LGMG T72J Service Manual
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LGMG T72J Service Manual

Telescopic boom mobile elevating work platform
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Service Manual
T72J
Telescopic boom Mobile
Elevating Work Platform
△
WARNING
!
Operators
and
maintenance
personnel
must
read
and
understand this manual before
operating and maintaining this
machine, otherwise it may lead to
casualties! This manual shall be
properly kept for reference and
check by relevant personnel.
LINGONG HEAVY MACHINERY CO., LTD.

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Summary of Contents for LGMG T72J

  • Page 1 Service Manual T72J Telescopic boom Mobile Elevating Work Platform △ WARNING Operators maintenance personnel must read understand this manual before operating and maintaining this machine, otherwise it may lead to casualties! This manual shall be properly kept for reference and check by relevant personnel.
  • 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 . Address: Floor 12, Building 3, Lushangguo Aocheng, No. 9777, Jingshi Road, Lixia District, Jinan City, Shandong, China. Tel: 86-0531-67605017 Web: www.lgmg.com.cn Technical service: 86-4009666569 Parts sales: 86-0531-67605016...

  • Page 3: Table Of Contents

    Service Manual of Telescopic boom Mobile Elevating Work Platform Contents Contents ..............................II Foreword ..............................VI Safety notices ............................VII Chapter I Safety and environment ......................1 Terms and definitions ........................3 Compliance ............................3 Before starting the repair ........................3 Requirements for work site .......................
  • Page 4 Service Manual of Telescopic boom Mobile Elevating Work Platform 3.3.11 Removal of upper leveling cylinder ....................22 Cable carrier assembly ........................23 3.4.1 Assembly of cable carrier ....................... 23 3.4.2 Removal of cable carrier......................... 24 Boom frame assembly ........................26 3.5.1 Assembly of boom frame ........................
  • Page 5 Service Manual of Telescopic boom Mobile Elevating Work Platform 3.10.1 Lowering and assembly of rotary table ..................47 3.10.2 Lowering and assembly of center slewing joint ................47 3.10.3 Lowering and assembly of slewing reducer ................. 48 3.10.4 Removal of slewing reducer ......................48 3.10.5 Assembly of slewing mechanism guard plate ................
  • Page 6 Service Manual of Telescopic boom Mobile Elevating Work Platform 4.2.16 Large rated load (450) test ......................68 4.2.17 Settlement test ..........................68 4.2.18 Lifting height test .......................... 69 4.2.19 Operation time test ........................69 4.2.20 Driving speed (high speed) test ....................71 4.2.21 Braking distance test ........................

  • Page 7: Foreword

    Foreword Thanks for purchasing the products produced by Lingong Heavy Machinery Co., Ltd. This Manual introduces the technical parameters and maintenance and adjustment data of T72J straight-arm lifting platform, and explains the troubleshooting and repair process for qualified maintenance personnel.

  • Page 8: Safety Notices

    Service Manual of Telescopic boom Mobile Elevating Work Platform Safety notices Operators shall understand and abide by the current national and local safety provisions. If there are no national or local provisions, the safety instructions in this manual shall apply. Most of the accidents are caused by failure to comply with the operation and maintenance regulations of machine.

  • Page 9: Chapter I Safety And Environment

    Service Manual of Telescopic boom Mobile Elevating Work Platform Chapter I Safety and environment...
  • Page 10 Service Manual of Telescopic boom Mobile Elevating Work Platform...

  • Page 11: Terms And Definitions

    Service Manual of Telescopic boom Mobile Elevating Work Platform 1.1 Terms and definitions Administrator: the entity unit or individual who directly controls the use and application of the lifting platform, usually the owner, the lessor or the owner's trustee who obtains the control rights.

  • Page 12: Maintenance And Repair Safety Specification

    Service Manual of Telescopic boom Mobile Elevating Work Platform 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. Please dispose of the discarded fluid correctly in an environmentally friendly way. 10.

  • Page 13: Intended Purpose

    Service Manual of Telescopic boom Mobile Elevating Work Platform water. Please wait until the water cools down before opening the radiator cap. 1.6 Intended purpose This machine is only intended for lifting personnel and their tools and materials to the high-altitude work site.
  • Page 14 Service Manual of Telescopic boom Mobile Elevating Work Platform...

  • Page 15: Chapter Ii Product Introduction

    Service Manual of Telescopic boom Mobile Elevating Work Platform Chapter II Product introduction...
  • Page 16 Service Manual of Telescopic boom Mobile Elevating Work Platform...

