LGMG T65J Service Manual
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LGMG T65J Service Manual

Telescopic boom mobile elevating work platform
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Service Manual
T20J、T22J、T26J
Telescopic 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.

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  • Page 1 Service Manual T20J、T22J、T26J Telescopic 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 LINGONG HEAVY MACHINERY CO., LTD. Telescopic boom Mobile Elevating Work Platform Service Manual 880*1230 mm Sextodecimo 8 sheets First edition, Dec. 2022 First print, Dec. 2022 LINGONG HEAVY MACHINERY CO., LTD.
  • Page 3 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: 86-0531-81666372 Web: www. lgmg. com. cn Parts sales hotline: 86-0531-67605016...

  • Page 4: Table Of Contents

    1.6 Intended use 1.7 Description Chapter II Product Introduction 2.1 Machine parameters 2.1.1 Parameters of T65J (T0020JNDAH21) 2.1.2 Parameters of T85J (T2623J0WND4AH2001) 2.2 Pecification for selection of tightening torque of the lifting platform 2.3 Key component moment table Chapter III Service 3.1 Notice...
  • Page 5 Service Manual of Telescopic Boom Mobile Elevating Work Platform 3.4.5 Assembling the telescopic boom frame 3.4.6 Assembling the telescopic cylinder 3.4.7 Assembling the lower leveling cylinder 3.4.8 Assembling the cable carrier 3.4.9 Rope 3.5 Engine side components (Deutz TD2.9L4) 3.5.1 Assembling the engine drivetrain 3.5.2 Assembling the engine intake system 3.5.3 Assembling the engine exhaust system 3.5.4 Assembling the engine cooling system...
  • Page 6 Service Manual of Telescopic Boom Mobile Elevating Work Platform 3.10.2 Removing the variable displacement walking pump 3.10.3 Assembling the variable displacement walking pump 3.10.4 Assembling tilt sensor 3.10.5 Assembling the warning lamp 3.11 leeding cylinder 3.11.1 Bleeding the variable displacement walking pump and gear pump 3.11.2 Bleeding the slewing gearbox 3.11.3 Bleeding the driving motor 3.11.4 Bleeding the steering cylinder...
  • Page 7 Service Manual of Telescopic Boom Mobile Elevating Work Platform 4.15.6 Check for Engine Air Filter 4.15.7 Cleaning or Replacement of Air Filter 4.15.8 Check for Coolant Liquid Level 4.15.9 Filling or Replacement of Engine Coolant 4.15.10 Check for Engine Belt 4.16 Regular Maintenance 4.17 Engine fault table 4.18 Engine fault Codes...

  • Page 8: Foreword

    Service Manual of Telescopic 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 parameter and maintenance adjustment data of the Telescopic boom Mobile Elevating Work Platform, and explains the troubleshooting and maintenance process for qualified professional maintenance personnel.

  • Page 9: Safety Notices

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Safety Notices The operator should understand and follow the current national and local safety regulations. If there are no national or local regulations, the safety instructions in this manual shall be applicable. Most accidents are caused by failure to comply with the regulations on the operation and maintenance of the machine.

  • Page 10: Chapter I Safety And Environment

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Chapter I Safety and Environment...
  • Page 11 Service Manual of Telescopic Boom Mobile Elevating Work Platform...

  • Page 12: I.1 Terms And Definitions

    Service Manual of Telescopic Boom Mobile Elevating Work Platform I.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 13: I.6 Intended Use

    Lingong Heavy Machinery Co., Ltd. Symbol representation Symbols, color codes and symbolic words used by LGMG products have the following meanings: Safety warning sign - used for warning of potential personal injury. Observe all safety tips after this sign to avoid possible personal injury or death.
  • Page 14 Service Manual of Telescopic Boom Mobile Elevating Work Platform Orange - Indicating a hazardous situation. If it is not avoided, it may cause death or serious injury. Yellow - Indicating a dangerous situation. If not avoided, it may cause minor or moderate personal injury.
  • Page 15 Service Manual of Telescopic Boom Mobile Elevating Work Platform...

  • Page 16: Chapter Ii Product Introduction

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Chapter II Product Introduction...
  • Page 17 Service Manual of Telescopic Boom Mobile Elevating Work Platform...
  • Page 18 Service Manual of Telescopic Boom Mobile Elevating Work Platform II.1 Machine parameters II.1.1 Parameters of T65J (T0020JNDAH21) 1. Machine performance specifications Item Parameter Item Parameter One rotation of turntable 250kg/551lbs 78-86 (Stowed position) (s) Rated load 2 persons One rotation of turntable (Raised...
  • Page 19 Service Manual of Telescopic Boom Mobile Elevating Work Platform Model D2.9L4 Rated speed (r/min) 2600 Displacement (L) Max. torque (Nm) 147/1600rpm Rated power (kW) 36.3 Emission standard EPA Tier 4f 4. Transmission system Item Parameter Rated output torque (Nm) 3390 Walking reducer Speed ratio 57.49：1...
  • Page 20 Service Manual of Telescopic Boom Mobile Elevating Work Platform (L/gal_US) II.1.2 Parameters of T85J (T2623J0WND4AH2001) 1. Machine performance specifications Item Parameter Item Parameter One rotation of turntable 250kg/551lbs 90-110 (Stowed position) (s) Rated load 2 persons One rotation of turntable (Raised 170-200 +90kg/198lbs cargo or extended) (s)
  • Page 21 Service Manual of Telescopic Boom Mobile Elevating Work Platform Model TD2.9L4 Rated speed (r/min) 2600 Displacement (L) Max. torque (Nm) 260/1800rpm Rated power (kW) 55.4 Emission standard EPA Tier 4f 4. Transmission system Item Parameter Rated output torque (Nm) 5500 Walking reducer Speed ratio 57.49：1...
  • Page 22 Service Manual of Telescopic Boom Mobile Elevating Work Platform (L/gal_US) II.2 Pecification for selection of tightening torque of the lifting platform The tightening torque tolerance range is 10% for all hydraulic seals, important transmission connectors and key processes with defined torque tightening requirements, and 20% for non-essential reference torques, which is to be rounded to the nearest integer when necessary.
  • Page 23 Service Manual of Telescopic Boom Mobile Elevating Work Platform 7/8-14 UN(F) 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: 1. 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; 2.
  • Page 24 Service Manual of Telescopic Boom Mobile Elevating Work Platform corresponding torque in Table 3 shall apply and shall be rounded to the nearest integer after calculation; 3) For Parker rubber hoses, right-angle joints and tee joints, the torque is to be selected according to the name and specification, and for ordinary rubber hoses, right-angle joints and tee joints, the torque is to be selected according to the thread specification.

