LGMG AR45J User manual

Service manual
AR45J、AR52J
Articulated 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.
LINGONG HEAVY MACHINERY CO.，LTD.

Articulated Boom Mobile Elevating Work Platform
Service Manual
880*1230 mm Sextodecimo 8 sheets
First edition, May 2022 First print, May 2022
L I N G O N G H E AV Y M A C H I N E R Y C O . , LT D .
Add.: 12F, Building 3, Lushang Olympic City, No. 9777, Jingshi Road, Lixia District, Jinan
City, Shandong Province, China
Tel: [phone] Technical service: 86-4009666569
Web: www.LGMG.com.cn Sales of accessories:86-0531-67605016

Service Manual of Articulated Boom Mobile Elevating Work Platform
I
Contents
Contents ............................................................................................................................................................. I
Foreword ......................................................................................................................................................... VII
Safety Notices................................................................................................................................................. VIII
1. Safety and Environment ............................................................................................................................ 1
1.1 Terms and Definitions................................................................................................................. 3
1.2 Compliance ................................................................................................................................. 3
1.3 Before maintenance ................................................................................................................... 3
1.4 Workplace requirements............................................................................................................ 3
1.5 Safety precautions for maintenance and repair......................................................................... 3
1.6 Intended use............................................................................................................................... 4
1.7 Description.................................................................................................................................. 4
2. Product Introduction ................................................................................................................................. 7
2.1 Machine parameters .................................................................................................................. 9
2.1.1 Parameters of AR45J（A0014JNKAH21）articulated lifting platform....................................... 9
2.1.2 Parameters of AR45J（A0014JNDAH21）articulated lifting platform .................................... 10
2.1.3 Parameters of AR52J（A0016JNKAH21）articulated lifting platform..................................... 12
2.1.4 Parameters of AR52J（A0016JNDAH21）articulated lifting platform .................................... 14
2.2 Specification for selection of tightening torque of the lifting platform ................................... 15
2.3 Key component moment table................................................................................................. 18
3. Service ..................................................................................................................................................... 21
3.1 Platform assembly .................................................................................................................... 23
3.1.1 Assembling the file box............................................................................................................. 23
3.1.2 Assembling the foot switch ...................................................................................................... 23
3.1.3 Assembling the lifting cross bar................................................................................................ 23
3.1.4 Assembling the load cell........................................................................................................... 23
3.1.5 Assembling the stop block........................................................................................................ 24
3.1.6 Assembling the swing motor mounting bracket ...................................................................... 24
3.1.7 Assembling the platform control unit (PCU) ............................................................................ 24
3.1.8 Assembling the platform .......................................................................................................... 24
3.2 Jib assembly.............................................................................................................................. 25
3.2.1 Disassembling the swing cylinder, the fly jib cylinder and the jib............................................ 25
3.2.2 Assembling the swing cylinder, the fly jib cylinder and the jib ................................................ 26
3.3 Cable carrier assembly.............................................................................................................. 28
3.3.1 Disassembling the cable carrier................................................................................................ 28
3.3.2 Assembling the cable carrier .................................................................................................... 30