  • Page 17: Machine Parameters

    Service Manual of Telescopic boom Mobile Elevating Work Platform 2.1 Machine parameters T72J(T2218J0WND4AH2000) Machine performance parameters Item Parameter/description Item Parameter/description Rotary table rotation time per 300kg/6611bs 78-86 cycle (stowed) (s) Rated load 2 persons +140 kg/3091 bs Rotary table rotation time per...
  • Page 18 Service Manual of Telescopic boom Mobile Elevating Work Platform Gear ratio 57.49：1 Rated output torque (N • 1690 Slewing reducer Gear ratio 36.13：1 Hydraulic system Item Parameter/description Type Closed system Pump displacement (ml/r) Walking system Max. working pressure (MPa/psi) 28/4061 Motor displacement (ml/r) Type Open system...

  • Page 19: Specification And Tightening Torque Of Nuts And Bolts

    Service Manual of Telescopic boom Mobile Elevating Work Platform M22X1.5 G1/2A M27X2.0 G3/4A M33X2.0 M42X2.0 G11/4A M48X2.0 G11/2A Table 2:Tightening torque of UN-threaded fittings and plugs (unit: N•m) Non-adjustable Non-adjustable Product series Thread UN/UNF assembly torque N•m assembly torque N•m 7/16-20 UN(F) 1/2-20 UN(F) 9/16-18 UN(F)
  • Page 20 Service Manual of Telescopic boom Mobile Elevating Work Platform M14X1.5 M16X1.5 M16X1.5 M18X1.5 M18X1.5 M20X1.5 M22X1.5 M22X1.5 M26X1.5 M24X1.5 M30X2 M30X2 M36X2 M36X2 M45X2 M45X2 M52X2 M52X2 Note: Al error of + 10% is allowed for the torque in Table 2; The torque value in Table 3 is determined according to the fact that the connected part is made of steel.

  • Page 21: Chapter Iii Repair

    Service Manual of Telescopic boom Mobile Elevating Work Platform Chapter III Service...
  • Page 22 Service Manual of Telescopic boom Mobile Elevating Work Platform...

  • Page 23: Description

    Service Manual of Telescopic boom Mobile Elevating Work Platform service center of the dealer of Lingong 3.1 Description Heavy Machinery Co., Ltd. are strongly Maintenance procedure shall be completed recommended. by qualified personnel trained in this 3.2 Platform component maintenance of the machine. Mark damaged or faulty machines and 3.2.1 Assembly of platform assembly...

  • Page 24: Removal Of Platform Assembly

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.2.2 Removal of platform assembly place it in the designated area. △ ! WARNING: risk of crushing hoisted correctly, platform assembly may become out of balance and fall off. 3.2.3 Assembly of protective mount 9.

  • Page 25: Assembly Of File Box And Tool Box

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.2.5 Assembly of file box and tool box interfere with each other. 3.2.7 Assembly of foot switch 1. Foot switch 2. Screw 3. Screw 4. Washer Assemble part 1 with part 2/3/4 to the assembling position on the bottom of the platform framework and tighten the screw.

  • Page 26: Assembly Of Platform Valve Block

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.2.9 Assembly of platform valve block 1. Saddle swing cylinder 2. Screw 3. Washer 4. Nut 5. Screw 6. Washer 7. Platform support Lift platform support to the swing cylinder assembly, pass the part 2 through the platform support 7 and the swing cylinder (part 1), and screw the part 2/4 manually;...

  • Page 27: Removal Of Jib

    Service Manual of Telescopic boom Mobile Elevating Work Platform 1. Pin 2. Pin 3. Bolt 4. Washer damage Hoist the subassembled jib to the mounting Damage may occur if hoses and cables are position on the boom frame, then connect kinked or squeezed.

  • Page 28: Fly Jib Cylinder Assembly

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.3.4 Fly jib cylinder assembly lifting platform specification for selection of tightening torque. Lift the jib slightly and place the cushion block under platform installation weldment. Then lower the boom pole until the platform stops on the cushion block so that the cushion block is just about to support the platform.

  • Page 29: Removal Of Saddle Swing Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.3.6 Removal of saddle swing cylinder 3.3.7 Assembly of load cell △ CAUTION: 1. Carry out this step when the boom is in the stowed position. 2. When the hose assembly or joint is removed, the O-rings of the joint and hose must replaced...

  • Page 30: Assembly Of Upper Leveling Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform bracket to part 1 using parts 2 (with pin hole O-ring of the joint and hose end (if equipped) facing left) /3/4, adjust the clearance must be replaced. All connections must be between the triangular bracket and the tightened to the specified torque during swing motor mounting bracket with part 5,...