  • Page 25: Key Component Moment Table

    5082 6577 II.3 Key component moment table Torque Value Interval Position Model Remark Hours Ft.lbs Assembling of T65J Direct the arrow towards the high-pressure /T85J engine. filter Parallelism between the rear Rear axle T65J axle upper plane and the clearance...
  • Page 26 Service Manual of Telescopic Boom Mobile Elevating Work Platform...

  • Page 27: Chapter Iiiservice

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Chapter IIIService...
  • Page 28 Service Manual of Telescopic Boom Mobile Elevating Work Platform...

  • Page 29: Notice

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Most maintenance processes can only be III.1 Notice performed professionally trained 1. The maintenance procedure should be maintenance personnel in a properly equipped completed by qualified personnel who have workshop. After troubleshooting, select been trained in the maintenance of the...

  • Page 30: Removing The Platform Assembly

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 1. Bolt 2. Washer 3. Nut  Removing the platform valve 1. As shown above, remove the PCU box fasteners 1/2/3, and remove the PCU box from the platform; 1. Platform valve (6/2 electromagnetic switching valve) 2.

  • Page 31: Assembling The Platform Assembly

    Service Manual of Telescopic Boom Mobile Elevating Work Platform applying any lifting pressure; 1. Bolt 2. Washer 3. Anti-collision rubber seat 4. Washer 5. Nut 6. Platform support 2. Remove fasteners 1/2/4/5 of part 3 from the platform support, remove the part 3 and set it aside.
  • Page 32 Service Manual of Telescopic Boom Mobile Elevating Work Platform 4. Bolt 5. Washer 6. Nut 7. Platform frame assembly 8. U-bolt 9. Washer 10. Nut 11. Platform support 1. Hoist part 7 to part 4 and fix it with parts 4 (from top to bottom)/5 (at both bolt end and nut end)/6.

  • Page 33: Jib Assembly

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 2. Connect the hose firmly with part 4; 1. File box 2. Bolt 3. Washer 4. Nut 5. Platform tool box 6. Screw 7. Washer Assemble part 5 to part 3 with parts 6/7. 3.

  • Page 34: Removing The Swing Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform This procedure shall pin using a soft metal hammer. WARNING: Risk of crushing. implemented with boom If not properly supported by the stowed. crane, the flying jib may fall during the 2.

  • Page 35: Removing The Flying Jib Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform loosen the hydraulic joint very slowly to WARNING: Risk of personal injury. Sprayed hydraulic oil can penetrate reduce pressure gradually. and burn the skin. Therefore, please Prevent from spraying loosen the hydraulic joint very slowly to ejection.

  • Page 36: Removing The Upper Leveling Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform III.3.4Removing the upper leveling 7. Carefully pull the cylinder out of the boom until it contacts the hydraulic hose. cylinder 8. Mark, disconnect and plug the hydraulic hoses CAUTION: on the upper leveling cylinder. Cover the 1.

  • Page 37: Assembling The Flying Jib Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 1. Shaft 2. Safety pin 3. Bolt 4. Washer 5. Nut 6. Shaft 7. Bolt 3. Connect the cylinder piston rod, the jib tail assembly and the lower link assembly with shaft (part 1), and fix them with parts 2/3/4/5;...

  • Page 38: Assembling The Stop Block

    Service Manual of Telescopic Boom Mobile Elevating Work Platform subassembled triangular bracket on swing motor mounting bracket, adjust the gap between the triangular bracket and the swing motor mounting bracket with shim, and install a shim at each end of the triangular bracket. III.3.9Hoisting the jib 1.

  • Page 39: Telescopic Boom Assembly

    Service Manual of Telescopic Boom Mobile Elevating Work Platform the specified torque, and make the mark for counterweight first. confirmation; WARNING: Risk of overturning When installing the boom frame to 3. Remove the protective plug (part 2) and protective cover (part 4), tighten part 4 on the machine, always install the boom part 3 to the specified torque, and make the frame...
  • Page 40 Service Manual of Telescopic Boom Mobile Elevating Work Platform fittings. counterweight, stay away from the 1. Remove the flying jib. concerning area. 2. Remove the cable carrier. 10. Attach the sling on the 5t/5,000kg overhead 3. Lift the boom until the pin from the upper/lower crane to the end of the boom frame.