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3.4 Boom/extension jib assembly................................................................................................... 31
3.4.1 Disassembling the boom .......................................................................................................... 31
3.4.2 Disassembling the extension jib assembly ............................................................................... 32
3.4.3 Assembling the extension jib assembly.................................................................................... 33
3.4.4 Assembling the boom assembly............................................................................................... 34
3.5 Cylinder assembly..................................................................................................................... 35
3.5.1 Disassembling the boom luffing cylinder ................................................................................. 35
3.5.2 Disassembling the boom telescopic cylinder............................................................................ 36
3.5.3 Disassembling the boom telescopic cylinder............................................................................ 36
3.5.4 Disassembling the lower leveling cylinder................................................................................ 37
3.5.5 Assembling the lower leveling cylinder.................................................................................... 38
3.5.6 Disassembling the upper leveling cylinder............................................................................... 39
3.6 Folding jib assembly.................................................................................................................. 40
3.6.1 Removing folding jib................................................................................................................. 41
3.6.2 Assembling folding jib assembly............................................................................................... 44
3.6.3 Removing folding jib lift cylinder.............................................................................................. 46
3.6.4 Assembling folding jib lift cylinder............................................................................................ 46
3.7 Kubota Engine Assembly .......................................................................................................... 48
3.7.1 Engine drivetrain....................................................................................................................... 48
3.7.2 Assembly of engine intake system ........................................................................................... 48
3.7.3 Assembly of engine exhaust system......................................................................................... 49
3.7.4 Assembly of engine cooling system.......................................................................................... 49
3.7.5 Hoisting and assembly of engine.............................................................................................. 49
3.8 Deutz Engine Assembly............................................................................................................. 50
3.8.1 Assembly of engine drivetrain.................................................................................................. 50
3.8.2 Assembly of engine intake system ........................................................................................... 50
3.8.3 Assembly of engine exhaust system......................................................................................... 50
3.8.4 Assembly of engine cooling system.......................................................................................... 51
3.8.5 Hoisting and assembly of engine.............................................................................................. 51
3.9 Tank side assembly................................................................................................................... 51
3.9.1 Disassembling the fuel tank...................................................................................................... 51
3.9.2 Assembling the fuel tank .......................................................................................................... 52
3.9.3 Disassembling the hydraulic tank............................................................................................. 52
3.9.4 Assembling the hydraulic tank.................................................................................................. 53
3.9.5 Assembling ground control system .......................................................................................... 54
3.9.6 Assembling slewing ring grease filler hose............................................................................... 55
3.9.7 Emergency power unit assembly.............................................................................................. 55

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3.9.8 Assembling horn....................................................................................................................... 55
3.10 Rotary table swing assembly .................................................................................................... 56
3.10.1 Removing slewing drive assembly............................................................................................ 56
3.10.2 Assembling slewing drive assembly.......................................................................................... 56
3.10.3 Lifting rotary table .................................................................................................................... 56
3.11 Axle assembly ........................................................................................................................... 57
3.11.1 Disassembling the front axle assembly .................................................................................... 57
3.11.2 Assembling the front axle assembly......................................................................................... 57
3.11.3 Disassembling the rear axle assembly...................................................................................... 60
3.11.4 Assembling the rear axle assembly .......................................................................................... 60
3.11.5 Disassembling the wheel .......................................................................................................... 61
3.11.6 Assembling the wheel............................................................................................................... 62
3.12 Bleeding cylinder ...................................................................................................................... 62
3.12.1 Bleeding function pump ........................................................................................................... 62
3.12.2 Bleeding slewing motor............................................................................................................ 62
3.12.3 Bleeding walking motor............................................................................................................ 62
3.12.4 Bleeding steering cylinder ........................................................................................................ 63
3.12.5 Bleeding folding jib luffing cylinder .......................................................................................... 63
3.12.6 Bleeding main boom luffing cylinder and lower leveling cylinder ........................................... 63
3.12.7 Bleeding main boom telescopic cylinder.................................................................................. 64
3.12.8 Bleeding fly jib luffing cylinder and upper leveling cylinder..................................................... 64
3.12.9 Bleeding platform swing cylinder............................................................................................. 64
3.13 Other components.................................................................................................................... 64
3.13.1 Assembling tilt sensor............................................................................................................... 64
3.13.2 Assembling hydraulic oil radiator............................................................................................. 64
3.13.3 Assembling battery................................................................................................................... 65
3.14 Valve group............................................................................................................................... 66
3.14.1 Installing the spool.................................................................................................................... 66
3.14.2 Walk control valve block........................................................................................................... 66
3.14.3 Luffing balance valve ................................................................................................................ 67
3.14.4 Balance valve ............................................................................................................................ 68
3.14.5 Boom function valve block ....................................................................................................... 69
3.14.6 Floating valve............................................................................................................................ 70
3.14.7 Floating cylinder balance valve................................................................................................. 71
3.14.8 Platform valve........................................................................................................................... 72
3.14.9 Counterbalance valve ............................................................................................................... 73
4. Maintenance............................................................................................................................................ 75

