LGMG T65J User manual

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.

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.

Add.: 12F, Building 3, Lushang Olympic City, No. 9777, Jingshi Road, Lixia District, Jinan
City, Shandong Province, China
Tel: [phone] Technical service hotline: [phone]
Web: www. lgmg. com. cn Parts sales hotline: [phone]

Service Manual of Telescopic Boom Mobile Elevating Work Platform
Contents
Foreword VIII
Safety Notices IX
Chapter I 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
Chapter II Product Introduction 7
2.1 Machine parameters 9
2.1.1 Parameters of T65J (T0020JNDAH21) 9
2.1.2 Parameters of T85J (T2623J0WND4AH2001) 10
2.2 Pecification for selection of tightening torque of the lifting platform 12
2.3 Key component moment table 14
Chapter III Service 17
3.1 Notice 19
3.2 Platform assembly 19
3.2.1 Removing the platform assembly 19
3.2.2 Assembling the platform assembly 21
3.3 Jib assembly 23
3.3.1 Removing the jib assembly 23
3.3.2 Removing the swing cylinder 24
3.3.3 Removing the flying jib cylinder 25
3.3.4 Removing the upper leveling cylinder 26
3.3.5 Assembling the jib assembly 26
3.3.6 Assembling the flying jib cylinder 27
3.3.7 Assembling the swing cylinder 27
3.3.8 Assembling the stop block 28
3.3.9 Hoisting the jib 28
3.3.10 Assembling the upper leveling cylinder 28
3.4 Telescopic boom assembly 29
3.4.1 Removing the telescopic boom frame 29
3.4.2 Removing the telescopic cylinder 31
3.4.3 Removing the lower leveling cylinder 33
3.4.4 Removing the cable carrier 34
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Service Manual of Telescopic Boom Mobile Elevating Work Platform
3.4.5 Assembling the telescopic boom frame 35
3.4.6 Assembling the telescopic cylinder 39
3.4.7 Assembling the lower leveling cylinder 41
3.4.8 Assembling the cable carrier 41
3.4.9 Rope 43
3.5 Engine side components (Deutz TD2.9L4) 45
3.5.1 Assembling the engine drivetrain 45
3.5.2 Assembling the engine intake system 45
3.5.3 Assembling the engine exhaust system 46
3.5.4 Assembling the engine cooling system 46
3.5.5 Subassembling the engine 46
3.6 Fuel tank side components 46
3.6.1 Removing the fuel tank 46
3.6.2 Installing the fuel tank 47
3.6.3 Removing the hydraulic tank 47
3.6.4 Installing the hydraulic tank 48
3.6.5 Assembling the ground control unit (GCU) 51
3.6.6 Assembling the emergency power unit 51
3.6.7 Assembling battery 51
3.6.8 Assembling the DC power switch 51
3.7 Turntable assembly 52
3.7.1 Hoisting the turntable 52
3.7.2 Removing the slewing gearbox 52
3.7.3 Assembling the slewing gearbox 53
3.7.4 Removing the open variable displacement pump 53
3.7.5 Assembling the open variable displacement pump 54
3.8 Front axle assembly 54
3.8.1 Removing wheels 54
3.8.2 Assembling wheels 54
3.8.3 Removing the front axle driving motor, steering knuckle and walking gearbox 54
3.8.4 Assembling the front axle driving motor, steering knuckle and walking gearbox 55
3.8.5 Removing the floating cylinder 56
3.8.6 Assembling the floating cylinder 56
3.8.7 Removing the steering cylinder 57
3.8.8 Assembling the steering cylinder 57
3.9 Rear axle assembly 57
3.9.1 Removing the rear axle driving motor and reducer 57
3.9.2 Assembling the rear axle driving motor and gearbox 58
3.10 Other components 58
3.10.1 Assembling the radiator assembly 58
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Service Manual of Telescopic Boom Mobile Elevating Work Platform
3.10.2 Removing the variable displacement walking pump 58
3.10.3 Assembling the variable displacement walking pump 59
3.10.4 Assembling tilt sensor 60
3.10.5 Assembling the warning lamp 60
3.11 leeding cylinder 60
3.11.1 Bleeding the variable displacement walking pump and gear pump 60
3.11.2 Bleeding the slewing gearbox 60
3.11.3 Bleeding the driving motor 61
3.11.4 Bleeding the steering cylinder 61
3.11.5 Bleeding the boom luffing cylinder and lower leveling cylinder 61
3.11.6 Bleeding the boom telescopic cylinder 61
3.11.7 Bleeding the flying jib luffing cylinder and upper leveling cylinder 62
3.11.8 Bleeding the swing cylinder 62
3.11.9 Bleeding the floating cylinder 62
3.12 Valve group 63
3.12.1 Installing the spool 63
3.12.2 Brake two-speed control valve group (4120705252) 63
3.12.3 Walking control valve (4120704651) 64
