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LGMG AR20J Maintenance Manual

Articulated boom mobile elevating work platform
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Maintenance manual
AR20J
Articulated Boom
Mobile Elevating Work Platform
△
WARNING
!
Before operation and maintenance, the
drivers and service personnel shall
always read and thoroughly understand
all information in this manual. Failure to
do so may result in, fatal accidents or
personal injury.
This manual must be kept with this
machine at all times.
LINGONG HEAVY MACHINERY CO., LTD.

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  • Page 1 Maintenance manual AR20J Articulated Boom Mobile Elevating Work Platform △ WARNING Before operation and maintenance, the drivers and service personnel shall always read and thoroughly understand all information in this manual. Failure to do so may result in, fatal accidents or personal injury.
  • 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: F12, Building 3 LushangGuoao Plaza, 9777 Jingshi Road,Lixia District, Jinan, Shandong, 250000,China Tel: 86-0531-67605017 Technical service: 86-0531-67605017 Web: www.LGMG.com.cn Sales of accessories: 86-0531-67605016...

  • Page 3: Table Of Contents

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Contents Foreword ..................... II Safety Notices .................... III Chapter 1 Maintenance ................1 1.1 Observing the Regulations ..............3 1.2 Inspection Manual ................3 1.3 Check Labels and Decals ..............3 1.4 Every Day or Every 8 Hours .............

  • Page 4: Foreword

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Foreword You are welcome to purchase and use the lifting platform produced by LINGONG HEAVY MACHINERY CO., LTD. This machine is designed according to AS/NZS 1418.10:2011+A1:2017. This manual introduces the maintenance and other aspects of the mobile elevating work platform. Getting the best out of your machine is a goal that we pursue together with you, depending on how familiar you are with it and how carefully and thoroughly it is maintained.

  • Page 5: Safety Notices

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Safety Notices Operators should understand and follow the current national and local safety regulations, and use the safety instructions in this manual if there are no corresponding regulations. Most accidents are caused by the user's violation of the regulations on machine operation and maintenance.
  • Page 6 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 7: Chapter 1 Maintenance

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Chapter 1 Maintenance...
  • Page 8 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform...

  • Page 9: Observing The Regulations

    Mobile Elevating Work Platform △ 1.1 Observing the CAUTION: If the manual needs to Regulations be replaced, please contact the LGMG You are properly trained and qualified to service personnel. operate and maintain the machine safely. 1.3 Check Labels and Decals...
  • Page 10 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform  Hydraulic hose, joint, valve block, hydraulic when the arm rod is in the stowed cylinder position.  Fuel and hydraulic tank  Park the machine on a flat ground. The arm rod shall retract to the stowed position.
  • Page 11 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform and protective gloves must be worn. each operation. At the same time, pay attention to the sealing and lubricating  The leakage of high-pressure oil may not oil pressure, and then check the be visible to eyes.
  • Page 12 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Pull out the oil measuring rod and read the operating the equipment. Repair the value of engine oil level. leakage immediately. The engine oil level shall always be 1.4.5 Check for Engine Air Filter between MIN and MAX! Check the maintenance indicator for the air filter Fill up to the maximum liquid level if...

  • Page 13: Every 100 Hours

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform The cooling system is under pressure! The 1.5 Every 100 Hours cover can only be opened in the cooling state. 1.5.1 Slewing Bearing and Slewing Coolant must have a specified concentration of Gear Lubrication cooling system protectant! Fill the slewing bearing and slewing gear with...

  • Page 14: Every 250 Hours

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform ② Ventilation check. △ CAUTION: If there is too much Result: air can pass through the vent cap. dust in the working environment, Result: if the air cannot pass through the vent increase frequency filling...
  • Page 15 △ ! NOTE: If an external power supply is required to charge the battery, only the charger approved by the LGMG can be used. Hydrometer  Do not replenish the battery with Figure 1-5 Battery Hydrometer white eyes. Replace the battery.
  • Page 16 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform tighten lock nut 5 and tighten fixing bolt 6 AR20J 595± 55N.m  Measure the backlash between slewing 1.6.4 Check the Clearance Between the bearing gear and slewing reducer gear Slewing Bearing and the Slewing again to verify that requirements are met.
  • Page 17 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform  Turn the wheel so that the plug 4 is in the △ highest position, and partially loosen it to CAUTION: To drain or fill oil and release the pressure that may exist. check the oil level, the drive axle must ...
  • Page 18 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform 1.6.8 Check the Oil Level of the 30° C < Minimum 85W/140 Slewing Reducer temperature -10° C < Minimum This inspection is carried out every 250 hours or 85W/90 temperature <30° C Gear quarterly, whichever comes first.
  • Page 19 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform 7 to 9 mm under load of 10 kg 1.6.11 Cleaning or Replacement of Air Filter Clean it every 250 hours or quarterly and replaced it for every 1000 hours or every year, whichever comes first.
  • Page 20 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Screw off the Primary element (4) and the Secondary element (3). Install the new Secondary element. Install the filter element (4), place the outer cover (2) and fix it with the hooking clip. 1.7 Every 400 Hours 1.7.1 Replacement of Engine Oil and Filter...
  • Page 21 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform drain plug and screw in and tighten it. engine oil level. Add engine oil at the engine oil filler. It is available in the first 50 hours, and the engine oil and filter shall be replaced every 400 Warm up and run the engine.
  • Page 22 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform and burning tobacco. -E3. A qualified fire extinguisher shall be △ placed in an easily accessible place. The engine must be shut down! Clean the Fuel Pre-filter No smoking and open fires! Clean the fuel filter every 100 hours operation to prevent dust from entering.

