LGMG H1840 Maintenance Manual
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LGMG H1840 Maintenance Manual

Telescopic handler
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Maintenance Manual
H1840
Telescopic handler
△
!
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 H1840

  • Page 1 Maintenance Manual H1840 Telescopic handler △ 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 personnel concerned. LINGONG HEAVY MACHINERY CO., LTD.
  • Page 2 First print, September 2022 Lingong Heavy Machinery Co., Ltd. Add.: 12F, Building 3, Lushang Olympic City, No. 9777, Jingshi Road, Lixia District, Jinan City, Shandong Province, China Tel.: 86-0531-67605017 Technical service hotline: 86-0531-67605017 Fax: 86-0531-67605017 Parts sales hotline: 86-0531-67605016 Website: www.lgmg.com.cn...
  • Page 3 Maintenance Manual of Telescopic Handler Foreword Thanks for purchasing the telescopic handler produced by Lingong Heavy Machinery Co., Ltd. This machine is designed according to EN 1459-1:2017+A1:2020. This manual introduces the maintenance of the telescopic handler for safety guidelines and correct operation and maintenance of the machine. How to get the best out of your machine is a goal we pursue together with you, and it depends to a large extent on how familiar you are with the machine and how carefully and thoroughly it is maintained.
  • Page 4 Maintenance Manual of Telescopic Handler  Please load the machine in strict accordance with the rating; otherwise all the consequences arising from overloading or unauthorized modification will be borne by the user.  The operation instructions and precautions in this manual apply only to the intended use of the machine.

  • Page 5: Safety Notices

    Maintenance Manual of Telescopic Handler 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 accidents are caused by failure to obey operation and maintenance specifications of the machine. To avoid unnecessary accident, please read and follow all warnings and precautions in this manual and on the machine before operation or maintenance.

  • Page 6: Table Of Contents

    Maintenance Manual of Telescopic Handler Contents Foreword ..........................I Safety Notices ........................III Contents ..........................IV Chapter 1 Maintenance......................1 1.1 Checking the safety manual ..................3 1.2 Checking the labels and signs ................. 3 1.3 Checking for damaged, loose or missing parts ............3 1.4 Daily or every 8 h .....................

  • Page 7: Chapter 1 Maintenance

    Maintenance Manual of Telescopic Handler Chapter 1 Maintenance...
  • Page 8 Maintenance Manual of Telescopic Handler...

  • Page 9: Checking The Safety Manual

    △ To replace the labels, please manual is illegible or missing, the safety and operation information necessary for safe running contact the service personnel of LGMG. cannot be provided. 1.3 Checking for damaged, Confirm that the Operation Manual and the...

  • Page 10: Daily Or Every 8 H

    1.4.2 Checking the coolant level 1.4 Daily or every 8 h H1840 is used as an example. For other model, 1.4.1 Checking the engine oil level please refer to this picture: Insufficient or excessive oil will cause engine Check the coolant level every 8 hours or damage.
  • Page 11 Maintenance Manual of Telescopic Handler △ CAUTION: Adding should always carried out before the diesel in the diesel tank is used up, or, the engine will stall and the diesel at the bottom of the diesel tank will contain more water and impurities, which will affect the 1.
  • Page 12 (km/h) load (Kg) ground, set the gear selector to N gear, pull up (kpa) the parking brake handle, and chock the tire to H1840 5600 prevent the machine from moving. Tightening torque of wheel nut: Check the DEF level. Model...

  • Page 13: Every 50 H Or Weekly

    △ CAUTION: 1.5.3 Cleaning the cab A/C filter If the operation isn’t performed carefully, H1840 is used as an example. For other model, the radiator core will be prone to please refer to this picture: damage. A. Cab outer filter element 1.
  • Page 14 Maintenance Manual of Telescopic Handler Take out the A/C filter element (1) and clean Oil outlet it with compressed air. If the filter element is Breather damaged, replace it. 1. Stop the engine, park the machine on a level Install the filter element (1) and housing. ground, set the gear selector to N gear, pull up B.