3.12.4 Boom function valve group (4120709022) 65
Chapter IV Maintenance 67
4.1 Compliance 69
4.2 Check for labels and signs 69
4.3 Check for damaged, loose or missing parts 69
4.4 Check for Batteries 70
4.5 Check for tires and hubs 70
4.6 Inspecting the Pivoting Support 71
4.7 Inspecting the Boom Wear Pad 71
4.8 Inspecting the Wire Rope 72
4.9 Inspecting the Drive Hub Oil Level 72
4.10 Inspecting the Hydraulic Oil and Filter 73
4.11 Replacing the return filter of hydraulic tank 74
4.12 Replacing the air cleaner 75
4.13 Replacing the high-pressure filter element 75
4.14 Changing hydraulic oil and replacing the suction filter 75
4.15 Engine maintenance- Deutz 77
4.15.1 .Check for Engine Oil Level 77
4.15.2 Replacement of Engine Oil and Filter 78
4.15.3 Check for Fuel Leakage 79
4.15.4 Vent Fuel Pre-Filter 80
4.15.5 Replacement of the Fuel filter 81
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Service Manual of Telescopic Boom Mobile Elevating Work Platform
4.15.6 Check for Engine Air Filter 82
4.15.7 Cleaning or Replacement of Air Filter 82
4.15.8 Check for Coolant Liquid Level 83
4.15.9 Filling or Replacement of Engine Coolant 83
4.15.10 Check for Engine Belt 84
4.16 Regular Maintenance 85
4.17 Engine fault table 86
4.18 Engine fault Codes 89
4.19 Maintenance Schedule 98
Chapter V Commissioning 103
5.1 Safety instructions 105
5.2 Start test 106
5.3 Basic operation test of ground control unit 107
5.4 Basic operation test of platform control unit 109
5.5 Drive enable system test 112
5.6 Walking pump overflow pressure test 112
5.7 Function pump overflow pressure test 112
5.8 Rated load calibration 113
5.9 1.1 times rated load test 113
5.10 1.25 times load test 113
5.11 Lifting height test 113
5.12 Operation time test 114
5.13 Driving speed (high speed) test 115
5.14 Braking distance test 115
5.15 Limit drive speed test 116
5.16 Tilt sensor test 116
5.17 Climbing detection (45%) 116
Appendix 117
Appendix I Machine fault codes 119
Appendix II Electrical schematic diagram 120
Appendix III Hydraulic schematic diagram 122
Appendix IV Diagram of common electrical part symbols 124
Appendix V Diagram of common hydraulic part symbols 127
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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. The information contained in this manual are
correct at the 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 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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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. 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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Service Manual of Telescopic Boom Mobile Elevating Work Platform
Chapter I Safety and Environment
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Service Manual of Telescopic Boom Mobile Elevating Work Platform
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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;
Operator:
Personnel who has been professionally trained 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.
I.2 Compliance
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.
I.3 Before 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.
I.4 Workplace requirements
Unless specially specified, the machine shall be able to operate safely under the following conditions:
1. Altitude ≤ 1000m;
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%。
I.5 Safety precautions for maintenance and repair
1. Before adjusting and repairing the machine, the following preventive measures shall be taken:
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Service Manual of Telescopic Boom Mobile Elevating Work Platform
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
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.
I.6 Intended use
This machine is only intended for lifting people and their tools and materials to a high-altitude
workplace.
I.7 Description
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 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.
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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.
Blue - Indicating a dangerous situation. If not
avoided, it may result in property damage.