  • Page 41: Removing The Telescopic Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Prevent from spraying may fall. ejection. III.4.2Removing the telescopic 17. Mark and disconnect the electrical connector cylinder of the cable limit switch. WARNING: Risk of personal injury. 18. Mark and disconnect all boom harness This procedure requires specific connectors at the pivot end of the boom.
  • Page 42 Service Manual of Telescopic Boom Mobile Elevating Work Platform retraction rope off the pulley. Put the rope 1. Extension rope adjusting nut 2. Extension rope flatly and set it aside. mounting plate 3. Extension rope mounting plate fastener 4. Extension rope bracket 13.

  • Page 43: Removing The Lower Leveling Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 23. Carefully support the telescopic cylinder and specification for selection of tightening slide it out of the boom. torque of the elevating work platform. WARNING: Risk of crushing. 1. Lift the boom until the lower leveling cylinder is properly supported, the above the turntable cover.
  • Page 44 Service Manual of Telescopic Boom Mobile Elevating Work Platform fitting and hose assembly must be end through which the cable is led into the cable carrier. replaced. During installation, 8. Mark and disconnect the electrical connectors connections must be tightened to of all cables led into the cable carrier.

  • Page 45: Assembling The Telescopic Boom Frame

    Service Manual of Telescopic Boom Mobile Elevating Work Platform carrier to the boom. the width of each component in accordance 17. Remove the cable carrier from the machine with SOP. with care, and place it on a structure with 2. Before assembling the basic section, appropriate bearing capacity.
  • Page 46 Service Manual of Telescopic Boom Mobile Elevating Work Platform with a brush, with part 9 located on the lower is as follows: the sum of the left and right side. clearance is less than 1mm; 6. Lower the sling, adjust the position of the sling Measure clearance between...
  • Page 47 Service Manual of Telescopic Boom Mobile Elevating Work Platform using shims 13 and 14) 17. Lower the sling, adjust the position of the requirement for upper and lower sling to the rear end of the part 1, lift the part clearance is as follows: the sum of upper again with the rear end slightly tilted, and and lower clearance is less than 1mm, and...

  • Page 48: Assembling The Telescopic Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform slider and the outer wall of the second The requirement for left and right clearance section, select shims 10 and 11, and fill the is as follows: the sum of left and right clearance evenly.
  • Page 49 Service Manual of Telescopic Boom Mobile Elevating Work Platform body under the lifted weight, prevent then clamp the part 4 into the mounting hole at the lower side of the third section; rope from crossing dung 9. Apply adhesive to the head of part 2, assembling, and replace the lifting rope pretighten part 4 with parts 2 and 3, and then in time if damaged.

  • Page 50: Assembling The Lower Leveling Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform and then, make the mark for confirmation. 13. Tie the nylon rope to the middle of the adjusting screw and lead it to the outside of the boom; Tie the nylon rope with a skipnot for the convenience of removal 14.

  • Page 51: Assembling The Cable Carrier

    Service Manual of Telescopic Boom Mobile Elevating Work Platform leveling bracket assembly, with the rod 1. Cable carrier assembly 2. Cable carrier guide chamber of the lower leveling cylinder wide plate 3. Cable carrier guide nylon block 4. connected to the basic section, and the Cable carrier guide nylon block 5.
  • Page 52 Service Manual of Telescopic Boom Mobile Elevating Work Platform 1. Bolt 2. Washer 3. Washer 4. Nut 5. Bolt 6. Upper wiring beam assembly 1. Nylon pipe 2. Bolt 3. Washer 4. Nut Tools: QSP25N4, socket wrench 10, open-end Tools: Ratchet wrench 16, open-end wrench wrench 10 5.

  • Page 53: Rope

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 43-49N•m with a torque wrench. Retract and extend the boom by about 1 m twice, and stop during the extension cycle to relax the retraction cable. CAUTION: Do not fully extend the boom 9.

  • Page 54: Engine Side Components (Deutz Td2.9L4)

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 7. Install new boom extension rope pulley, pin the cord until the new rope reaches the end of the boom tube. Remove the cord. and snap ring. CAUTION: Make sure that the boom extension 18.

  • Page 55: Assembling The Engine Intake System

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 1. Assemble part 3/4 to the engine with parts 1/2 III.5.3Assembling the engine as shown, and tighten them to the specified exhaust system torque. III.5.2Assembling the engine intake system 1. Upper exhaust tailpipe 2. Exhaust pipe 3. Bolt 4.

  • Page 56: Subassembling The Engine

    Service Manual of Telescopic Boom Mobile Elevating Work Platform it with parts 6/7; Acceptable fire extinguishers should be 3. Connect the part 14 to the position as shown, always equipped in easily accessible and fasten it with part 2; places. 4.

  • Page 57: Removing The Hydraulic Tank

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Reference torque of part 4: 37±4N.m; hydraulic hoses and fittings. Tools: Electric impact wrench SATA 51082, 1. Close the two hydraulic ball valves on the socket wrench 1/2-16, open-end wrench hydraulic tank. 16-17, torque wrench QSP50N3 CAUTION: Risk of part damage.
  • Page 58 Service Manual of Telescopic Boom Mobile Elevating Work Platform tank is free of paint damage, scratch and tube, and pre-install parts 5/6/7/8/9 on the deformation and that the oil ports of the tank other side. well sealed. remove 4. Tight parts 3/7. protections of the tank unless assembling is Tools: Electric impact wrench SATA 51082, about to start;...
  • Page 59 Service Manual of Telescopic Boom Mobile Elevating Work Platform with the parts 3 and 4. specified torque. Tools: Open-end wrench 8-10, torque wrench 11. Assemble part 2 to the end of oil return steel QSP50N3, electric impact wrench SATA tube. 51082, socket wrench 1/2-13, adapter 3/8-1/2 8.