  • Page 31: Cable Carrier Assembly

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.4 Cable carrier assembly 3.4.1 Assembly of cable carrier Remove the screw for securing the cable carrier 1. Bolt 2. Washer 3. Washer 4. Nut guide plate 5. Bolt 6. Upper wiring beam assembly Install the cable carrier assembly with part 1 (from top to bottom)/2 (nut end)/3 (bolt 1.

  • Page 32: Removal Of Cable Carrier

    Service Manual of Telescopic boom Mobile Elevating Work Platform 1. Bolt 2. Nut 3. Bolt 4. Washer 5. Washer 6. Nut to the PCU box. Number each cable and its entrance position in the PCU box. After passing one end of the subassembled cable carrier from the platform through the Disconnect the cable from the bottom of the upper wiring beam support, fasten it to the...
  • Page 33 Service Manual of Telescopic boom Mobile Elevating Work Platform squirt or spray. 12) Pull the hydraulic hose out of the main jib. Remove cotter pin from upper cable carrier of platform end of boom CAUTION: Always replace the cotter pin with a new one.

  • Page 34: Boom Frame Assembly

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.5 Boom frame assembly Boom frame assembly 1) Lower link assembly to boom pivot 2) Boom frame assembly 3) Pivot at connecting rod end of luffing cylinder 4) Luffing cylinder 5) Upper link assembly (GCU side) 6) Upper link assembly (engine side) 7) Upper link assembly to rotary table pivot...

  • Page 35: Assembly Of Boom Frame

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.5.1 Assembly of boom frame Washer 7. Bolt 8. Bolt Use two slings to hoist the basic boom 9. Washer 10. Slider pad 40-1 11. Slider pad assembly to the straight arm subassembly 40-2 trolley.

  • Page 36: Boom Frame Removal

    Service Manual of Telescopic boom Mobile Elevating Work Platform insert the slider from the gap, evenly coat machine stability. If the counterweight is not the molybdenum disulfide grease on the installed after installation of the boom frame surface of the slider using brush, and assembly, the machine stability will be pre-tighten the parts 14/15/16 to the affected, and the machine will tip over and...
  • Page 37 Service Manual of Telescopic boom Mobile Elevating Work Platform Connect a sling or chain with a min. rated cylinder carefully so that it stays on the loading capacity of 5 tons/5000 kg securely boom support washer. Protect the cylinder to the lifting point of the rotary table rod from damage.

  • Page 38: Subassembly Of Telescopic Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform overhead crane, the boom frame assembly Keep the lifting rope horizontal during may fall. hoisting. Never place any part of the body under the hoisted weight during hoisting. If △ the lifting rope is damaged, replace it in time. ! WARNING: risk of crushing Refer to part 2 for the assembly method of part 7;...

  • Page 39: Assembly Of Telescopic Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform shown in the figure (the slider is facing downward), and apply FUCHS grease on the rope. Apply molybdenum disulfide grease on the surface of the head bracket slider, slowly extend the cylinder into the 2nd boom section inner cavity, manually push it to the middle position of the boom, slowly lower the cylinder, drop it onto the inner arm, and...
  • Page 40 Service Manual of Telescopic boom Mobile Elevating Work Platform Telescopic system mounting plate 8. Shaft 9. Washer 10. Retainer ring 11. Bolt 12. Washer 13. Nut 11) Align the front side mounting hole of the cylinder with the basic boom riser mounting hole;...

  • Page 41: Removal Of Telescopic Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform nut. 5) Loosen the retracting rope assembly nut at the platform end of the boom. Pull the anchor pole off the bracket and allow it to hang down. Retracting 6) Remove the fastener of retracting pulley rope baffle assembly and remove the retracting pulley baffle assembly.

  • Page 42: Assembly Of Luffing Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform of the basic boom. △ CAUTION: Danger component 11) Pull the extension rope mounting plate back. until it leaves the stopper welded to damage the inside of the basic boom. Be careful not to damage the rope break 12) Lift the extension rope mounting plate and limit switch.

  • Page 43: Removal Of The Luffing Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform 7.Shaft with double circlips 8.Washer 9.Retainer 5. Bolt 6. Washer 7. Nut ring 10) Adjust the penetration depth of the shaft in Adjust the cylinder to make it be aligned the luffing cylinder so that the pin shaft with the mounting hole of the boom, center hole is aligned with the bolt hole of connect it with part 7 inserted through the...

  • Page 44: Assembly Of Lower Leveling Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform lifting platform specification for selection of 3.5.8 Assembly of lower leveling cylinder tightening torque. 1) Lift the boom frame to the horizontal position. 2) Attach a 5 t/5000 kg overhead crane to the boom at the end of the platform for support.