  • Page 15: Every 250 H

    1.6.2 Check the drive axle final 1.6.1 Replacing cab A/C filter drive and wheel reducer oil level Change every 250 hours. △ H1840 is used as an example. For other model, CAUTION: Be the operation, fore please refer to this picture: the engine shall be stopped, the vehicle A.
  • Page 16 Maintenance Manual of Telescopic Handler 1.6.3 Checking transfer box oil level 1. Carefully clean breather surrounding area. Description Oil filler 2. Check the oil level: remove the oil filler plug (1) Oil outlet and check whether the oil level is at the lower Breather edge of the filler.
  • Page 17 Maintenance Manual of Telescopic Handler the chain and the top of the boom with a ruler. The distance of the two same chain must be consistent. 3) Boom 1: The distance shall be between 97 1) Raise the outrigger and keep the boom level. mm and 117 mm, and if necessary, adjust it 2) Fully extend the boom.
  • Page 18 Maintenance Manual of Telescopic Handler chains shall also be replaced together. heat can be smelled, but there is no "burnt" smell) or the friction between the fingers 1.6.5 Lubricating boom slider (there shall be a sticky feeling, no rough Carry it out every 10 hours for the first 50 hours feeling of any particles).

  • Page 19: Every 500 H

    Maintenance Manual of Telescopic Handler 1.7 Every 500 h 1.7.1 Replacing engine oil and oil filter First 50 hours, and then change it every 500 hours or every half a year (whichever comes first). Unscrew the oil drain plug (1) and drain the △...
  • Page 20 Maintenance Manual of Telescopic Handler (4). 1.7.2 Replacing primary fuel filter 3. Remove the filter element (3) from the cover element (1). Replace every 500 hours or every six 4. Remove the seal ring (2) from the cover (1). months (whichever comes first). 5.
  • Page 21 Maintenance Manual of Telescopic Handler performed in open areas away from heaters, sparks, flames, and burning tobacco. A conforming fire extinguisher should be placed in an easily accessible place. △ The secondary fuel filter element must be replaced at the same time as the primary fuel filter element.
  • Page 22 Maintenance Manual of Telescopic Handler and remove the filter element. Clean the filter 1.7.3 Replacing secondary fuel fuel cup. filter 1. Ensure that the fuel supply valve (if equipped) is in the OFF position. 2. Place a suitable container under the fuel filter to collect all spilled fuel.
  • Page 23 Maintenance Manual of Telescopic Handler  The fuel tank is empty or some fuel is conditions occur.  discharged from the fuel tank. There are cracks in at least two belt ribs.   Disconnect the low-pressure fuel pipe. There is at least one segment of belt ...

  • Page 24: Every 1000 H

    Maintenance Manual of Telescopic Handler 1.8 Every 1000 h 1.8.1 Replacing air filter element Check the dust discharge valve every day, replace the cracked and deformed dust discharge valve, and cleat the dust in it. 1. Breather 2. Oil return filter assembly 1.
  • Page 25 Maintenance Manual of Telescopic Handler Remove the air filter element cover. the pressure of the end cap, which will Remove the primary filter. damage the housing and the buckle. If the Clean the filter element from the inside out end cap cannot be installed in place due to with a low pressure compressed air (up to the filter element, remove the end cap and 207Kpa) at least 30mm from the filter...
  • Page 26 Maintenance Manual of Telescopic Handler drain plug (2), drain all oil, clean and install vehicle every 1000 h. the plug (2). Drain the transmission fluid Description 1) Stop the engine, park the machine on a level Oil filler ground, set the gear selector to N gear, shut Oil outlet down the engine, pull up the parking brake handle, and chock the tire to prevent the...