  • Page 60: Assembling The Ground Control Unit (Gcu)

    Service Manual of Telescopic Boom Mobile Elevating Work Platform III.6.5Assembling the ground control unit (GCU) 1. Bolt 2. Washer 3. Spring nut 4. Bolt 5. Nut Tools: Electric impact wrench 51082, socket wrench 1/2-16, torque wrench QL100N4 14. Tear off the protection of hydraulic tank body, and pay attention to cleaning the edge.

  • Page 61: Assembling Battery

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 3. Install part 6 to part 7, fasten it with part 8, and III.7 Turntable assembly fix the subassembled emergency power unit III.7.1Hoisting the turntable with parts 9/10/11 to the battery tray. III.6.7Assembling battery 1.

  • Page 62: Assembling The Slewing Gearbox

    Service Manual of Telescopic Boom Mobile Elevating Work Platform specified torque. Please refer to the III.7.3Assembling the slewing specification for selection of tightening gearbox torque of the elevating work platform. 1. Lock the turntable with the turntable rotation lock to prevent the turntable from rotating. 2.

  • Page 63: Removing The Open Variable Displacement Pump

    Service Manual of Telescopic Boom Mobile Elevating Work Platform tightening the part 1, so that the back of the care. gearbox gear fits the copper strip (meshing WARNING: Risk of part damage. After installing the pump, make sure to gap: 0.20-0.30mm), and then pre-tighten part open the two valves of the hydraulic tank and 2, apply red marking adhesive, and then fill the pump with oil.

  • Page 64: Assembling Wheels

    Tools: Torque wrench QLE550N, sling, 24 CAUTION: Risk of crushing. socket wrench If not supported during removal Assembling of wheel torque value：T65J： from the machine, the steering knuckle, 595±55Nm；T85J：305±25Nm。 driving motor, and gearbox may be out III.8.3Removing the front axle of balance or fall.

  • Page 65: Removing The Floating Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform the pin mounting hole as shown above. Next, the connecting plate and the front axle remove the plug as indicated by the yellow weldment. Install the pin (part 2) from top to circle in the figure, which is located at bottom (or from bottom to top for the lower right-hand...

  • Page 66: Assembling The Floating Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform hammer. and burn the skin. Therefore, please 4. Attach the sling from the crane to the floating loosen hydraulic connectors very cylinder tube end. slowly to reduce the oil pressure 5. Remove the fasteners that fix the cylinder tube gradually.

  • Page 67: Rear Axle Assembly

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 1) to the subassembly tooling, and lift part 2 III.9 Rear axle assembly to the mounting positions at both ends of the III.9.1Removing the rear axle walking gearbox. Then rotate the part 2 to driving motor and reducer adjust its mounting angle, ensuring that the motor mounting hole is at the horizontal...

  • Page 68: Other Components

    Service Manual of Telescopic Boom Mobile Elevating Work Platform this case, please get the machine serviced by III.10Other components the dealer. III.10.1 Assembling the 1. Disconnect the electrical connector on the radiator assembly variable displacement walking pump. 2. Position the two hydraulic tank valves on the hydraulic tank through the access hole below the turntable.

  • Page 69: Assembling Tilt Sensor

    Service Manual of Telescopic Boom Mobile Elevating Work Platform for the assembly of the open variable displacement pump. When there is no oil flowing out, wipe off the oil stain of the variable displacement walking pump. 2. Sleeve the side of the coupling iron core without retaining ring into the spline hole at the head of the variable displacement walking pump, make the head of the variable...

  • Page 70: Leeding Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 3. Screw III.11.4 Bleeding the steering 4. Washer 5. Nut cylinder 1. Assemble part 1 on part 2 with parts 3/4/5. 2. Assemble the subassembled warning lamp to the counterweight end of turntable. 3.

  • Page 71: Bleeding The Boom Telescopic Cylinder

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 2. Activate the boom lifting button to operate the III.11.7 Bleeding the flying jib machine to retract and extend the boom luffing cylinder and upper luffing cylinder. The boom luffing cylinder can leveling cylinder be divided into three parts.
  • Page 72 Service Manual of Telescopic Boom Mobile Elevating Work Platform...

  • Page 73: Installing The Spool

    Service Manual of Telescopic Boom Mobile Elevating Work Platform III.12Valve group III.12.1 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 74: Walking Control Valve (4120704651)

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Plug 11-12 Reversing valve Controlling the brake action 27.1 Controlling the floating Reversing valve 27.1 action Controlling the two-speed Reversing valve 27.1 action III.12.3 Walking control valve (4120704651) Name Function Torque (N·m) Flow diverter/combiner Controlling the front and 133-138...

  • Page 75: Boom Function Valve Group (4120709022)

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Plug 25-28 Plug 41-48 Damper Plug 72-82 Valve block III.12.4 Boom function valve group (4120709022) Name Function Torque (N·m) Valve block Enabling one-way flow of Check valve 85-95 hydraulic oil Limiting the maximum Relief valve 55-65 pressure of the lifting...
  • Page 76 Service Manual of Telescopic Boom Mobile Elevating Work Platform system Maintaining a constant flow Flow valve of hydraulic oil in 40.6 circulation Switching between left turn Solenoid valve 33.9 and right turn Compensating the system Compensation valve 55-60 pressure Stabilizing hydraulic oil Damper flow Maintaining a constant flow...
  • Page 77 Service Manual of Telescopic Boom Mobile Elevating Work Platform function Balance valve Balancing pressure 40-45 Enabling one-way flow of Check valve 40-45 hydraulic oil Coil Coil Coil Plug 11-12 Plug 25-28 Plug 41-48...

