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LiuGong LT20JE Operation And Maintenance Manual

Mobile elevating work platform
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202302000
LT20JE MOBILE ELEVATING
WORK PLATFORM
OPERATION AND
MAINTENANCE MANUAL

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  • Page 1 202302000 LT20JE MOBILE ELEVATING WORK PLATFORM OPERATION AND MAINTENANCE MANUAL...
  • Page 3 The specification, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. LiuGong has the most current information available.

  • Page 5: Table Of Contents

    February,2023 LT20JE CONTENTS Foreword Maintenance Pre-delivery Inspection ........41 Safety Precautions Maintenance and Inspection Report ....42 General Safety Precautions ......10 Inspection Items ..........46 Work Area Safety ..........15 Tightening Torque .......... 67 Change of Product Purpose......19 INDEX Replacement of Service Parts ......
  • Page 6 February,2023 LT20JE...

  • Page 7: Foreword

    The correct steps for checking, starting, Use this machine only for the purpose described operating and stopping the machine are in this manual. Contact your LiuGong dealer for graphically described to guide the operator. approval before making any modifications or adding attachments to the machine.
  • Page 8 10 working hours or every day should be performed simultaneously. All the information, figures, tables, and specifications in this manual are the latest product data available at the time of publication. Guangxi LiuGong reserves the right to make changes without notice.

  • Page 9: Safety Precautions

    February,2023 Safety Precautions LT20JE Safety Precautions Safety Signs The words "Danger", "Warning" and "Caution" found on the aerial work platform are defined as Safety Warning Symbols follows: Safety warning symbols can be found on machines operating on the aerial work platform, safety signs, manuals and anywhere else concerning important safety information.
  • Page 10 Safety Precautions February,2023 LT20JE Description of Decals and Symbols Location Plan of LT20JE Decals 1. Reflective decal 8. Warning decal 15. Warning decal 22. Decorative decal 2. Warning decal 9. Hazard decal 16. Symbol decal 23. Rivet 3. Decorative decal 10.
  • Page 11 February,2023 Safety Precautions LT20JE Table 1-1 Description of LT20JE Decals and Symbols Material Description of Identification identification Keep a safe distance from 74A5150 the machine The decal assembly includes: 79A7171 instruction decal 79A8023 warning decal 16G1443 16G1351 warning decal 79A8034 warning decal...
  • Page 12 Safety Precautions February,2023 LT20JE Table 1-1 Description of LT20JE Decals and Symbols Material Description of Identification identification 16G1351 Tilt warning decal Machine operation 79A8034 instruction 79A8011 Warning decal LT20JE performance curve...
  • Page 13 February,2023 Safety Precautions LT20JE Table 1-1 Description of LT20JE Decals and Symbols Material Description of Identification identification Read and understand the operation manual, responsibility manual and 74A3080 safety manual, as well as all safety signs before using or maintaining the machine.
  • Page 14 Safety Precautions February,2023 LT20JE Table 1-1 Description of LT20JE Decals and Symbols Material Description of Identification identification Do not wash the vehicle with a high-pressure water gun or other water 74A2221 spraying tools to prevent damaging the motor and electrical components.
  • Page 15 February,2023 Safety Precautions LT20JE Table 1-1 Description of LT20JE Decals and Symbols Material Description of Identification identification Precautions for operation 79A8024 of turntable lock pin Nameplate of complete 00G6485 machine The decal assembly includes: 74A3345 warning decal 79A7403 79A7927 warning decal...

  • Page 16: General Safety Precautions

    Safety Precautions February,2023 General Safety Precautions LT20JE General Safety Precautions Do not wear loose-fitting clothing, jewelry, or have unsecured long hair. They may get caught in control systems or moving parts, causing Please read these safety precautions carefully. severe injury or death.
  • Page 17 It is prohibited to modify the aerial Compressed air may lead to personal injury. work platform without LiuGong's permission, and Wear masks, safety clothing and safety shoes LiuGong is not responsible for any when cleaning with compressed air.
  • Page 18 Repair any loose or damaged hard pipes and hoses of the hydraulic system in time. Leakage may cause fire. For repair or replacement, please contact the dealer designated by Guangxi LiuGong Machinery Co., Ltd. If any of the following problems are found, replacement is necessary. ●...
  • Page 19 February,2023 Safety Precautions LT20JE General Safety Precautions ● The reinforcement steel of the hose is When you start a power-deficient machine by embedded into the outer layer. using a normal machine with a negative grounding system, you must follow the following The end fittings are displaced.
  • Page 20 Safety Precautions February,2023 General Safety Precautions LT20JE Influence of Wind on Working at Heights Do not use the machine only intended for indoor operation for outdoor operations. Do not use the machine running outdoors to lift the platform when the wind speed is greater than 12.5 m/ s (28 mph).