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IV
4.1 Compliance ............................................................................................................................... 77
4.2 Check for labels and signs......................................................................................................... 77
4.3 Check for damaged, loose or missing parts.............................................................................. 77
4.4 Check Hydraulic Oil Level.......................................................................................................... 78
4.5 Check for hydraulic oil leakage................................................................................................. 78
4.6 Check for Batteries ................................................................................................................... 78
4.7 Checking the Wires................................................................................................................... 79
4.8 Check for tires and hubs........................................................................................................... 80
4.9 Checking Oil Level in the Drive Hub.......................................................................................... 80
4.10 Check for exhaust cover of hydraulic oil tank .......................................................................... 80
4.11 Visual Inspection of the Hydraulic Oil....................................................................................... 81
4.12 Platform weighing structure lubrication .................................................................................. 81
4.13 Replacing the return filter of hydraulic tank ............................................................................ 82
4.14 Replacing the high-pressure filter element.............................................................................. 82
4.15 Replacing Drive Hub Gear Oil ................................................................................................... 83
4.16 Replacing the air cleaner .......................................................................................................... 83
4.17 Maintenance of worm-Type Slewing Drive .............................................................................. 83
4.17.1 Maintenance before Delivery................................................................................................... 84
4.17.2 Market Maintenance................................................................................................................ 84
4.18 Changing hydraulic oil and replacing the suction filter............................................................ 84
4.19 Engine maintenance –Deutz..................................................................................................... 86
4.19.1 Checking Engine Oil Level ......................................................................................................... 86
4.19.2 Replacement of Engine Oil and Filter ....................................................................................... 87
4.19.3 Check for Fuel Leakage............................................................................................................. 88
4.19.4 Vent Fuel Pre-Filter................................................................................................................... 89
4.19.5 Replacement of the Fuel filter.................................................................................................. 90
4.19.6 Check for Engine Air Filter ........................................................................................................ 90
4.19.7 Cleaning or Replacement of Air Filter....................................................................................... 91
4.19.8 Check for Coolant Liquid Level ................................................................................................. 92
4.19.9 Filling or Replacement of Engine Coolant................................................................................. 92
4.19.10 Check for Engine Belt ........................................................................................................ 93
4.20 Engine maintenance –Kubota................................................................................................... 93
4.20.1 Check for Engine Oil Level ........................................................................................................ 93
4.20.2 Replacement of Engine Oil and Filter ....................................................................................... 94
4.20.3 Check for Fuel Leakage............................................................................................................. 95
4.20.4 Clean or Replace the Fuel Filter................................................................................................ 95
4.20.5 Check for Engine Air Filter ........................................................................................................ 98

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4.20.6 Cleaning or replacement of air filter ........................................................................................ 98
4.20.7 Check for coolant liquid level ................................................................................................... 99
4.20.8 Filling or Replacement of Engine Coolant................................................................................. 99
4.20.9 Check for Engine Belt.............................................................................................................. 100
4.21 Regular Maintenance.............................................................................................................. 101
4.22 Engine Fault Table................................................................................................................... 102
4.23 Engine fault Codes .................................................................................................................. 105
4.23.1 Engine fault Codes (Kubota) ................................................................................................... 105
4.23.2 Engine fault Codes (Deutz) ..................................................................................................... 109
4.24 Maintenance Schedule ........................................................................................................... 114
5. Commissioning ...................................................................................................................................... 119
5.1 Safety instructions .................................................................................................................. 121
5.2 Basic test................................................................................................................................. 122
5.2.1 Start test ................................................................................................................................. 122
5.2.2 Basic operation test of ground control unit ........................................................................... 123
5.2.3 Basic operation test of platform control system.................................................................... 124
5.2.4 Hydraulic oil level test ............................................................................................................ 127
5.2.5 Load test (1.1 times rated load).............................................................................................. 127
5.2.6 Travel speed (high speed) test................................................................................................ 127
5.2.7 Braking distance test .............................................................................................................. 127
5.2.8 Drive speed limit test.............................................................................................................. 128
5.2.9 Braking distance test (at slow speed)..................................................................................... 128
5.2.10 Drive enable system test ........................................................................................................ 128
5.2.11 Tilt sensor test ........................................................................................................................ 129
5.2.12 Gradeability test（45%）...................................................................................................... 129
5.2.13 Gradeability test（25%）...................................................................................................... 129
5.2.14 Floating test............................................................................................................................ 129
5.2.15 Operation time test ................................................................................................................ 130
5.2.16 Lifting height test.................................................................................................................... 131
5.2.17 Load test (1.25 times)............................................................................................................. 131
5.2.18 Rated load calibration............................................................................................................. 131
5.3 Pressure test........................................................................................................................... 132
5.3.1 System overflow pressure test ............................................................................................... 132
5.3.2 Functional overflow pressure test.......................................................................................... 132
6. Appendix................................................................................................................................................ 133
Appendix I Machine fault code.................................................................................................................. 135
Appendix II Electrical schematic diagram.................................................................................................. 136