  • Page 45: Removal Of Lower Leveling Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.5.9 Removal of lower leveling cylinder 3.5.10 Rope How to adjust boom wire rope △ ! WARNING: risk of personal injury The boom wire rope is designed for the telescoping of boom. Regular and proper This procedure requires...
  • Page 46 Service Manual of Telescopic boom Mobile Elevating Work Platform ensure that the roller of the limit switch arm Retraction rope assembly: is centered in the groove of the extension 10) Remove the fixing pin from the boom system connecting bracket. retraction rope located at the platform end.

  • Page 47: Transmission Component

    Service Manual of Telescopic boom Mobile Elevating Work Platform years, whichever comes first. 3.7 Variable displacement pump 3.6 Transmission component 3.7.1 Assembly of open variable displacement pump 3.6.1 Installation of flywheel coupling 1. Open variable displacement pump 2. Bolt 3. Washer 4.

  • Page 48: Walking Variable Displacement Pump Assembly

    Service Manual of Telescopic boom Mobile Elevating Work Platform damage When the hydraulic tank shut-off valve is in the closed position, do not start the engine, otherwise the component will be damaged. If the tank valve is closed, remove the key from the ignition switch and put a label on the machine to inform the personnel of the situation...

  • Page 49: Removal Of Walking Variable Displacement Pump

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.7.4 Removal of walking variable △ displacement pump CAUTION: Danger component △ damage ! CAUTION: walking variable displacement pump may fall if improperly supported. When removing the hose assembly or joint, always replace the O-ring at the joint When installing the walking variable and / or hose end (if equipped).
  • Page 50 Service Manual of Telescopic boom Mobile Elevating Work Platform head of the return tube, assemble part 1 tank and tighten it to specified torque with with part 3/4 to the return filter and tighten it, part 8 / 9. and fix the part 1 with part 5/6/7/8/9 on the other side.

  • Page 51: Removal Of Hydraulic Oil Tank

    Service Manual of Telescopic boom Mobile Elevating Work Platform on the hydraulic oil tank. △ CAUTION: Danger component damage. Do not start the engine when the valve of hydraulic oil tank is closed, otherwise the component will be damaged. If the tank valve is closed, the key shall be removed from the ignition switch and the machine shall be marked and informed.

  • Page 52: Fuel Tank Removal

    Service Manual of Telescopic boom Mobile Elevating Work Platform and nut side)/4 (coated with adhesive) Remove the tank from the machine. (from top to bottom). CAUTION: before installation, clean the fuel Remove the protective cover at the top of tank check for crack and other the fuel tank.

  • Page 53: Assembly Of Steering Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform When removing the hose assembly or secure it with the part 7. joint, always replace the O-ring at the Secure the steering fluid reservoir end joint and / or hose end (if equipped). All using parts 2/3/4/5 to the front axle.

  • Page 54: Subassembly Of Walking Motor

    Service Manual of Telescopic boom Mobile Elevating Work Platform the same. on front axle, and assemble the wear washer on the lower contact surface 3.9.6 Subassembly of walking motor between the connecting plate and the front axle weldment. Insert the part 1 from top to bottom, and for the lower part, insert from bottom to top.

  • Page 55: Assembly Of Wheel

    Service Manual of Telescopic boom Mobile Elevating Work Platform when the rotary table rotation assembly is 3.10 Assembly of rotary table being removed. 3.10.1 Lowering and assembly of rotary table △ ! WARNING: risk of crushing When removing the fixing part of the Front steering connecting disc, it may fall due to unbalanced fixing.

  • Page 56: Lowering And Assembly Of Slewing Reducer

    Service Manual of Telescopic boom Mobile Elevating Work Platform Insert part 1 (coated with adhesive)/2 into adjustment is completed. the mounting hole from top to bottom and 3.10.4 Removal of slewing reducer fasten them diagonally. △ 3.10.3 Lowering and assembly of slewing CAUTION: reducer When removing the hose assembly or joint,...

  • Page 57: Assembly Of Slewing Mechanism Guard Plate

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.10.5 Assembly of slewing mechanism switch guard plate Assemble part 1 to the left bracket of center slewing joint with part 2 / 3 / 4, and install part 8 to part 1 with part 5 / 6 / 7. 3.11.2 Assembly of DC power switch 1.

  • Page 58: Assembly Of Tilt Sensor

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.11.4 Assembly of tilt sensor 1. Bolt 2. Washer 3. Nut 4. Tilt sensor bracket 5. Tilt sensor Fit part 5 with part 1/2/3 to the part 4 and secure the tilt sensor bracket to the battery carrier.

