Service manual of Articulated Boom Mobile Elevating Work Platform Check the position of the limit switch rocker ● arm and if it is wired loosely Check if the motor is ● wired normally Check if buttons on the ● ground control panel operate normally Check if the warning ●...
  • Page 78 Service manual of Articulated Boom Mobile Elevating Work Platform Change the reducer First 150h, thereafter every 1,000h or every year, whichever comes first. gear oil Replace the return oil Every 500h or every six months, whichever comes first. filter element Check if the attached documents are complete, easy to...

  • Page 79: Commissioning

    Service manual of Articulated Boom Mobile Elevating Work Platform Commissioning...
  • Page 80 Service manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 81: Safety Instructions

    Service manual of Articulated Boom Mobile Elevating Work Platform regulations and the instructions in the table 5.1 Safety instructions below to maintain a sufficient safety distance Before commissioning, please make sure to from wires, power supplies, and electrical refer to the Operation and Maintenance Manual, equipment.

  • Page 82: Machine Inspection

    Service manual of Articulated Boom Mobile Elevating Work Platform Control criteria: 4≤A≤5mm 5.2 Machine inspection 2. Check the gap between the left and right Pick-up inspection covers and the counterweight 1. Check the machine to be tested: basic information, appearance of the machine, configuration of the machine, oil and water volume, electrical components, etc.;...

  • Page 83: Basic Test

    Service manual of Articulated Boom Mobile Elevating Work Platform Turntable Swing control handle 5.3 Basic test 10. Horn button Start test 11.Speed regulation switch 12. Auxiliary power button switch 1. If the emergency stop switch of the GCU is pressed, and the enable button and the control button are toggled, the machine will not run;...
  • Page 84 Service manual of Articulated Boom Mobile Elevating Work Platform Short arm lifting/lowering test GCU panel The jib will rise if the jib lift switch is moved 1. Platform leveling button upwards; the jib will drop if the jib lift switch is moved downwards.

  • Page 85: Basic Operation Test Of Platform Control Unit

    Service manual of Articulated Boom Mobile Elevating Work Platform completed, the buttons and switches shall be returned to their positions. Auxiliary power switch Turn the key switch to "GCU"; pull the red "emergency stop" button outward to "ON"; move the auxiliary power switch to either side, repeat Second arm rod all the above operations until all operations can lifting/lowering test...
  • Page 86 Service manual of Articulated Boom Mobile Elevating Work Platform Platform leveling test The platform level will rise if the platform Foot switch leveling switch is moved upwards; the platform After the machine is started, the key is level will drop if the platform leveling switch is turned to "PCU", and the foot switch is moved downwards.

  • Page 87: Hydraulic Oil Level Test

    Service manual of Articulated Boom Mobile Elevating Work Platform Second arm rod lifting/lowering test 1) The machine will be driven forward if the right The articulated boom will rise if the control lever is moved upwards; the machine articulated boom lift switch is moved upwards; will be driven backward if the right control the articulated boom will drop if the articulated lever is moved downwards...

  • Page 88: Travel Speed (High Speed) Test

    Service manual of Articulated Boom Mobile Elevating Work Platform emergency stop switch to the “OFF” position, 2. When the center of the front wheel of the pull open the rubber hook under the right machine passes the 20m/65.6ft test line, turn cover by hands, open the right cover, and off the power switch and let the machine stop snap the support rod into the rubber groove.

  • Page 89: Braking Distance Test (At Slow Speed)

    Service manual of Articulated Boom Mobile Elevating Work Platform Conduct timing in one of the three arm rod moves over one non-steered wheel states. For other two states, determine (in both directions); that the speed limit function can be Control criteria: the drive indicator light is on achieved under specific conditions;...

  • Page 90: Operation Time Test

    Service manual of Articulated Boom Mobile Elevating Work Platform Control criteria: the machine climbs to the Control criteria:26S-30S. top normally, the tires do not slip and the 5. Press the enable button and the second arm machine does not tip over. rod lift switch (up) at the same time to lift the During downhill driving, apply the brake to folding jib and start timing simultaneously;...

  • Page 91: Lifting Height Test

    Service manual of Articulated Boom Mobile Elevating Work Platform start the platform rotary switch in the opposite Load test (1.25 times) direction, rotate the platform and start timing Place a load 1.25 times the rated load simultaneously; when the platform is rotated (287.5Kg) on the lifting platform, and to the rightmost side, stop rotating and timing.

  • Page 92: Boom Pressure Test

    Service manual of Articulated Boom Mobile Elevating Work Platform Boom pressure test Articulated boom pressure test Remove the pressure measuring port plug Remove the pressure tap plug (red of the control valve and install the pressure indication) of the control valve and install the tap;...

  • Page 93: Slewing Pressure Test

    Service manual of Articulated Boom Mobile Elevating Work Platform and slewing of articulated lifting the lift relief valve; restore the rocker arm to platform around it. the normal position. 2. The laser range finder shall be placed on △ CAUTION: a flat ground;...
  • Page 94 Service manual of Articulated Boom Mobile Elevating Work Platform overflow pressure value, and the pressure value should be recorded. Control criteria: 235 bar ± 10 bar. 4) In case of inconsistency with the control criteria, do correction as follows: Unscrew the fastening nut of the lift relief valve, and rotate the valve spool clockwise or counterclockwise with the Allen wrench to increase...

  • Page 95: Appendix

    Service manual of Articulated Boom Mobile Elevating Work Platform Appendix...
  • Page 96 Service manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 97: System Fault Code

    Service manual of Articulated Boom Mobile Elevating Work Platform 6.1 System fault code Display Error code Description and solution EVERYTHING OK 0/0 Normal GROUND MODE ACTIVE!,0/0 Ground mode STARTUP!,0/0 Startup MOVING PLATFORM!,0/0 Moving platform MOVING JIB!,0/0 Moving jib SWINGING!,0/0 Swinging TELESCOPING!,0/0 Telescoping LIFTING!,0/0...