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Appendix III Hydraulic schematic diagram ................................................................................................ 138
Appendix IV Diagram of common hydraulic part symbols........................................................................ 139
Appendix V Diagram of common electrical part symbols ......................................................................... 146

Service Manual of Articulated Boom Mobile Elevating Work Platform
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Foreword
You are welcome to purchase and use the products produced by LingongHeavy MachineryCo., Ltd.
This manual introduces the technical parameter and maintenance adjustment data of the Articulated
Boom Mobile Elevating Work Platform, and explains the troubleshooting and maintenance process for
qualified professional maintenance personnel. The information contained in this manual are correct atthe
time of publication, but due to the continuous improvement of the structure and performance of our
products, the design as well as operation and maintenance instructions of the product may be subject to
change without notice. For the latest information about the machine and questions about this manual,
please contact our company. At the same time, we encourage readers to feedback errors to Lingong
Group Jinan Heavy Machinery Co., Ltd. and put forward suggestions for improvement. All suggestions
will be carefully considered in the future publication and printing of this manual.
The copyright of this manual belongs to Lingong Heavy Machinery Co., Ltd., and it is not allowed to
be copied or reprinted without the written permission of our company.
△
!WARNING
Only specially trained and qualified personnel can operate, repair and maintain the
machine.
Incorrect operation, maintenance and repair are dangerous and can lead to
personal injury or death.
Before operating or maintaining the machine, the operator should read this manual
carefully. Do not operate, maintain or repair this platform without reading and
understanding this manual.
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 operating procedures and precautions provided in this manual are only
applicable to the specified purposes of this machine. If it is used for operations other
than those specified but not prohibited, make sure that this operation does not cause
harm to you or others.

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VIII
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. In order to avoid accidents, please read, understand and observe all
warning requirements and precautions in this manual and on the machine before operation and
maintenance. Failure to comply with the instructions and safety rules in this manual and the
corresponding manual on the machine will result in death or serious injury.
Since it is impossible to foresee all possible dangers, the safety instructions in this manual and on
the machine cannot include all safety precautions. If steps and operations not recommended in this
manual are used, you must ensure that you and other people are safe and the machine will not be
damaged. If you are not sure about the safety of some operations, please contact our company or
dealer.
Some operations to the machine require not only basic mechanical, hydraulic and electrical skills,
but also professional skills, tools, lifting equipment and suitable workshop. In these cases, we strongly
recommend that the maintenance and repair should be carried out at a service center authorized by
Lingong Heavy Machinery Co., Ltd.
The maintenance precautions given in this manual are only applicable when the machine is used
for the specified purpose. If the machine is used in the scope out of this manual, our company will not
assume any safety responsibility, and the safety responsibility in such operations shall be borne by the
user and the operator. Under no circumstances shall the operations prohibited in this manual be
performed.
Most of the maintenance process can only be performed by trained professional service personnel
in properly equipped workshops.
△
!DANGER - Indicating any existing dangers that, if not avoided, will cause serious
injury or even death, and also serious machine damage.
△
!WARNING - Indicating any potential dangers that, if not avoided, may cause death
or serious injury, and also serious machine damage.
△
!CAUTION - Indicating situations that, if not avoided, may cause minor or moderate
injury, and also machine damage or shortened machine service life.