  • Page 21: Work Area Safety

    February,2023 Safety Precautions LT20JE Work Area Safety Work Area Safety Do not rise the boom if the wind speed may exceed 12.5 m/s (28 mph) when using the platform outdoors. Lower the boom and do not Lift the platform only on firm and flat ground.
  • Page 22 Safety Precautions February,2023 Work Area Safety LT20JE Do not get on or off the work platform when Danger of Working on Slopes ● lifting. User shall obtain guidance and approval from ● Do not drive on the maximum allowable slope.
  • Page 23 February,2023 Safety Precautions LT20JE Work Area Safety below the slope: 350kV~500 kV 7.62 m 25 ft 500kV~750 kV 10.67 m 35 ft 750kV~1000 kV 13.72 m 45 ft The influence of strong wind or gust on platform movement, wire swing and slack shall be considered, and the platform shall be able to withstand strong wind or gust.
  • Page 24 Safety Precautions February,2023 Work Area Safety LT20JE Do not get off the platform when lifting it. Beware of the danger of squeezing when grasping the platform guardrail. Keep the platform floor free of debris. Lower the platform only if there is no people or Lower the intermediate hurdles at platform obstacle under the platform.

  • Page 25: Change Of Product Purpose

    Replacement of Service Parts Make sure that the operator's manual, safety manual and responsibility manual are complete, Please purchase the original parts of LiuGong in legible and located in the file storage box on the order to ensure the product performance and machine.

  • Page 26: Product Overview And Main Technical Parameters

    Product Overview and Main Technical Parameters February,2023 Replacement of Service Parts LT20JE Product Overview and Main Technical Parameters Product Overview The machine can only be used to lift personnel, tools and materials to the workplace. Main Components Fig. 2-1 Main Components 1.

  • Page 27: Main Technical Parameters

    February,2023 Product Overview and Main Technical Parameters LT20JE Main Technical Parameters Main Technical Parameters List of LT20JE Main Technical Parameters Design value Item Unit (s) LT20JE Maximum working height 21.5 Maximum platform height 19.5 Platform amplitude at maximum platform height Maximum platform amplitude 13.4...

  • Page 28: Vehicle Operation

    Vehicle Operation February,2023 Workplace Inspection LT20JE Vehicle Operation Pre-operation inspection refers to a visual inspection performed by the operator prior to each shift. The purpose of the inspection is to detect obvious problems with the machine before Workplace Inspection the operator carries out a functional test.
  • Page 29 February,2023 Vehicle Operation LT20JE Inspection before Operation 5. Wear-resistant sliding blocks 6. Tires and rims 7. Limit switches and horns 8. Alarms and indicators 9. Nuts, bolts and other fasteners 10. Intermediate hurdles or door at platform entrance 2. Check the complete machine for: 1.

  • Page 30: Controller

    Vehicle Operation February,2023 Controller LT20JE Controller Platform Control Panel Fig.3-3 1. Work platform leveling switch 10. Driving/steering lever 19. Platform operation indicator 2. Main boom luffing/turntable swing 11. Emergency power switch 20. Front area unlocking indicator lever 12. Audible and visual alarm 21.
  • Page 31 February,2023 Vehicle Operation LT20JE Controller 1. Work platform leveling switch 6. Main boom telescopic switch The platform level will rise when the platform The main boom will retract when the switch is leveling switch is pulled upward. pulled upward. The platform level will descend when the The main boom will extend when the switch is platform leveling switch is pulled downward.
  • Page 32 Vehicle Operation February,2023 Controller LT20JE 12. Audible and visual alarm 21. Low speed indicator The action buzzer and alarm buzzer will warn the When the function speed control is turned to the surroundings of the vehicle and the staff. slow position, this indicator is used to remind that all functions have been set to the minimum 13.
  • Page 33 February,2023 Vehicle Operation LT20JE Controller Ground Control Panel Fig.3-4 1. LCD screen 4. Turntable swing switch 7. Platform swing switch 10. Platform/off/ground selector switch 2. Main boom telescopic 5. Emergency power switch 8. Platform leveling switch switch 11. Red "Emergency stop"...
  • Page 34 Vehicle Operation February,2023 Controller LT20JE 6. Turtle/rabbit enable switch The low-speed mode is applied when the enable switch is turned to the "Turtle" position. The high-speed mode is applied when the enable switch is turned to the "Rabbit" position. 7. Platform swing switch The platform will rotate rightward when the platform swing switch is pulled to the right.