  • Page 23: Every 500 Hours

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Clean the sealing surface of the filter holder pressure filter element every 500 hours or half a with a clean fiber-free wiper. year, whichever comes first. Apply a thin layer of diesel to the seal ring The replacement of the hydraulic filter is of the new filter.
  • Page 24 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform ⑤ Install the main return pipe and plug. installation. ⑥ Use marker note marker note replacement date Filter replacement date on the Filter Replacement Replacement Record. Record. Use GCU to operate any arm rod function. ⑦...
  • Page 25 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform △ or every six months, whichever comes first. Please observe the safety An appropriate tightening of fasteners is regulations for engine oil and relevant essential for the safe operation of the machine, local regulations.
  • Page 26 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Figure 1-23 1. Oil filter 2. Remove with a filter wrench (Tighten with your hand) The engine oil filter element must also be replaced every time the engine oil is replaced. Release and unscrew the filter element with a wrench.
  • Page 27 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform △ △ Risk of explosion and fire. Where Please observe the safety there is fuel leakage, prevent any regulations for fuel and relevant local irrelevant personnel from entering the regulations. Dispose of spilled fuel and area and strictly prohibit operating the filter elements in accordance with equipment.
  • Page 28 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform the fuel system, exhaust the system, Remove the old water separator filter with a perform the trial operation and check filter wrench. the seal performance. Apply a film of oil to the gasket for the new Replace the fuel filter cartridge with a water separator filter.

  • Page 29: Every 1000 Hours

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform 1.9 Every 1000 Hours 1.9.1 Replacement of Hydraulic Tank Air Filter Replace the hydraulic tank air filter every 1000 hours or every year, whichever comes first. Park the machine on a level ground. Remove the old air filter and replace it with a new air filter.

  • Page 30: Every 2000 Hours

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform  plug to release the possible pressure. Place a suitable container under the transfer box. Rotate the wheel so that the drain plug 4 is  in the lowest position and place a suitable Remove the plug 1、2 and drain oil.
  • Page 31 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Place a suitable container under the △ hydraulic tank. In a dusty working environment, Remove the drain plug from the hydraulic this step should be performed more tank. frequently. Completely drain the hydraulic oil from the Replace hydraulic oil and suction filter hydraulic tank into a suitable container.
  • Page 32 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Coolant must have a specified concentration of cooling system protectant! Please observe the safety regulations for coolant and relevant local regulations. Dispose of the spilled coolant as specified, without leaving it on the ground. Never run the engine without coolant, even if it's a very short time.

  • Page 33: Scheduled Maintenance

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform lower than the local minimum temperature. 1.11 Scheduled maintenance Quarterly, annual biannual maintenance items must be performed by personnel who have been trained in the maintenance of this machine and have obtained corresponding qualifications.

  • Page 34: Engine Fault Table

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform 1.12 Engine Fault Table V2403-E3 Fault Cause Measures Check the fuel tank and fuel filter. Remove water, dust and other impurities. Because all fuel will be filtered by the fuel Thick fuel hard to flow filter, if there is water or other foreign matter in the fuel filter, please clean the fuel filter with kerosene.
  • Page 35 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Valve leaks. piston and bushing are excessively worn, leading to insufficient compression. Replace them with new ones. Grind the valve. Insufficient fuel Check the fuel system. Check the lubricating oil system. Check whether the lubricating oil filter works properly.
  • Page 36 Check whether the clearance of engine bearings is within the factory specifications. Damaged fuel regulating device Contact the service personnel of LGMG. Choose quality fuel. Inferior fuel Please use No. 2-D diesel only. If necessary, replace the nozzle with a Damaged nozzle new one.
  • Page 37 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform V2403-CR-E5 Fault Cause Measures Check the fuel tank, and remove water, dirt and other impurities. Fuel is thick and doesn't flow. Check the fuel filter cartridge and replace it if necessary. When it is difficult to start the Use oils of different viscosities, depending engine...
  • Page 38 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Check pressure switch. Check filter base gasket Engine warning lamp lights up. Consult your KUBOTA Dealer DPF service lamps light up Consult your KUBOTA Dealer Engine oil insufficient Check oil level. Replenish oil as required Fan belt broken or elongated Change belt or adjust belt tension Coolant insufficient...