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1
1. Safety and Environment

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3
1.1 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;
Operator: personnel who has been professionallytrained and mastered qualified knowledge and practical
experience to operate the lifting platform.
Qualified personnel: those with recognized academic qualifications, certificates, professional status, or
relevant professional knowledge, trained and experienced, who can effectively prove their ability to solve
the difficulties encountered in related matters, work or projects.
Safety notice: relevant safety information issued by Lingong Heavy Machinery Co., Ltd.
1.2Compliance
1. The maintenance is required to be carried out by personnel who have received and qualified in
the maintenance training of this machine.
2. Immediately mark the machine if it is damaged or faulty, and withdraw it out of service.
3. Repair any damage or fault before operating the machine.
1.3Before maintenance
1. Read and follow the safety rules and maintenance instructions in the corresponding operation
manuals on the machine.
2. Ensure that all necessary tools and parts are in place.
3. Do not use parts not sold by Lingong Heavy Machinery Co., Ltd.
4. Please read each step thoroughly and follow the instructions, and do not try to perform repair by
shortcut, as this is dangerous.
1.4Workplace requirements
Unless specially specified, the machine shall be able to operate safely under the following conditions:
1. Altitude ≤ 1000m/3281ft;
2. Ambient humidity ≤ 90% (at +25℃).
3. The machine shall be able to operate normally under the following safe conditions:
—Ambient temperature of -20℃~ +40℃;
—Wind speed: ≤ 12.5m/s/28mph.
4. The ground should be firm and smooth,and should not sag during operation；
5. The allowable fluctuation of the supply voltage should be 10%。
1.5Safety precautions for maintenance and repair
1. Before adjusting and repairing the machine, the following preventive measures shall be taken
Park the machine on a solid and level ground
Block the wheels
Cut off the power supply to disable the machine;
Set all controls in “OFF” position to prevent the operating system from being started by

Service Manual of Articulated Boom Mobile Elevating Work Platform
4
accident;
If possible, lower the platform to the lowest position, otherwise, ensure that it will not fall;
Before loosening or removing hydraulic components, release the hydraulic oil pressure in
the hydraulic pipeline;
Place safety supports as required.
2. Maintenance personnel training
Maintenance personnel must be trained by qualified personnel to inspect and maintain the
machine in accordance with the requirements of this manual.
3. Parts replacement
The replacement components and parts must be the original parts of our company, otherwise
the product will not be maintained or repaired.
4. Service announcement
Users shall maintain and repair the machine in strict accordance with the service announcement
issued by Lingong Heavy Machinery Co., Ltd.
1.6Intended use
This machine is only intended for lifting people and their tools and materials to a high-altitude
workplace.
1.7Description
Most maintenance processes can only be performed by professionally trained maintenance
personnel in a properly equipped workshop. After troubleshooting, select the appropriate maintenance
steps.
Perform the disassembly steps until the repair can be completed. Then perform the disassembly
steps in the reverse order.
It is strongly recommended to carry out maintenance and repair at the service center authorized by
Lingong Group Jinan 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.
Red - Indicating a hazardous situation. If it is not
avoided, it will lead to death or serious injury of
personnel.
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 maycause minor or moderate personal
injury.

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Blue - Indicating a dangerous situation. If not
avoided, it may result in property damage.