  • Page 35: Functional Test

    February,2023 Vehicle Operation LT20JE Functional Test 2. Press and hold the function enable button Functional Test and turn on the toggle switch for each boom and platform function. Result: All boom and platform functions shall work properly. The Basic Principles of Functional Test lowering alarm (if equipped) shall sound when the boom is lowered.
  • Page 36 Vehicle Operation February,2023 Functional Test LT20JE Test of Manual Emergency Descent 4. Do not depress the pedal switch. Test each function of the machine. Result: The machine 1. Remove the right counterweight cover plate function shall be disabled. of the machine and take out the emergency pump pressure lever.

  • Page 37: Emergency Stop

    February,2023 Vehicle Operation LT20JE Emergency Stop 2. Move the drive control lever slowly in the 4. Move and pull the drive enable toggle switch direction indicated by the green arrow on the to either side and move the drive controller...

  • Page 38: Auxiliary Controller

    Vehicle Operation February,2023 Auxiliary Controller LT20JE Auxiliary Controller 2. Move the corresponding function control lever or toggle switch slowly according to the marks on the control panel. Use the auxiliary power if the main power source (drive motor) fails. Steering 1.

  • Page 39: Driving On A Slope

    February,2023 Vehicle Operation LT20JE Driving on a Slope Driving on a Slope Determination of Slope Measure the slope with a digital inclinometer or Determine the machine's uphill, downhill, and as follows. You need the following tools: sidehill ratings and the slope.

  • Page 40: Front Area Detection

    Vehicle Operation February,2023 Front Area Detection LT20JE Front Area Detection Drive Speed Selection The motor will run at the The boom has moved to more than one of the minimum set speed when the two non-steering wheels, and the drive function knob is turned to the leftmost has been turned off when the indicator is on.
  • Page 41 February,2023 Vehicle Operation LT20JE Front Area Detection Machine Tilt Indicator Machine Fault Indicator The machine is not in a All functions have been disabled horizontal state if the indicator is when the indicator is on. on. A tilt alarm will be given when this indicator is on.

  • Page 42: Active Release Of Brake

    Vehicle Operation February,2023 Active Release of Brake LT20JE Active Release of Brake Disengage Engage Chock wheels to prevent the machine from rolling. Type 2WD: Turn over the drive hub release cover to release the non-steering wheel brake. Type 4WD: Turn over the four drive hub release covers to release the wheel brakes.

  • Page 43: Guarantee Of Truck Or Trailer Transportation Safety

    February,2023 Vehicle Operation LT20JE Guarantee of Truck or Trailer Transportation Safety Guarantee of Truck or Trailer Fixed Platform Transportation Safety Put a cushion block under the rotary cylinder of the platform without any contact between them. Use the turntable rotation lockpins when Pass a nylon tape through the platform support transporting the machine each time.

  • Page 44: Lifting Instructions

    Vehicle Operation February,2023 Lifting Instructions LT20JE Lifting Instructions Pay attention to the following requirements when lifting and transferring the machine with a crane: Make sure that the boom is in the retracted state during lifting, the direction of the boom coincides with traveling direction of the chassis, and the controller and chassis components are safe and reliable;...

  • Page 45: Maintenance

    February,2023 Maintenance LT20JE Lifting Instructions Maintenance Maintenance Symbol Legend The following symbols are used in this manual to help express relevant meanings in the operation instructions. The symbols (one or more) before the maintenance procedures have the following meanings. 1. The operator can only perform the routine maintenance items specified in this manual.
  • Page 46 Maintenance February,2023 Lifting Instructions LT20JE 6. All inspection records shall be kept for at least 10 years or until the machine is taken out of service or as required by the machine owner/company/custodian. 7. Machines that have not been maintained for more than three months must be inspected quarterly.