  • Page 59: Valve

    Service Manual of Telescopic boom Mobile Elevating Work Platform 3.12 Valve Brake two-speed flowing control valve block (4120705252) Torque N•m Name Function descriptions Prevent backflow of brake fluid to Check valve STCV08-0-000A 40-45 port P Pressure relief of floating Reversing valve SV08-21-0-N-0 32-35 mechanism Coil 4303612...
  • Page 60 Service Manual of Telescopic boom Mobile Elevating Work Platform Walking control valve (4120704651) Torque N•m Name Function descriptions Flow diverter/combiner valve FD56-45-0-P-66 Flow control of front and rear axle 133-138 Flow diverter/combiner valve FD52-45-0-P-66 Flow control of left and right wheel 99-104 M6 damping STTY002-1.0 Control the flow rate...
  • Page 61 Service Manual of Telescopic boom Mobile Elevating Work Platform Torque N•m Name Function descriptions Balance valve C02AD350155300A Balance hydraulic oil on both sides Plug 4BN-02WD 11-12 Plug 4BN-04WD 25-28 Plug 4BN-06WD 41-48 O-ring 10.77*2.62...

  • Page 62: Bleeding Of Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform extension and retraction of piston rod is 3.13 Bleeding of cylinder counted as one time. The steps are as Start of vehicle follows: After checking and confirming the "Ignition Step 1: Operate the machine to make the switch", start the ground control mode;...

  • Page 63: Bleeding Of Fly Jib Luffing Cylinder And Upper Leveling Cylinder

    Service Manual of Telescopic boom Mobile Elevating Work Platform In boom frame subassembly area, turn on HCU button to carry out the bleeding of boom telescopic cylinder ; Divide the boom luffing cylinder into three parts, and take the 1st boom section as reference, as shown in the figure.
  • Page 64 Service Manual of Telescopic boom Mobile Elevating Work Platform...

  • Page 65: Chapter V Commissioning

    Service Manual of Telescopic boom Mobile Elevating Work Platform Chapter V Commissioning...
  • Page 66 Service Manual of Telescopic boom Mobile Elevating Work Platform...

  • Page 67: Safety Notices

    Service Manual of Telescopic boom Mobile Elevating Work Platform wire, keep away from the machine immediately. 4.1 Safety notices Before cutting off the wire power supply, it is not Before commissioning, commissioning allowed for the personnel to contact or operate personnel is required to read operation and the machine.

  • Page 68: Clearance Detection

    Service Manual of Telescopic boom Mobile Elevating Work Platform Control standard: the pointer of hydraulic oil of counterweight and engine hood: 4-10 mm level gauge is located at 1/2-2/3 of the level Height difference between counterweight gauge. and engine hood: ± 5 mm Flush between counterweight and engine hood: ±...

  • Page 69: Basic Operation Test Of Gcu

    Service Manual of Telescopic boom Mobile Elevating Work Platform status. At this time, the display will turn black, Control standard: in compliance with the but any operation of the vehicle will not be requirements affected. To restore the working state, press the Horn switch F5 button.
  • Page 70 Service Manual of Telescopic boom Mobile Elevating Work Platform without jitter, abnormal sound or impact; Ground control Jib luffing switch system panel When you turn the rotary table rotary switch to Platform leveling the left, the rotary table will rotate to the left Enable button switch without jitter, abnormal sound and impact;...

  • Page 71: Basic Operation Test Of Platform Control Unit

    Service Manual of Telescopic boom Mobile Elevating Work Platform 5) Jib lifting: Ground control system Jib luffing switch panel Jib lifting test Platform leveling Enable button switch Boom extension and Platform rotary retraction switch switch Boom luffing switch Auxiliary power switch Rotary table rotary switch...
  • Page 72 Service Manual of Telescopic boom Mobile Elevating Work Platform the jib will luff downward without jitter, abnormal sound and impact; 4) Rotary table rotation: When you move the left control lever to the left, the rotary table will rotate to the left without jitter, Foot switch abnormal sound and impact;...

  • Page 73: Drive Enable System Test

    Service Manual of Telescopic boom Mobile Elevating Work Platform idle at the lowest speed. Turtle symbol: the low direction of driving and idle speed by the foot switch; Rabbit symbol: the steering control lever high idle speed is activated by the foot switch. movement;...

  • Page 74: Slewing Pressure Test

    Service Manual of Telescopic boom Mobile Elevating Work Platform 4.2.9 Slewing pressure test Control standard (pressure target value): 280-385 bar If it does not meet the target value, correct it as follows: Loosen the relief valve fastening nut, then increase or decrease the valve spool clockwise or counterclockwise with an Allen wrench according to the pressure condition.