  • Page 78: Chapter Iv Maintenance

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Chapter IV Maintenance...
  • Page 79 Service Manual of Telescopic Boom Mobile Elevating Work Platform...

  • Page 80: Compliance

    If the labels need to be replaced, applicable laws regulations please contact the service staff of government. LGMG. Protective articles, such as safety helmet, safety belt, work shoes, goggles and IV.3 Check for damaged, protective clothing, have been equipped all...

  • Page 81: Check For Batteries

    Note: If an external power supply is required to charge the battery, only the charger  Check the wiring of the battery cable. The approved by the LGMG can be used. wiring is firm and free from corrosion.  Do not replenish the battery with white ...

  • Page 82: Check For Tires And Hubs

    Service Manual of Telescopic Boom Mobile Elevating Work Platform terminals and cables. IV.5 Check for tires and hubs This check item is conducted every 250 hours or quarterly, whichever comes first. Keeping tires and hubs in a good condition is critical for safe operation and good performance.

  • Page 83: Inspecting The Boom Wear Pad

    Service Manual of Telescopic Boom Mobile Elevating Work Platform not synchronized, separation of wire rope from IV.7 Inspecting the Boom pulley, boom shaking during extension, contact of Wear Pad wire rope to inner wall of boom sections or rubbing between wire rope and inner wall of the Inspect the wear pad every 1,000 h or boom and other problems.

  • Page 84: Inspecting The Drive Hub Oil Level

    Service Manual of Telescopic Boom Mobile Elevating Work Platform and retracting, there must be no flapping in  Coat the plugs with pipe thread sealant and the pulley. In the case of any abnormalities, install the plugs. stop using the machine immediately and tag ...

  • Page 85: Inspecting The Hydraulic Oil And Filter

    Service Manual of Telescopic Boom Mobile Elevating Work Platform boards as a search tool for hydraulic oil IV.10Inspecting the Hydraulic leakage. Hands shall be prohibited from Oil and Filter being used for leakage confirmation. Inspect oil drops or residual oil on the following Inspect hydraulic oil level every 8 h or every components: day.

  • Page 86: Replacing The Air Cleaner

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Install a new air cleaner. IV.13Replacing the high-pressure filter element Risk of personal injury. Be careful of hot oil. The contact with hot oil will cause severe burns. Fig.4.7 Hydraulic tank Caution: This step shall be performed when the Tightening...

  • Page 87: Changing Hydraulic Oil And Replacing The Suction Filter

    Service Manual of Telescopic Boom Mobile Elevating Work Platform date on the filter replacement record. Implement any arm rod function with the GCU. Check the filter components for oil leakage. IV.14Changing hydraulic oil and replacing the suction filter Fig. 4.8 Hydraulic oil tank Risk of personal injury.

  • Page 88: Engine Maintenance- Deutz

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 7. Flush the inside of the hydraulic tank with a IV.15Engine maintenance- mild solvent. (Clean it with chemical cleaning Deutz agent at first. After drying, flush with clean hydraulic oil and drain the oil.) IV.15.1 .Check for Engine Oil 8.

  • Page 89: Replacement Of Engine Oil And Filter

    Service Manual of Telescopic Boom Mobile Elevating Work Platform a piece of clean and fiber-free cloth. be below -10℃. (14゜F) or the temperature of Insert the oil measuring rod into the bottom. engine oil is below 60℃ (84゜F), or the sulphur Pull out the oil measuring rod and read the content in the diesel fuel is 0.5 - 1%, the oil value of engine oil level.

  • Page 90: Check For Fuel Leakage

    Service Manual of Telescopic Boom Mobile Elevating Work Platform drain plug. Screw off the engine oil drain plug to drain the old engine oil. Install the new seal ring for the engine oil drain plug and screw in and tighten it. Add engine oil at the engine oil filler.

  • Page 91: Vent Fuel Pre-Filter

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Visually check for fuel leakage every 8 hours or every day. CAUTION: There is danger of explosion and fire. fuel engine combustible. Check the position of the machine. When this step is performed, the machine should be in a well- ventilated area away from the heater, Fig.

  • Page 92: Replacement Of The Fuel Filter

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 10. Open the fuel shutoff tap and vent the cleaning. Blow parts with system, see venting the fuel system. compressed air.  Vent the fuel system CAUTION: The fuel system is vented via the electric fuel Please observe safety...

  • Page 93: Check For Engine Air Filter

    Service Manual of Telescopic Boom Mobile Elevating Work Platform and cleaned or replaced. IV.15.7 Cleaning or Replacement of Air Filter Clean it every 250 hours or quarterly and replaced it for every 1000 hours. Do not operate on running engines! Fig.

  • Page 94: Check For Coolant Liquid Level

    Service Manual of Telescopic Boom Mobile Elevating Work Platform element 4. Primary element 5. Evacuator cover can only be opened in the cooling state. valve Coolant must have a specified concentration Make sure the hooking clip for the element is of cooling system protectant! tight enough.

  • Page 95: Check For Engine Belt

    Service Manual of Telescopic Boom Mobile Elevating Work Platform  Filling of the Coolant 3. Reinstall the protector if necessary. 4. When it is a new belt, check whether the 1. Carefully open the cover for the cooling position is correct. After running for 15 system.