  • Page 27: Every 1500 H

    Maintenance Manual of Telescopic Handler 1.9 Every 1500 h 1.9.1 Replacing the drive axle reducer oil The first maintenance is 150h, and then the 2. Rotate the wheel so that the drain plug is in the maintenance is carried out every 1500h. lowest position and place a suitable container Stop the engine, park the machine on a level underneath.
  • Page 28 Maintenance Manual of Telescopic Handler necessary. Check the water radiator for leakage, damage and dirt accumulation, and clean and repair it as required. Fill slowly by the filler until the maximum allowable level of the Radiator. Install the coolant filler cap. Run the engine at idle speed, check for leakage and level, and refill if necessary.
  • Page 29 Maintenance Manual of Telescopic Handler △ CAUTION: If the size is less than the minimum size (52.2 mm-52.2 × 2%= 51.156 mm; 42.2 mm-42.2 × 2%= 41.356mm), replace the chain. In addition to wear, the high pressure between the side plate and the pulley may cause joint jamming. In this case, a pair of chains should also be replaced.
  • Page 30 Maintenance Manual of Telescopic Handler Before replacing the hydraulic oil, a speed up the oil drain, open the oil tank filler hydraulic oil test can be performed to cap. confirm whether it is necessary to replace it. 4) Remove the suction filter from the hydraulic If the hydraulic oil is not replaced during the oil tank.
  • Page 31 Maintenance Manual of Telescopic Handler fuel tank and add oil to the 1/2 of the tank. It is strictly prohibited for the oil to overflow. The following figure shows the HR2150 hydraulic oil tank for example: Name Moment Cover plate bolt 28±...