  • Page 98: Diagram Of Common Hydraulic Part Symbols

    Service manual of Articulated Boom Mobile Elevating Work Platform 6.2 Diagram of common hydraulic part symbols (1) Hydraulic pump, hydraulic motor and hydraulic cylinder Name Symbol Description Name Symbol Description Hydraulic General Detailed pump symbol symbol Non- One-way adjustable One-way rotation, one-way fixed...
  • Page 99 Service manual of Articulated Boom Mobile Elevating Work Platform motor fixed displaceme One-way One-way flow, one- variable Telescopic displaceme rotation, nt hydraulic variable motor displaceme Two-way One-way flow, two- variable One-way displaceme rotation, action nt hydraulic variable Gas-liquid motor displaceme converter Two-way Swing...
  • Page 100 Service manual of Articulated Boom Mobile Elevating Work Platform Simplified Weight- symbol loaded type Detailed Single Spring type symbol piston rod cylinder (with return Simplified Auxiliary gas cylinder spring) symbol Plunger rod Gas tank Hydraulic Telescopic General pressure cylinder symbol source Detailed Air pressure...
  • Page 101 Service manual of Articulated Boom Mobile Elevating Work Platform Electro- Hydraulic hydraulic external Bounce pilot control, mechanism pressure internal oil control drainage Internal pressure Ejector rod control, type Hydraulic internal oil pilot drain pressure External relief Variable pressure control travel control (with control type remote relief...
  • Page 102 Service manual of Articulated Boom Mobile Elevating Work Platform Double- acting Button type electromag Single- acting adjustable electromag netic Button type operation (proportiona electromag net) Double- acting adjustable Press-pull electromag type netic operation (torque motor, etc.) Rotary motion Handle type electrical control device...
  • Page 103 Service manual of Articulated Boom Mobile Elevating Work Platform The control External channel is pressure outside the control original (3) Pressure controller Pilot General proportional symbols or solenoid Relief valve direct- pressure acting relief reducing valve valve Pressure Proportional Pressure Pilot relief reducing pressure...
  • Page 104 Service manual of Articulated Boom Mobile Elevating Work Platform valve Pilot Double pressure overflow reducing brake valve valve Brake valve Relief Overflow oil pressure bridge reducing brake valve valve (4) Directional control valve Two- position Detailed five-way symbol hydraulic valve Check Check valve...
  • Page 105 Service manual of Articulated Boom Mobile Elevating Work Platform check valve electro- leakage (with hydraulic manual valve emergency control device) Three- Throttling position Detailed type, four-way symbol overlapped proportional center valve Shuttle Or gate valve valve Three- position Simplified Underlapped four-way symbol center...
  • Page 106 Service manual of Articulated Boom Mobile Elevating Work Platform valve Temperatur Non- adjustable General compensat Simplified throttle symbol ed flow symbol valve regulating valve One-way One-way flow Simplified throttle regulating symbol valve valve Double one-way Flow divider throttle valve valve One-way Stop valve flow divider...
  • Page 107 Service manual of Articulated Boom Mobile Elevating Work Platform Magnetic General Cooler filter symbol Filter with Cooler Cooler to bypass the coolant valve pipeline P1: oil inlet General Duplex filter P2: oil Heater symbol return Galvanomet Pressure er (liquid indicator flow indicator) Pressure...

  • Page 108: Diagram Of Common Electrical Part Symbols

    Service manual of Articulated Boom Mobile Elevating Work Platform Flexible coupling (10) Pipeline, pipeline joints and connectors Pressure The two pipeline and Cross pipelines are Pipeline return pipeline crossed and pipeline unconnected pipelines Control Flexible intersected Pipeline pipeline Pipeline pipeline connected It can represent...
  • Page 109 Service manual of Articulated Boom Mobile Elevating Work Platform Three-level Normally isolating open switch button Normally Three-level closed load switch button Combination Composite Button knob switch button Low voltage Emergency circuit breaker stop button Controller or Key- operating operated switch button Coil operating Thermal...
  • Page 110 Service manual of Articulated Boom Mobile Elevating Work Platform Undercurre nt coil Normally open contact which Normally open Instantaneousl contact y closed Normally closed contact Normally which is closed instantaneousl contact y disconnected Normally open contact which Overvoltag is closed with e coil delay Normally...
  • Page 111 Service manual of Articulated Boom Mobile Elevating Work Platform Separately Electromagneti excited DC c clutch motor Electromagneti Shunt DC c brake motor Series DC Solenoid valve motor Speed relay normally open Fuse Fuse Non- contact electricity- Single- controlled Pressure relay phase relay normally open...
  • Page 112 Service manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 113: Wire Harness Number Description

    Service manual of Articulated Boom Mobile Elevating Work Platform 6.4 Wire harness number description Main harness...

  • Page 114: Platform Wire

    Service manual of Articulated Boom Mobile Elevating Work Platform Platform wire...
  • Page 115 Service manual of Articulated Boom Mobile Elevating Work Platform Wire size Function Colour Wire size Function Colour Load power P101 PCU power supply supply P104 Load ground wire Black P1401 Foot switch White P102 Signal 1+ White P411 Workbar swing White P103 Signal 1-...

  • Page 116: Schematic Diagram

    Service manual of Articulated Boom Mobile Elevating Work Platform 6.5 Schematic diagram Electrical schematic diagram...

  • Page 117: Hydraulic Schematic Diagram

    Service manual of Articulated Boom Mobile Elevating Work Platform Hydraulic schematic diagram...

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