  • Page 96: Regular Maintenance

    Service Manual of Telescopic Boom Mobile Elevating Work Platform damage. 2. Replace damaged components. 3. Reinstall the protector if necessary. 4. When it is a new belt, check whether the position is correct. After running for 15 minutes, check the tension. Tensioning of Belt Fig.

  • Page 97: Engine Fault Table

    Service Manual of Telescopic Boom Mobile Elevating Work Platform IV.17Engine fault table DEUTZ Engines: Faults Cause Measures Not disconnected (if possible) Check coupling Fuel tank empty Tanks Fuel suction pipe blocked Check Below starting limit temperature Check Cold starting device Check/replace Wrong SAE viscosity class of the Change the lubricating oil...
  • Page 98 Service Manual of Telescopic Boom Mobile Elevating Work Platform Fuel filter contaminated Clean Fuel quality does not comply with Change the fuel operating manual Injector defective Change Injection line leaks Check injection line Engine cable harness defective Check/replace Engine electronics has detected a Speed changes are possible and Check error according to error code system...
  • Page 99 Check injection line Injector defective Change Throttle valve defective Check/replace Exhaust gas recirculation, actuator Check/replace defective Exhaust gas backpressure too high Check/clean Exhaust gas turbocharger defective Change Engine performs poorly Engine electronics reduce Please contact your LGMG partner diagnostic lamp lights performance...
  • Page 100 Service Manual of Telescopic Boom Mobile Elevating Work Platform Injection line leaks Check injection line Injector defective Change Engine does not run on all cylinders Compression pressure too low Check compression pressure Engine cable harness defective Check/replace Lubricating oil level too low Fill up lube oil Check engine mounting / reduce Excessive inclination of engine...

  • Page 101: Engine Fault Codes

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Fuel quality does not comply with Change the fuel operating manual Engine producing white smoke Injector defective Change Warm up engine so that water Condensation residues evaporate Air filter clogged / turbocharger Check/replace defective filter...
  • Page 102 Service Manual of Telescopic Boom Mobile Elevating Work Platform DTC-Code Error Identification 1003 Oil sensor invalid sensor status. Sensor status can not be read correctly. 1004 Oil sensor temperature out of range (-48°C > temp. > 168°C). Oil sensor is broken or disconnected. PWM input signal from sensor is not 1005 available or not correct.
  • Page 103 Service Manual of Telescopic Boom Mobile Elevating Work Platform DTC-Code Error Identification Pressure turbine upstream stuck check failed. Pressure does not change 1127 1209 between engine operating points. 1130 1209 Diagnostic fault check for SRC high for outlet-valve downstream pressure. 1131 1209 Diagnostic fault check for SRC low for outlet-valve downstream pressure.
  • Page 104 Service Manual of Telescopic Boom Mobile Elevating Work Platform DTC-Code Error Identification Sensor error rail pressure. 1208 Sensor voltage above upper limit. 1209 Sensor error rail pressure. Sensor voltage below lower limit. 520252 Wrong checksum in the CAN message EAT Control. Error generated from DemEvent RBA_IOEXTLIB_KEEPALIVE_DRV: 1212 KeepAlive error during runtime at an external device.
  • Page 105 Service Manual of Telescopic Boom Mobile Elevating Work Platform DTC-Code Error Identification 1311 Starter relay low side short circuit to ground. 1323 Plausibility error between APP1 and APP2 or APP1 and idle switch. In case of dual analog accelerator pedal, it is the plausibility check between RmtAPP1 and RmtAPP2 and in case of potentiometer switch 1326 accelerator pedal, it is the plausibility check between APP1 and idle...
  • Page 106 Service Manual of Telescopic Boom Mobile Elevating Work Platform DTC-Code Error Identification Stuck check for TOxiCatUs_t failed. Temperature does not change 1408 4765 anymore. 520256 Timeout of EAT Control Receive Message. The message is not received. 523211 Timeout error of CAN-Receive-Frame EBC1. 523212 Timeout error of CAN-Receive-Frame ComEngPrt.
  • Page 107 Service Manual of Telescopic Boom Mobile Elevating Work Platform DTC-Code Error Identification EGR valve, open load. EGR valve, short circuit to battery1. EGR valve, short circuit to battery2. EGR valve, short circuit to ground1. EGR valve, short circuit to ground2. EGR valve, over load.
  • Page 108 Service Manual of Telescopic Boom Mobile Elevating Work Platform DTC-Code Error Identification Cold start aid relay: Open load. Intake air massflow not in expected range. Intake Air Heater Device: Short circuit to battery. Powerstage on CJ945, short circuit to ground. 2797 Number of possible injections limited by the injection valve.
  • Page 109 Service Manual of Telescopic Boom Mobile Elevating Work Platform DTC-Code Error Identification 7103 Short circuit to ground on the low side power stage of MeUn. 7103 Short circuit between high side and low side power stage of MeUn. Function monitoring: fault of ECU ADC - Null Load Test Pulse. Function monitoring: fault of ECU ADC - test voltage.
  • Page 110 Service Manual of Telescopic Boom Mobile Elevating Work Platform DTC-Code Error Identification Internal ECU error. Internal ECU error. Internal ECU error. Internal ECU error. 1109 Engine shut off demand ignored. Internal ECU error. Internal ECU error. Internal ECU error. Internal ECU error. Internal ECU error.