  • Page 47: Pre-Delivery Inspection

    February,2023 Maintenance LT20JE Pre-delivery Inspection Pre-delivery Inspection When the machine owner/company changes, in addition to the pre-delivery inspection, other inspections shall be carried out according to the requirements for maintenance and inspection time and the inspection procedures. The pre-delivery inspection shall meet the following requirements: 1.

  • Page 48: Maintenance And Inspection Report

    Maintenance February,2023 Maintenance and Inspection Report LT20JE Maintenance and Inspection Report 1. The Maintenance and Inspection Report is divided into four stages (daily or every 8 hours, quarterly or every 250 hours, semi-annually or every 500 hours, annually or every 1000 hours) according to the maintenance procedure, time requirements of the maintenance plan, and the requirements of the maintenance procedure.
  • Page 49 February,2023 Maintenance LT20JE Maintenance and Inspection Report Maintenance and Inspection Report Model Factory No. Inspection items every day or every 8 hours NO/ Machine REPAIRED / YES / Machine in Inspection Items damaged or Machine Problem good condition failed repaired...
  • Page 50 Maintenance February,2023 Maintenance and Inspection Report LT20JE Inspection items every quarter or every 250 hours NO/ Machine REPAIRED / YES / Machine in Inspection Items damaged or Machine Problem good condition failed repaired Inspection and replacement of oil return filter of hydraulic tank...
  • Page 51 February,2023 Maintenance LT20JE Maintenance and Inspection Report Inspection items every half a year or every 500 hours NO/ Machine REPAIRED / YES / Machine in Inspection items damaged or Machine Problem good condition failed repaired Replacement of the lubricating oil of swing...