  • Page 75: Floating Test Of Machine

    Service Manual of Telescopic boom Mobile Elevating Work Platform 4.2.12 Floating test of machine counterweight trolley 10-15 cm off the ground, and let it stay in a stable status to enter rated load calibration of system. Subseq uent Control standard: calibration is completed. vehicle pressur 4.2.14...

  • Page 76: Large Rated Load (450) Test

    Service Manual of Telescopic boom Mobile Elevating Work Platform Control standard: The vehicle shall be free of oil leakage, structural interference, and the oil pipe and harness shall be free of squeezing and damage. CAUTION: Counterweight application safety harness is associated with the platform;...

  • Page 77: Lifting Height Test

    Service Manual of Telescopic boom Mobile Elevating Work Platform than 1%, the ground shall not sag during the operation, and there shall be no obstacles around the straight-arm lifting platform that affect its lifting and slewing. 4.2.19 Operation time test CAUTION: The operation time test control standard Distance...
  • Page 78 Service Manual of Telescopic boom Mobile Elevating Work Platform lifts and the timing starts at the same time. Ground control When the boom is lifted to the highest position, system panel it will stop and the timing will end. Control standard: 60-70 s Enable button Press and hold the enable button and the boom lift switch (downward) at the same time, lower...

  • Page 79: Driving Speed (High Speed) Test

    Service Manual of Telescopic boom Mobile Elevating Work Platform Operation time test-platform rotation Control standard: 4.8± 0.25 km/h Start the vehicle, keep the in-situ status, use the High-speed straight driving ground control mode for test, press and hold the enable button and platform rotary switch (to the left) at the same time, and rotate the platform to the leftmost side;...

  • Page 80: Tilt Sensor Test

    Service Manual of Telescopic boom Mobile Elevating Work Platform test surface; When the vehicle center of the Slope 2 with an angle of 5° front wheel passes through the test start line, the timing starts until the center of the front wheel passes through the end line, and then stop timing, that is, the trolley passes through the test road, and the test...

  • Page 81: Chapter V Maintenance

    Service Manual of Telescopic boom Mobile Elevating Work Platform Chapter V Maintenance...
  • Page 82 Service Manual of Telescopic boom Mobile Elevating Work Platform...

  • Page 83: Compliance

    Service Manual of Telescopic boom Mobile Elevating Work Platform  Loosen fixing bolt 6 and lock nut 5 5.1 Compliance  Turn the adjusting bolt 4 to adjust the You are required to be trained properly in reducer position safety operation and maintenance of machine and are qualified accordingly.

  • Page 84: Inspection Of Rope

    Service Manual of Telescopic boom Mobile Elevating Work Platform Check the clearance between the slider extension rope balance block 2 is deflected and the arm rod. If the clearance between to one side, and whether the retracting rope the slider and the arm is greater than 1 mm, balance block 8 is deflected to one side.

  • Page 85: Inspection Of Hydraulic Oil And Filter

    Service Manual of Telescopic boom Mobile Elevating Work Platform  Apply pipe thread sealant to the plug and or every day. install the plug into the gearbox. △  ! CAUTION: Carry out this step when Repeat this step for each walking reducer. Inspection of slewing reducer oil level the arm rod is in the stowed position.

  • Page 86: Maintenance Of Deutz Engine

    Service Manual of Telescopic boom Mobile Elevating Work Platform Test or replace the hydraulic oil every 2000 relevant local regulations. Handle overflow hours or every two years. The grades of the oil and filter element as specified. Prevent hydraulic oil used are shown in Table 1-1. the waste oil from penetrating into the ground.

  • Page 87: Check For Fuel Leakage

    Service Manual of Telescopic boom Mobile Elevating Work Platform △ CAUTION: Please follow the oil safety provisions and relevant local regulations. Handle overflow oil and filter element as specified. Prevent the waste oil from penetrating into the ground. △ CAUTION A trial run is required after each operation.

  • Page 88: Draining Or Replacement Of Fuel Filter

    Service Manual of Telescopic boom Mobile Elevating Work Platform location of the machine. When carrying out this step, the machine should be in an open and well-ventilated area away from heater, spark, flames, and burning tobacco. A qualified fire extinguisher shall be placed in an easily accessible place.

  • Page 89: Check Of Engine Air Filter

    Service Manual of Telescopic boom Mobile Elevating Work Platform To ensure that no error message is sent, do plate 4. End cap 5. Dust discharge valve not try to start the engine during bleeding. Open the positioning plate (3). The bleeding are as follows: Remove the filter cover (4) and unscrew the Turn ignition switch "ON"...