  • Page 111: Maintenance Schedule

    Service Manual of Telescopic Boom Mobile Elevating Work Platform DTC-Code Error Identification Internal ECU error. Internal ECU error. Diagnostic fault check to report ABE active state. Function monitoring: fault of ECU, WDA active by inquiry/response communication. Function monitoring: fault of ECU, Error Pin active suspision of HW fault. Function monitoring: fault of ECU, WDA active by overvoltage detection.
  • Page 112 Service Manual of Telescopic Boom Mobile Elevating Work Platform clean the radiator Clean the fuel tank filler ● ● ● ● ● filter Drain deposits from the ● ● ● ● ● fuel tank Replace the secondary Every 500h (DeutzD2011-L03i/D2.9L4/TD2.9L4; Kubota-V2403-E5) or fuel filter every six months, whichever comes first.
  • Page 113 Service Manual of Telescopic Boom Mobile Elevating Work Platform are normal Is the wiring of the solenoid valve coils of the Daily main valve block normal or loose Check whether the starter motor terminal is loose or Daily broken Check if the battery terminals are loose or Daily rusted...
  • Page 114 Service Manual of Telescopic Boom Mobile Elevating Work Platform bottom of the hydraulic reservoir are open Check whether the fixing clip of the travel Daily tubing is loose hydraulic Check the oil level of oil when Daily the hydraulic reservoir the oil level is below MIN...
  • Page 115 Service Manual of Telescopic Boom Mobile Elevating Work Platform they are in the tray Check if the safety signs are correct or Daily defaced Check the bolts, nuts and other fasteners of Daily the machine for looseness and noise Check whether the structural parts of the machine have cracks Daily...
  • Page 116 Service Manual of Telescopic Boom Mobile Elevating Work Platform Measure the backlash between the slewing 0.2-0.3 ● ● ● ● bearing gear and the slewing drive gear Lithium Grease the slewing ● ● ● ● ● base bearing grease 2# Grease the slewing Lithium Lubricati...

  • Page 117: Chapter V Commissioning

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Chapter V Commissioning...
  • Page 118 Service Manual of Telescopic Boom Mobile Elevating Work Platform...

  • Page 119: V.1 Safety Instructions

    Service Manual of Telescopic Boom Mobile Elevating Work Platform regulations and the instructions in the table below V.1 Safety instructions to maintain a sufficient safety distance from Before commissioning, commissioning wires, power supplies, and electrical equipment. personnel shall be sure to refer to the Operation Voltage Required safety distance and Maintenance Manual, be familiar with...

  • Page 120: V.2 Start Test

    Service Manual of Telescopic Boom Mobile Elevating Work Platform V.2 Start test Key switch: After the key is inserted into the key switch socket and turned to "Platform Control" mode, then the beacon will flash, the screen will light up, and the platform control unit will run after the key switch is turned to the neutral position, the machine will be turned off, and the beacon will be turned off, the screen will be off;...

  • Page 121: V.3 Basic Operation Test Of Ground Control Unit

    Service Manual of Telescopic Boom Mobile Elevating Work Platform control) is turned; the working engine stops working if the emergency stop switch is pressed; Control criteria: conforming to requirements 5. Horn switch Press the horn switch to sound the horn; Control criteria: effective in use V.3 Basic operation test of ground control unit Enable switch test:...
  • Page 122 Service Manual of Telescopic Boom Mobile Elevating Work Platform 2. Each commissioning should be done separately, two or more operations cannot be carried out at the same time; 3. The commissioning time of each operation should be 3-5S, the commissioning is visible to the naked eye, and it should be stopped when it is effective;...

  • Page 123: V.4 Basic Operation Test Of Platform Control Unit

    Service Manual of Telescopic Boom Mobile Elevating Work Platform When the platform leveling switch is pulled upward, the horizontal plane of the platform will rise without jitter, abnormal noise or impact; When the platform leveling switch is pulled down, the horizontal plane of the platform will drop without jitter, abnormal noise or impact;...
  • Page 124 Service Manual of Telescopic Boom Mobile Elevating Work Platform The engine operates normally, step on the foot switch, push all function control levers, and all functions of the machine operate normally. Push a function control lever, then press the foot switch, and this function of the machine has no action.
  • Page 125 Service Manual of Telescopic Boom Mobile Elevating Work Platform 5. Boom luffing: If the left handle is moved forward, the boom upward luffing will occur without jitter, abnormal noise or impact; If the left handle is moved backward, the boom will luff downward without jitter, abnormal noise or impact;...

  • Page 126: V.5 Drive Enable System Test

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Unscrew the fastening nut of the relief valve, V.5 Drive enable system test and rotate the valve spool clockwise or Start the vehicle and operate with the counterclockwise with the Allen wrench to platform control system;...

  • Page 127: V.8 Rated Load Calibration

    Service Manual of Telescopic Boom Mobile Elevating Work Platform 2. Place 1.25 times the rated load on the V.8 Rated load calibration working platform, and connect the safety belt 1. When the vehicle is stopped, use the ground to the platform guardrail. control mode and enter the system according 2) Turn the emergency stop switch of the ground to the prompts.

  • Page 128: V.11 Lifting Height Test

    Service Manual of Telescopic Boom Mobile Elevating Work Platform condition. enable button and rotary table rotary switch at the same time (to the left) to move the rotary V.11 Lifting height test table to the far left; Then start the rotary table 1.

  • Page 129: Driving Speed (High Speed) Test

    Service Manual of Telescopic Boom Mobile Elevating Work Platform extend the boom, and start timing at the same time; When the boom is extended to the limit, stop extending and timing. Press and hold the enable button and boom extension and retraction switch (down) at the same time to retract the boom and start timing at V.13Driving speed (high the same time;...