  • Page 52: Inspection Items

    Check all decals for legibility and damage, and replace the damaged and illegible decals in time. Note: If you need to replace or update the decal, please contact LiuGong Machinery Co., Ltd.
  • Page 53 February,2023 Maintenance LT20JE Inspection Items Inspection of Hydraulic Oil Level Maintaining the hydraulic oil at proper level is essential for operation of the machine. If the hydraulic oil level is too high, the oil will overflow from the tank during operation of the equipment.
  • Page 54 Maintenance February,2023 Inspection Items LT20JE Selection of Hydraulic Oil The following table lists the characteristics and grades of hydraulic oil required according to ambient temperature (seasons of different regions), which shall be read carefully during the selection of hydraulic oil.
  • Page 55 February,2023 Maintenance LT20JE Inspection Items Inspection of Hydraulic Oil Inspection of Hydraulic Oil Leakage Checking the hydraulic oil is essential for proper operation and for prolonging service life of the Preventing hydraulic oil leakage is essential for machine. The dirty hydraulic oil may cause safe and normal operation of the machine.
  • Page 56 Maintenance February,2023 Inspection Items LT20JE Replacement of Hydraulic Oil 8. Install the hydraulic tank onto the machine. 9. Connect the oil suction pipe and oil return pipe to the hydraulic tank. Regular replacement of hydraulic oil is essential for normal operation and for prolonging service life of the machine.
  • Page 57 February,2023 Maintenance LT20JE Inspection Items Inspection and Replacement of 5. Install a new oil return filter and tighten it. Oil Return Filter of Hydraulic Tank 6. Remove the hydraulic oil spilled during replacement. 7. Operate the boom from the ground control Regular replacement of the oil return filter of the panel.
  • Page 58 Maintenance February,2023 Inspection Items LT20JE Inspection of Air Filter of Replacement of High-pressure Hydraulic Tank Filter Good ventilation of the hydraulic tank cover is Regular replacement of the high-pressure filter is essential for normal operation and for prolonging essential for proper operation and for prolonging service life of the hydraulic pump.
  • Page 59 February,2023 Maintenance LT20JE Inspection Items Inspection of the Oil Level of Traveling Reducer Operating performance of the machine may be reduced due to incorrect gear oil level in the traveling reducer, and continued use of such reducer may result in damage to components.
  • Page 60 8. Make sure that the oil level is flush with the oil port. LiuGong specifications require that the gear oil 9. Add gear oil if the oil level is lower than the oil shall be replaced after 150 hours of first use, and port.
  • Page 61 February,2023 Maintenance LT20JE Inspection Items Inspection of Bolt of Swing 6. Confirm that the lower mounting bolts of each slewing mechanism have been tightened with Reducer the correct torque in sequence according to the star pattern as specified in relevant specifications.
  • Page 62 LT20JE Replacement of the Lubricating Oil of Swing Reducer This work shall be done semi-annually according to LiuGong's specifications. This work needs to be performed more frequently when the machine runs in dusty conditions or high-temperature environment. Filling the slewing mechanism with grease...
  • Page 63 February,2023 Maintenance LT20JE Inspection Items Inspection of Fasteners of Inspection of Cylinder Offset Platform Swing Cylinder Platform Offset Regular inspection of fasteners of platform swing Measure the settlement from platform to ground. cylinder is essential for proper and safe The maximum allowable settlement within 10 operation of the machine.
  • Page 64 Maintenance February,2023 Inspection Items LT20JE Inspection of the Exhaust of Inspection of Balance Valve Locking Floating Cylinder and the Locking of Balance Valve The floating system shall be checked Exhaust of Floating Cylinder quarterly, or after any system components have been replaced, or when the system is found to be working abnormally.
  • Page 65 February,2023 Maintenance LT20JE Inspection Items 12. If the floating cylinder works abnormally, the fault shall be eliminated by qualified maintenance personnel before further operation.
  • Page 66 Maintenance February,2023 Inspection Items LT20JE Inspection of Angle Sensor Inspection of Tilt Protection System Regular inspection of angle sensor is essential for safe operation of the machine. There will be a 1. When the machine is not working, put two danger if the sensor cannot work normally.
  • Page 67 February,2023 Maintenance LT20JE Inspection Items Inspection of Weighing System Inspection of Platform Protection Device Before this test, it is necessary to completely luff the boom up and down and retract it twice to When the safety protection device is disengaged...
  • Page 68 Maintenance February,2023 Inspection Items LT20JE Inspection of Rim, Tire and Their Fasteners Maintaining rims and tires and their fasteners is essential for proper and safe operation of the machine. Problems with rims or tires may result in machine tipping. Any problems with rims and tires shall be repaired before operation of the machine.
  • Page 69 February,2023 Maintenance LT20JE Inspection Items Inspection of Boom Sliding Block LT20JE Checking the boom sliding block regularly is Thickness of sliding block (mm) essential for safe operation of the machine. There is a friction pair between each sliding block and the surface of the telescopic boom.
  • Page 70 Maintenance February,2023 Inspection Items LT20JE Inspection of Wire Inspection of Battery The maintenance of electrical equipment is Battery in good condition is essential for good essential for proper and safe operation of the performance and safe operation of the machine.
  • Page 71 February,2023 Maintenance LT20JE Inspection Items Function Inspection Test of Running Speed Checking functions of the machine is essential 1. Turn the "Platform/off/ground selector key for safe operation of the machine. A danger will switch" on the ground control panel to the left be caused if any function fails.
  • Page 72 Maintenance February,2023 Inspection Items LT20JE Inspection of Emergency Lowering Function When the motor pump fails, the emergency power unit or manual pump on the turntable control box or platform control box can be used as appropriate. Any emergency power unit...