  • Page 90: Check The Engine Belt

    Service Manual of Telescopic boom Mobile Elevating Work Platform △ △ High temperature coolant poses risk of CAUTION: scalding. Work on the belt drive can only be carried 1. The cooling system is under pressure! The out when the engine is stationary. If the cover can only be opened under the coolant is double-layer belt is worn or the V belt is cooled down.

  • Page 91: Scheduled Maintenance

    Service Manual of Telescopic boom Mobile Elevating Work Platform 1. Bolt 2. Bolt 3. Bolt Loosen bolt and lock nut. Alternator moves towards (B) direction until the belt is loose. Remove the old belt and install the new belt. The alternator moves to the (A) direction until the correct belt tension is reached.

  • Page 92: Engine Fault Diagnosis

    Service Manual of Telescopic boom Mobile Elevating Work Platform 5.9 Engine fault diagnosis Symptom Cause Solution Disengagement failure (if possible) Check coupling No fuel in fuel tank Fill the tank Fuel suction pipe blocked Check Below starting temperature limit Check Cold starter damage Inspect/replace Incorrect engine oil SAE viscosity grade...
  • Page 93 Service Manual of Telescopic boom Mobile Elevating Work Platform looseness Turbocharger air pipe not sealed Check turbocharger air pipe Charge air cooler dirty Inspection/cleaning Air filter dirty/exhaust turbocharger damage Inspect/replace Air filter maintenance switch/maintenance indicator Inspect/replace damaged Check fan/V-belt, and replace them when Fan damaged/V belt broken or loosened necessary High exhaust back pressure...
  • Page 94 Service Manual of Telescopic boom Mobile Elevating Work Platform system (<20-30%) Damaged valve oil seal Inspect/replace Exhaust turbocharger damage Inspect/replace Check lubricating oil for oil level and drain High lubricating oil level Blue smoke from the it if necessary engine Excessive inclination of engine Check engine mount/lower tilt position The fuel quality does not conform to the...
  • Page 95 Service Manual of Telescopic boom Mobile Elevating Work Platform between the engine and the tray least First maintenance at 50 h, and thereafter replace every 250 h Replace engine oil once or 6 months, whichever comes first. year least Replace the engine oil First maintenance at 50 h, and thereafter replace every 500 h once filter element...
  • Page 96 Service Manual of Telescopic boom Mobile Elevating Work Platform connector is dirty or damaged Check whether the PCU harness is Every day squeezed or broken Check if the tilt sensor Every day harness is secured Check whether the rotary table slewing limit switch is in the Every day rocker arm position and...
  • Page 97 Service Manual of Telescopic boom Mobile Elevating Work Platform spool for oil leakage. Check whether the two ball valves at the oil suction port at the Every day bottom of the hydraulic oil tank are opened Check whether the walking oil pipe fixing Every day clamp is loose hydr...
  • Page 98 Service Manual of Telescopic boom Mobile Elevating Work Platform without dirt Check whether the bolt, nut and other fasteners of the machine are Every day loose or have abnormal sound Check whether the structural parts of the Every day machine have crack and open weld.

  • Page 99: Chapter Vi Annex

    Service Manual of Telescopic boom Mobile Elevating Work Platform Chapter VI Annex...
  • Page 100 Service Manual of Telescopic boom Mobile Elevating Work Platform...

  • Page 101: System Dtc

    Service Manual of Telescopic boom Mobile Elevating Work Platform 6.1 System DTC Fault Description Restricted action Open circuit of control unit output Boom luff-up power supply 1 Open circuit of control unit output Boom luff-up power supply 2 Open circuit of control unit output Boom luff-up power supply 3 and 4 Open circuit of platform electric box...
  • Page 102 Service Manual of Telescopic boom Mobile Elevating Work Platform Length/angle sensor fault Boom luff-up, boom extension Low oil level alarm None Working radius out of the limit of safety Boom luff-down, boom extension area Manual locking reminder Boom luff-up and boom extending Manual locking Boom luff-up, boom extension, walking Mismatch of GPS with ECU...

  • Page 103: Description Of Harness Wire Size

    Service Manual of Telescopic boom Mobile Elevating Work Platform 6.2 Description of harness wire size 6.2.1 Main harness PCU connection wire Protective sleeve: 174357 Lock piece: 174358 Terminal: 171662 Sealing plug: Front and Floating on/off valve 17888-2 Flasher light rear Flasher light Level sensor detection...