  • Page 130: Limit Drive Speed Test

    Service Manual of Telescopic Boom Mobile Elevating Work Platform power switch and let the machine stop 3. Pay attention to driving safety. automatically. 1. In the platform control mode, depress the foot Use a tape measure to measure the distance switch, after which the boom is lifted by about from the 20m line to the center line of the front 90cm (or the boom is extended by 30cm);...

  • Page 131: Appendix

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Appendix...
  • Page 132 Service Manual of Telescopic Boom Mobile Elevating Work Platform...

  • Page 133: Appendix I Machine Fault Codes

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Appendix I Machine fault codes Error Description Limit action code Controller output power supply 1 open circuit Main boom upper luffing Controller output power supply 2 open circuit Main boom upper luffing Controller output power supply 3, 4 open circuit Main boom upper luffing The CAN bus of the expansion module of the...
  • Page 134 Service Manual of Telescopic Boom Mobile Elevating Work Platform The turntable is tilted, the main boom angle is Main boom upper luffing, main boom extended、 greater than positive 5 degrees, the main boom turntable rotation, walking is up and the main boom is extended The turntable is tilted, the extension length of the main boom exceeds 60cm, the main boom is in Main boom upper luffing, main boom extended、...

  • Page 135: Appendix Ii Electrical Schematic Diagram

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Appendix II Electrical schematic diagram Electrical schematic diagram of T65J...
  • Page 136 Service Manual of Telescopic Boom Mobile Elevating Work Platform Electrical schematic diagram of T85J...
  • Page 137 Service Manual of Telescopic Boom Mobile Elevating Work Platform...

  • Page 138: Appendix Iii Hydraulic Schematic Diagram

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Appendix III Hydraulic schematic diagram Hydraulic schematic diagram of T65J...
  • Page 139 Service Manual of Telescopic Boom Mobile Elevating Work Platform...
  • Page 140 Service Manual of Telescopic Boom Mobile Elevating Work Platform Hydraulic schematic diagram of T85J...

  • Page 141: Appendix Iv Diagram Of Common Electrical Part Symbols

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Appendix IV Diagram of common electrical part symbols Lette Lette Graphic Graphic Name Category Name Socket symbol symb symbol symb Unipolar Normally control open switch contact General Normally symbols of Position closed manual switch...
  • Page 142 Service Manual of Telescopic Boom Mobile Elevating Work Platform Normally Normally open main closed contact contact Normally open Coil auxiliary contact Normally Intermedi Normally closed ate relay open auxiliary contact contact Power-on Normally delay closed (slow pull-in) contact coil Overcurren t coil Power-off delay (slow...
  • Page 143 Service Manual of Telescopic Boom Mobile Elevating Work Platform Normally Normally open contact closed which is disconnecte contact d with delay Three-pha General se cage symbol of electromagn asynchron ous motor Three-pha se wound Electromagn rotor etic chuck asynchron ous motor Separately Electromagn Motor...

  • Page 144: Appendix V Diagram Of Common Hydraulic Part Symbols

    Service Manual of Telescopic Boom Mobile Elevating Work Platform Appendix V 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-adjust able One-way one-way One-way rotation,...
  • Page 145 Service Manual of Telescopic Boom Mobile Elevating Work Platform Two-way Swing Continuous swing, fixed motor action angle One-way Fixed flow, displaceme one-way One-way nt hydraulic rotation, action pump-moto fixed displaceme Turbocharg Two-way flow, Variable two-way displaceme Pump-moto rotation, Continuous nt hydraulic variable action pump-moto...
  • Page 146 Service Manual of Telescopic Boom Mobile Elevating Work Platform Hydraulic Axle of External Arrows can pilot rotary pressure be omitted pressure motion control control Hydraulic Internal secondary pressure Positioning pilot control, device pressure co internal oil ntrol drain External control of air Gas-liquid pressure, * Control...
  • Page 147 Service Manual of Telescopic Boom Mobile Elevating Work Platform Single-actin adjustable electromag netic Button type operation (proportion electromag net) Double-acti adjustable Press-pull electromag type netic operation (torque motor, etc.) Rotary motion Handle electrical type control device One-way Feedback General pedal type control symbol The position...
  • Page 148 Service Manual of Telescopic Boom Mobile Elevating Work Platform General Direct-actin symbols or Sequence harmonious- proportiona valve acting l relief sequence valve valve Pilot Sequence Pilot proportiona valve sequence l relief valve valve One-way Unloading sequence Unloading it when valve relief valve p2>p1 (balance...
  • Page 149 Service Manual of Telescopic Boom Mobile Elevating Work Platform External control and Three-posit Double internal hydraulicall leakage (with four-way y controlled manual electro-hyd check valve emergency raulic valve control device) Three-posit Throttling Detailed type, four-way symbol overlapped proportiona center Shuttle Or gate l valve valve...
  • Page 150 Service Manual of Telescopic Boom Mobile Elevating Work Platform Roller-contr olled Flow throttle combiner valve valve (deceleratio n valve) Diverter Flow regula Flow regula Detailed collector ting valve ting valve symbol valve (6) Oil tank Pipe end at Pipe end the bottom above the of the oil...
  • Page 151 Service Manual of Telescopic Boom Mobile Elevating Work Platform Torque meter (9) Other auxiliary components Detailed Differential pressure symbol switch Pressure relay (pressure switch) General General Sensor symbol symbol Detailed Pressure Sensor symbol sensor Travel switch General Temperatur symbol e sensor General Coupling symbol...

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