  • Page 32: Appendix

    Maintenance Manual of Telescopic Handler 1.11 Appendix 1.11.1 Maintenance instructions 1. General instructions Before starting the Telescopic handler, ensure that the area is well ventilated. Wear suitable clothes and avoid jewelry and loose and comfortable clothes. If necessary, tie and protect your hair.
  • Page 33 Maintenance Manual of Telescopic Handler Never Short circuit the starter to start the Engine. If the forward / N gear / reverse selector is not in the position of N gear and the parking brake is not engaged, the Telescopic handler may move abruptly. Do not touch the battery with metal objects.
  • Page 34 Maintenance Manual of Telescopic Handler 1.11.2 Selection of oils and refilling capacity Type Recommended types and standards Oil level Oil parts Ambient temperature ≥-20° 15W/40 Engine oil 9.5L Engine API CJ-4 Ambient temperature <-20° 10W/30 Front axle: 10.6 L 30° C < minimum temperature, 85W/140 Axle Rear axle: 10.6 L Gear oil...
  • Page 35 Maintenance Manual of Telescopic Handler Maintenance level Every Maintenance Every Every Operation content Weekly Quarterly item year months 250h 500h 1000h 2000h 4000h Replace the secondary fuel filter ● element Replace the primary fuel filter ● element ● Clean the fuel tank Replace air cleaner primary ●...
  • Page 36 Maintenance Manual of Telescopic Handler Maintenance level Every Maintenance Every Every Operation content Weekly Quarterly item year months 250h 500h 1000h 2000h 4000h Check the final drive and the ● wheel reducer oil level Replace the final drive lubricating The first maintenance is 150h, and then the maintenance is oil (at least once a year) carried out every 1500h.
  • Page 37 Maintenance Manual of Telescopic Handler Maintenance level Every Maintenance Every Every Operation content Weekly Quarterly item year months 250h 500h 1000h 2000h 4000h system steering system ● Check hydraulic oil level ● Replace return filter element Replace the hydraulic oil tank ●...
  • Page 38 Maintenance Manual of Telescopic Handler raised) The torque anti-tipping signal input is T_Warning_013_TipOverOn prohibited to move in the dangerous direction. It is forbidden to move after the T_Warning_014_StopTravelByJackDw outrigger is on the ground. When the Boom angle is greater than T_Warning_015_StopJackUpByMbAngleLT60 60 degrees, it is forbidden to retract the outrigger.
  • Page 39 Maintenance Manual of Telescopic Handler upward action is prohibited When the outrigger is not on the T_Warning_031_StopTeleOutManModeStabNotOnG ground in the man mode, boom extension action is prohibited When the outrigger is not on the T_Warning_032_StopForkUpDwManModeStabNotO ground in the man mode, the fork nGnd action is prohibited Load moment limiter cuts off the...
  • Page 40 Maintenance Manual of Telescopic Handler T_ALARM_008_BoomLengthCh2OpenCirc Boom length sensor channel 2 Open circuit T_ALARM_009_BoomLengthCh2ShortCirc Boom length sensor channel 2 short circuit The actual length of boom length sensor T_ALARM_010_BoomLengthCh1ActMax channel 1 is greater than the maximum set value The actual length of boom length sensor T_ALARM_011_BoomLengthCh1ActMin channel 1 is less than its minimum set value The actual length of boom length sensor...
  • Page 41 Maintenance Manual of Telescopic Handler T_ALARM_033_RRJackPressRndErr Right rear Outrigger pressure Redundancy fault T_ALARM_034_BmAmpJoyFullUpLimit Boom luffing up Handle more than the Set value T_ALARM_035_BmAmpJoyFullDwLimit Boom luffing down Handle more than Set value Boom telescopic extension Handle exceeds Set T_ALARM_036_BmTeleJoyFullUpLimit value Boom retraction handle or joystick exceeds set T_ALARM_037_BmTeleJoyFullDwLimit value Fork lifting and lowering: Up joystick exceeds...
  • Page 42 Maintenance Manual of Telescopic Handler Boom amplitude with remote controller: joystick T_ALARM_059_BmAmpJoyFullUpLimit_RC up exceeds set value Boom amplitude with remote T_ALARM_060_BmAmpJoyFullDwLimit_R controller: the downward joystick exceeds the set value Boom extension and retraction with remote T_ALARM_061_BmTeleJoyFullUpLimit_RC controller: the up joystick exceeds the set value Boom extension and retraction with remote T_ALARM_062_BmTeleJoyFullDwLimit_RC controller: the down joystick exceeds the set...
  • Page 43 Maintenance Manual of Telescopic Handler alarm MIDAC PLUS LMI force limit controller C_ALARM_107_MDP_LMI_TIMEOUT communication timeout alarm C_ALARM_108_AUTEC_REMOTE_TIMEO AUTEC remote control communication timeout alarm C_ALARM_109_NOT_USED NOT USED C_ALARM_110_STAB_V_SENSOR_FAULT FL left front longitudinal ground outrigger sensor check fault C_ALARM_111_STAB_V_SENSOR_FAULT FR right front longitudinal ground outrigger sensor check fault C_ALARM_112_STAB_V_SENSOR_FAULT RL left rear longitudinal ground outrigger sensor...