  • Page 104: Valve Block Harness

    Service Manual of Telescopic boom Mobile Elevating Work Platform 6.2.2 Valve block harness PCU connection wire Protective sleeve: 174357 Lock piece: 174358 Front Terminal: 171662 and rear Sealing plug: Floating on/off valve Flasher light detection Flasher light 17888-2 Level sensor Floating on/off valve 48-core...
  • Page 105 Service Manual of Telescopic boom Mobile Elevating Work Platform 6.2.3 Platform harness Platform protection PCU box 28+4-core Fly jib/platform slewing change-over valve Wire size Function Color Wire size Function Color Wire size Function Color X402 Power supply Battery GND Black Proximity switch signal White Platform protection warning...

  • Page 106: Schematic Diagram

    Service Manual of Telescopic boom Mobile Elevating Work Platform 6.3 Schematic diagram 6.3.1 Electrical schematic diagram Foot switch...

  • Page 107: Hydraulic Schematic Diagram

    Service Manual of Telescopic boom Mobile Elevating Work Platform 6.3.2 Hydraulic schematic diagram...

  • Page 108: Symbols Of Common Hydraulic Parts

    Service Manual of Telescopic boom Mobile Elevating Work Platform 6.4 Symbols of common hydraulic parts Common symbols of hydraulic components: (1) Hydraulic pump, hydraulic motor and hydraulic cylinder Descriptio Name Symbols Description Name Symbols Hydraulic Detailed General symbols pump symbols Non-adjustable one-way Single-directio...
  • Page 109 Service Manual of Telescopic boom Mobile Elevating Work Platform Single-direction rotation, variable Hydraulic displacement, General integral Accumulator fixed symbols transmission displacement motor Gas isolation Detailed symbols type Accumulat Single piston rod cylinder Heavy hammer Simplified symbol type Detailed symbols Spring type Single-a Single piston ction...
  • Page 110 Service Manual of Telescopic boom Mobile Elevating Work Platform external draining Hydraulic Electro-hyd external Jumper raulic pilot control, mechanism pressure internal control draining Internal pressure Ejector rod control, type Hydraulic internal pilot draining pressure External relief pressure control Variable travel control (with control type remote relief...
  • Page 111 Service Manual of Telescopic boom Mobile Elevating Work Platform operation (torque motor, etc.) Rotation Handle type electronic control unit One-way Feedback General pedal type control symbols The position is detected by Two-way Electrical potentiometer Feedback pedal type feedback , differential control method transformer, etc.
  • Page 112 Service Manual of Telescopic boom Mobile Elevating Work Platform General Direct-acting symbol or Two-way relief Unloading , external direct-acting valve valve draining unloading valve Unloading valve General Pilot symbol or electromag Pressure direct-acting netic p1>p2 reducing valve pressure unloading reducing valve valve Pressure...
  • Page 113 Service Manual of Telescopic boom Mobile Elevating Work Platform l valve center Three-posit Simplified Underlapped four-way symbol center proportiona l valve Two-positio Normally n four-way opened proportiona Two-position l valve two-way solenoid valve Normally Four-way open servo valve Four-way Two-position electro-hyd Reversin three-way...
  • Page 114 Service Manual of Telescopic boom Mobile Elevating Work Platform (6) Tank Pipe end is Pipe end at the above the bottom of liquid level Ventilate the tank Tank d type Pipe end Local oil With air above the leakage or filter liquid level return...

  • Page 115: Schematic Diagram Of Symbols Of Common Electrical Components

    Service Manual of Telescopic boom Mobile Elevating Work Platform Detailed Differential pressure symbols switch Pressure relay (pressure switch) General General Sensor symbols symbols Detailed Pressure Sensor symbols sensor Travel switch General Temperatur symbols e sensor General Coupling symbols Coupling Amplifier Flexible coupling (9) pipeline, pipe joint and joint...
  • Page 116 Service Manual of Telescopic boom Mobile Elevating Work Platform Three-level Composite control switch contact Three-level Normally isolating opened button switch Three-level Normally load switch closed button Combined Combined Button rotary switch button Low-voltage Emergency circuit stop button breaker Control unit Key-operated or control button...
  • Page 117 Service Manual of Telescopic boom Mobile Elevating Work Platform Power-up Normally delay (slow closed contact closing) coil Overcurrent coil Power-off delay (slow opening) coil Undercurrent coil Current relay Instantaneou Normally open sly closed NO contact contact Instantaneou Normally sly opened closed contact Time relay NC contact...
  • Page 118 Service Manual of Telescopic boom Mobile Elevating Work Platform Separately Electromagn excited DC etic clutch motor Electromagn Shunt-excited etic brake DC motor Solenoid Series DC valve motor Speed relay normally Fuse Fuse open contact Relay of non-electr icity Pressure control relay Single-phase normally...

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