  • Page 73: Tightening Torque

    February,2023 Maintenance LT20JE Tightening Torque Tightening Torque Tightening Torque of Bolt (Nut) Table 5-1 Tightening Torque of Common Bolts (Nuts) Materials and Quenching and tempering of carbon thermal Low or medium carbon steel steel in low-carbon alloy steel treatment Bolt performance 4.6 ～...
  • Page 74 Maintenance February,2023 Tightening Torque LT20JE Table 5-2 Tightening Torque of Common Bolts (Nuts) Materials Quenching and tempering of carbon steel Low or medium carbon steel thermal in low-carbon alloy steel treatment Bolt 4.6 ～ 4.8 5.6 ～ 5.8 performance 10.9 12.9...
  • Page 75 February,2023 Maintenance LT20JE Tightening Torque Table 5-3 Tightening Torque of Hexagon Flange Bolt (Nut) Bolt grade 8.8 Bolt grade 10.9 Bolt Tightening torque Tightening torque Tightening torque Tightening torque specifications ft-lbs ft-lbs 7 ± 1 5.2 ± 0.8 10 ± 1 7.4 ±...
  • Page 76 Maintenance February,2023 Tightening Torque LT20JE Table 5-4 Tightening Torque of Nylon Lock Nut Bolt performance rating 12 ± 1 15 ± 2 18 ± 3 22 ± 2 26 ± 3 32 ± 4 39 ± 3 51 ± 6 47 ±...
  • Page 77 February,2023 Maintenance LT20JE Tightening Torque Table 5-5 Tightening Torque of Nylon Lock Nut Bolt performance rating 8.9 ± 0.8 11.1 ± 1.5 13.3 ± 2.3 16.3 ± 1.5 19.2 ± 2.3 23.7 ± 3 28.8 ± 2.3 37.7 ± 4.5 34.7 ±...
  • Page 78 Maintenance February,2023 Tightening Torque LT20JE Tightening Torque of Hydraulic Pipe Joint ° Table 5-6 Tightening Torque of 24 Tapered O-ring Sealed Pipe Joint Tightening torque Bolt Inner diameter Series specifications of hose (mm) kgf.m ft-lbs M12 × 1.5 16 ± 1 1.6 ±...
  • Page 79 February,2023 Maintenance LT20JE Tightening Torque Table 5-7 Tightening Torque of Split Flange Pressing Plate Bolt Bolt Bolt performance Tightening torque Tightening torque Series specifications rating (Nm) (ft-lbs) 25 ± 1 18.5 ± 0.8 52 ± 2 38.4 ± 1.5 96 ± 4 70.9 ±...
  • Page 80 Maintenance February,2023 Tightening Torque LT20JE Table 5-8 Tightening Torque of Thread Angle Sealed Transition Joint Tightening torque Tightening torque (ft- Series Thread size (Nm) lbs) 8.5 ± 0.5 6.3 ± 0.4 16 ± 0.5 11.9 ± 0.4 26 ± 1 19.2 ±...
  • Page 81 February,2023 Maintenance LT20JE Tightening Torque Table 5-9 Tightening Torque of Thread Angle Sealed Transition Joint Tightening torque Tightening torque (ft- Series Thread size (Nm) lbs) 8.5 ± 0.5 6.3 ± 0.4 16 ± 0.5 11.9 ± 0.4 26 ± 1 19.2 ±...
  • Page 82 Maintenance February,2023 Tightening Torque LT20JE Table 5-10 Tightening Torque of Thread Angle Sealed Transition Joint Tightening torque Tightening torque (ft- Series Thread size (Nm) lbs) 10.5 ± 0.5 7.8 ± 0.4 3/8-24 UNF 19 ± 1 14.1 ± 0.8 7/16-20 UNF 26 ±...
  • Page 83 February,2023 Maintenance LT20JE Tightening Torque Table 5-11 Tightening Torque of ED Gasket Sealed Transition Joint Tightening torque Tightening torque (ft- Series Thread size (Nm) lbs) 21 ± 1 15.5 ± 0.8 31 ± 1 22.9 ± 0.8 52 ± 2 38.4 ±...
  • Page 84 Maintenance February,2023 Tightening Torque LT20JE Table 5-12 Tightening Torque of Thread Angle Sealed Transition Joint Tightening torque Tightening torque (ft- Series Thread size (Nm) lbs) 21 ± 1 15.5 ± 0.8 G 1/8 52 ± 2 38.4 ± 1.5 G 1/4 84 ±...
  • Page 85 February,2023 INDEX LT20JE INDEX Functional Test ..........29 Functional Test - Operation on the Ground ..29 Functional Test - Operation on the Platform..30 Active Release of Brake........36 Auxiliary Controller ........... 32 Auxiliary Controller Test ........32 General Safety Precautions......10 Ground Control Panel ........
  • Page 86 INDEX February,2023 LT20JE the Locking of Balance Valve......58 er ..............56 Inspection of the Oil Level of Traveling Reducer . Risk of Damage to Components...... 19 Risk of Damage to Machine ......19 Inspection of Tilt Protection System....60 Risk of Physical Injury ........

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