  • Page 44 Maintenance Manual of Telescopic Handler nsor C_ALARM_134_TCU_Err_22_PumpValveF Travel pump valve forward drive fault_22 C_ALARM_135_TCU_Err_23_PumpValveR Travel pump valve backward drive fault_23 C_ALARM_136_TCU_Err_28_HydMotorCtrl Travel pump hydraulic motor control valve Valve fault_28 C_ALARM_137_TCU_Err_25_DOutputsA1 Travel pump output A1A2 fault_25 C_ALARM_138_TCU_Err_26_DOutputsB1 Travel pump output B1B2 fault_26 C_ALARM_139_TCU_Err_75_EngineRPMp Travel pump engine speed POTI_75 C_ALARM_140_TCU_Err_72_CANmsgTim...
  • Page 45 Maintenance Manual of Telescopic Handler CRC error M_ALARM_242_C1_IOSysTaskStatus Mdp Load moment limiter CPU1 IO task error M_ALARM_243_C1_E2promAlarm Mdp Load moment limiter CPU1 E2PROM error Mdp Load moment limiter CPU1 CAN M_ALARM_244_C1_CAN_Init_ErrorCode Initialization error Mdp Load moment limiter CPU1 Data exchange M_ALARM_245_C1_DataExc_InitError initialization error M_ALARM_246_C1_DExc_FrmError...
  • Page 46 Maintenance Manual of Telescopic Handler Load moment limiter fork cylinder rod cavity M_ALARM_312_CCYl_PH_A_Fault_Tmax pressure sensor channel A Short circuit Load moment limiter fork cylinder rodless cavity M_ALARM_313_CCYl_PL_B_Fault_Tmin pressure sensor channel B open circuit Load moment limiter fork cylinder rodless cavity M_ALARM_314_CCYl_PL_B_Fault_Tmax pressure sensor channel B short circuit Open circuit of Load moment limiter fork...
  • Page 47 Maintenance Manual of Telescopic Handler Load moment limiter length sensor redundancy M_ALARM_334_S1D_Fault_MaxDiff error Load moment limiter level sensor channel A is M_ALARM_335_TOut_U2AMU_C1_A communication timeout Load moment limiter level sensor channel B is M_ALARM_336_TOut_U2AMU_C1_B communication timeout Load moment limiter angle sensor channel A is M_ALARM_337_C1_A_Fault faulty Load moment limiter angle sensor channel B is...
  • Page 48 Maintenance Manual of Telescopic Handler 102–16 Engine Intake Manifold #1 Pressure: High - Medium Severe Level (2) 102–18 Engine Intake Manifold #1 Pressure: Low - Moderately Severe Level (2) 105–0 Engine Intake Manifold #1 Temperature: High - Most Severe Level (3) 105–3 Engine Intake Manifold #1 Temperature: Voltage Above Normal 105–4...
  • Page 49 Maintenance Manual of Telescopic Handler 411–3 EGR Pressure Difference: Voltage Above Normal 411–4 EGR Pressure Difference: Voltage Below Normal 411–13 EGR Pressure Difference: Out of Calibration 412–3 EGR Temperature: Voltage Above Normal 412–4 EGR Temperature: Voltage Below Normal 412–15 EGR Temperature: High - Least Severe Level (1) 412–16 EGR Temperature: High - Moderately Severe Level (2) 441–0...
  • Page 50 Maintenance Manual of Telescopic Handler 1075–5 Electric Fuel Delivery Pump for Engine Fuel Supply: Current Below Normal 1075–6 Electric Fuel Delivery Pump for Engine Fuel Supply: Current Above Normal 1076–5 Engine Fuel Injection Pump Fuel Control Valve: Current Below Normal 1076–6 Engine Fuel Injection Pump Fuel Control Valve: Current Above Normal 1188–3...
  • Page 51 Maintenance Manual of Telescopic Handler 3251–3 EGR #1 DPF Pressure Difference: Voltage Above Normal 3251–4 EGR #1 DPF Pressure Difference: Voltage Below Normal 3251–13 EGR #1 DPF Pressure Difference: Out of Calibration 3251–16 EGR #1 DPF Pressure Difference: High - Moderately Severe Level (2) 3251–18 EGR #1 DPF Pressure Difference: Low - Moderately Severe Level (2) 3358–3...
  • Page 52 Maintenance Manual of Telescopic Handler 4337–8 EGR #1 DEF Metering Valve #1 Temperature: Abnormal Frequency, Pulse Width or Cycle 4354–5 EGR #1 DEF Line Heater #1: Current Below Normal 4354–6 EGR #1 DEF Line Heater #1: Current Above Normal 4355–5 EGR #1 DEF Line Heater #2: Current Below Normal 4355–6 EGR #1 DEF Line Heater #2: Current Above Normal...
  • Page 53 Maintenance Manual of Telescopic Handler 8631–17 SCR Operator Induction Override Update Required 8631–18 Engine Turbocharger #1 Efficiency: Low - Least Severe Level...
  • Page 54 Maintenance Manual of Telescopic Handler 1.11.7 Lubrication points indication Lubrication point of the whole machine: 1. If work time is less than 50 h per week, then maintain it once a week. 2. If work continuously for a long time, the lubrication period is reduced to every 10 hours or every day.
  • Page 55 Maintenance Manual of Telescopic Handler...
  • Page 56 Maintenance Manual of Telescopic Handler...

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