  • Page 39: Engine Fault Codes

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform 1.13 Engine fault codes V2403-E3 item DTC set parameter Inspection Despite rpm，oil pressure Oil Pressure Error Oil pressure switch switch is on Overheat of engine water Engine water temperature Engine overheat ≥110 °C temperature Voltage of coolant...
  • Page 40 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Speed sensor pulse Engine speed sensor pulse Less than correct gear tooth 523740 abnormal abnormal number CAN Communication 523774 CAN bus CAN bus off Abnormal Emergency stop CAN signal Emergency stop Emergency stop switch into ECU +B disconnection before key...
  • Page 41 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform V2403-CR-E5 DTC Description Inspection Item DTC Set Parameter Large phase shift between NE Phase difference between (crankshaft position sensor) pulse NE-G Phase Shift NE pulse and G pulse within and G (camshaft position sensor) +30 ~-20°...
  • Page 42 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform No.1 Cylinder Injector Harness open circuit; Harness or injector coil open Harness/Coil Open Circuit Injector coil open circuit circuit No.3 Cylinder Injector Harness open circuit; Harness or injector coil open Harness/Coil Open Circuit Injector coil open circuit circuit No.4 Cylinder Injector...
  • Page 43 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform below 0.08 V DOC inlet temperature Exhaust Gas Temperature Sensor Sensor/harness open or shorted sensor (T0) voltage: 4765 0: High to +B above 4.92 V The battery voltage identified Harness open circuit, short circuit by the ECU in the 12 V Battery Voltage: Low or damage;...
  • Page 44 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform error recovery operations Accelerator Position Sensor 1: Sensor/harness shorted to ground Accelerator position sensor or open 1 voltage below 0.3 V Accelerator Position Sensor 1: Short circuit to ground outside Accelerator position sensor High sensor/harness 1 voltage below 4.8 V...
  • Page 45 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Intake throttle lift sensor Intake Throttle Lift Sensor: Low Intake throttle lift sensor low voltage: 523582 below 0.151 V Intake throttle lift sensor Intake Throttle Lift Sensor: High Intake throttle lift sensor high 523582 voltage: above 4.848 V DOC is heated up due to...
  • Page 46 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Error CAN ETC5 CAN_ETC5 communication CAN ETC 5 frame timeout 523595 (Neutral Switch) Frame Error interruption No “C1 cache" request initiated for 3 consecutive CAN_TSC1 communication CAN TSC1 Frame Error times after the override 523596 interruption control request (non-0x00) is...

  • Page 47: Maintenance Point

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform 1.14 Maintenance Point 1.14.1 Routine Inspection and Maintenance Intervals Maintenance Routine Level 1 Level 2 Level 3 Level 4 Level 5 100h level inspection maintenance maintenance maintenance maintenance maintenance Maintenance Every day 100h 250h 500h...
  • Page 48 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform element times generally. Change coolant Every 2000h or every two years, whichever comes first. Check the fixing of the battery terminals ● ● ● ● and apply grease to the electrodes (if necessary) Re-tighten the drive ●...
  • Page 49 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform extruded or broken. Check whether the wiring of angle sensor and length Every day sensor, tilt sensor and weighting sensor are firm Check the rotary table slewing limit switch rocker arm Every day and if it is wired loosely...
  • Page 50 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Check whether the oil pipe fixing clip is Every day loose hydraulic oil Check the oil level of Rando MV32 Every day hydraulic tank when oil level is below "M" position Visual inspection of Check quarterly hydraulic oil...
  • Page 51 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Check whether the structural parts of the whole machine have Every day cracks and whether the weld is open weld Check whether the paint of the whole vehicle falls off and whether there is Every day serious rust,...
  • Page 52 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform 1.14.3 Machine Lubrication Location Qty. The lubricating point for tire steering The slewing lubrication points of the front and rear axles The lubricating point of the drive shaft The lubricating point for slewing bearing Slewing bearing and slewing gear contact surface Platform weighing structure lubrication...

  • Page 53: Chapter 2 Schematic Diagram

    Maintenance Manual of Articulated Boom Mobile Elevating Work Platform Chapter 2 Schematic Diagram...
  • Page 54 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform...
  • Page 55 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform AR20J Hydraulic schematic diagram...
  • Page 56 Maintenance Manual of Articulated Boom Mobile Elevating Work Platform AR20J Electrical schematic diagram (V2403-E3)

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