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2. Product Introduction

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2.1Machine parameters
2.1.1 Parameters of AR45J（A0014JNKAH21）articulated lifting platform
1. Parameters of machine
Item
Parameter
Item
Parameter
Rated load (kg/lbs)
230/510
Rotary table rotation time
per circle (stowed) (s)
82-92
Rotary table rotation time
per circle (extended) (s)
82-92
Total weight (kg/lbs)
6960/15344
Boom lifting time (s)
35-45
Max. allowed workers
2
Boom lowering time (s)
30-40
Max. working height (m/ft)
16.09/52.8
Articulating boom lifting
time (s)
25-35
Max. platform height (m/ft)
14.09/46.2
Articulating boom lowering
time (s)
26-40
Max. horizontal reach
(m/ft)
7.67/25.2
Boom extension time (s)
20-30
Max. span height (m/ft)
7.56/24.8
Boom retraction time (s)
20-30
Min. turning radius (inner
wheel) (m/ft)
1.94/6.36
Jib lifting time (s)
30-50
Min. turning radius (outer
wheel) (m/ft)
4.41/14.47
Jib lowering time (s)
20-35
Max. braking distance (no-
load, stowed) (m/ft)
1≤S≤1.5/
3.3≤S≤4.9
Platform rotation time (s)
13-26
Max. travel speed (stowed)
(km/h/mph)
6.1±0.5/
3.8±0.3
Theoretical maximum
gradeability (no-load,
stowed)
45%
Max. travel speed
(extended) (km/h/mph)
0.8±0.05/
0.5±0.03
Max. operation effort (N)
400
Climbing speed (stowed)
(km/h/mph)
>1.5/>0.9
Max. allowed wind speed
(m/s/mph)
12.5/28
Climbing speed (extended)
(km/h/mph)
≤0.8/≤0.5
Drive mode
Four-wheel drive
Front wheel steering
Max. allowed
inclination of
chassis
Along the
boom
4.5°
Orthogonal
to boom
4.5°
2. Main dimensions
Item
Parameter
Item
Parameter
Overall length (mm/in)
6766/267
Track width (mm/in)
2059/81
Overall width (mm/in)
2310/91
Wheelbase (front/rear)
(mm/in)
1981.5/78
Overall height (mm/in)
2170/86
Min. ground clearance
(mm/in)
360/14
Dimension of working
platform (length ×
width) (mm/in)
1830×760/72×30
Tire specification
315/55D20
3. Engine system
Item
Parameter
Item
Parameter
Model
V2403-CR-E5B-LGL-1
Rated speed（r/min）
2600
Displacement（L）
2.4L
Maximum torque
（Nm）
159.8/1600rpm
Rated power（KW）
36
Emission standard
EPA Tier 4f
4. Transmission system
Item
Parameter

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Walking reducer
Rated output torque
(Nm)
3500
Speed ratio
57.49：1
Slewing reducer
Rated output torque
(Nm)
8729
Speed ratio
86：1
5. Hydraulic system
Item
Parameter
Walking
system
Type
Closed
Pump displacement (ml/r)
46
Max. working pressure
(MPa/psi)
28/4061
Motor displacement (ml/r)
38
Functional
system
Type
Open
Pump displacement（ml/r）
11
Lifting system Max. working
pressure（MPa/psi）
23.5/3408
Slewing
system
Max. working
pressure（MPa/psi）
23.5/3408
Motor displacement
（ml/r）
160
Steering system
Max. working pressure
（MPa/psi）
23.5/3408
6. Electronic control system
Item
Parameter
Battery
Output voltage (V)
12
Capacity (Ah)
120（20HR discharge rate）
Control system
Voltage (V)
12
7. Refilling capacity
Item
Parameter
Item
Parameter
Hydraulic oil
（L/gal_US）
130/34.3
Engine oil（L/gal_US）
8/2.1
Gearbox oil（L/gal_US）
0.68×4/0.18×4
Engine antifreeze
（L/gal_US）
7.5/2
Diesel（L/gal_US）
65/17.2
2.1.2 Parameters of AR45J（A0014JNDAH21）articulated lifting platform
1. Parameters of machine
Item
Parameter
Item
Parameter
Rated load (kg/lbs)
230/510
Rotary table rotation time
per circle (stowed) (s)
82-92
Rotary table rotation time
per circle (extended) (s)
82-92
Total weight (kg/lbs)
6960/15344
Boom lifting time (s)
35-45
Max. allowed workers
2
Boom lowering time (s)
30-40
Max. working height (m/ft)
16.09/52.8
Articulating boom lifting
time (s)
25-35
Max. platform height (m/ft)
14.09/46.2
Articulating boom lowering
time (s)
26-40
Max. horizontal reach
(m/ft)
7.67/25.2
Boom extension time (s)
20-30