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Service Manual of Telescopic Boom Mobile Elevating Work Platform
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Service Manual of Telescopic Boom Mobile Elevating Work Platform
Chapter II Product Introduction
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Service Manual of Telescopic Boom Mobile Elevating Work Platform
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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
Rated load
250kg/551lbs
One rotation of turntable
(Stowed position) (s)
78-86
2 persons
+90kg/198lbs cargo
One rotation of turntable (Raised
or extended) (s)
125-165
Limit load
—
Main Boom ascent(s)
60-70
—
Main Boom descent (s)
60-70
Machine weight (kg/lbs)
11400/25132
Boom extension (s)
58-66
Maximum working height (m/ft)
21.7/71.2
Boom retraction (s)
53-62
Maximum platform height (m/ft)
19.7/64.6
Jib boom lift (s)
40-50
Maximum horizontal extension
(m/ft)
17.2/56.4
Jib boom descent (s)
20-35
Driving Speed (Stowed)
(km/h/mph)
4.8±0.25/3±0.25
Platform rotation (s)
13-26
Driving Speed ( Raised or
extended state) (km/h/mph)
0.8±0.05/0.5±0.05
Max.
inclination of
chassis
Along the
boom
4.5°
Machine climbing speed
(retracted state) (km/h/mph)
1.2≤v≤1.5/0.7≤v≤0.9
Orthogonal to
boom
4.5°
Machine climbing speed
(lifting state) (km/h/mph)
0.3≤v≤0.8/0.2≤v≤0.5
Maximum manual force (N)
400
Minimum turning radius (inner
wheel) (m/ft)
2.5/8.1
Maximum allowable wind speed
(m/s/mph)
12.5/28
Minimum turning radius (outer
wheel) (m/ft)
5.5/17.8
Drive mode
Four wheel drive
Front wheel steering
Theoretical gradeability (no-load
retraction)
45%
Max. braking distance (no-load
retraction)(m/ft)
1≤S≤1.5/3.3≤v≤4.9
2. Main dimensions
Item
Parameter
Item
Parameter
Machine length (mm/in)
9470/373
Wheelbase (front/rear) (mm/in)
2510/99
Machine width (mm/in)
2495/98
Track width (mm/in)
2130/84
Machine height (mm/in)
2770/109
Min. ground clearance (middle)
(mm/in)
395/15.5
Work platform size (length ×
width) (mm/in)
2440×900/96×35
Tire specifications（
Diameter×width）
355/55D 625
3. Engine system
Item
Parameter
Item
Parameter
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Service Manual of Telescopic Boom Mobile Elevating Work Platform
Model
D2.9L4
Rated speed (r/min)
2600
Displacement (L)
2.9
Max. torque (Nm)
147/1600rpm
Rated power (kW)
36.3
Emission standard
EPA Tier 4f
4. Transmission system
Item
Parameter
Walking reducer
Rated output torque (Nm)
3390
Speed ratio
57.49：1
Slewing reducer
Rated output torque (Nm)
1690
Speed ratio
36.13：1
5. Hydraulic system
Item
Parameter
Walking system
Type
Closed
Pump displacement (ml/r)
46
Maximum working pressure
(Mpa/psi)
28/4061
Motor displacement (ml/r)
38
Functional
system
Type
Open
Pump displacement (ml/r)
23
Lifting
system
Maximum working pressure
(Mpa/psi)
22/3191
Slewing
system
Maximum working pressure
(Mpa/psi)
22/3191
Motor displacement (ml/r)
60
Steering
system
Maximum working pressure
(Mpa/psi)
15/2175
Floating system
Type
\
Pump displacement (ml/r)
\
Maximum working pressure
(Mpa/psi)
\
6. Electrical system
Item
Parameter
Battery
Output voltage (V)
12
Capacity ( Ah)
120(20 hours)
Control system
Voltage (V)
12
7. Oil filling amount
Item
Parameter
Item
Parameter
Hydraulic oil (L/gal_US)
180/47.5
Engine oil (L/gal_US)
8.5/2.2
Walking reducer gear oil
(L/gal_US)
0.68×4/0.18×4
Engine antifreeze (L/gal_US)
7.7/2.0
Slewing reducer gear oil
0.45/0.12
Capacity of diesel tank (L/gal_US)
100/26.4
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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
Rated load
250kg/551lbs
One rotation of turntable
(Stowed position) (s)
90-110
2 persons
+90kg/198lbs cargo
One rotation of turntable (Raised
or extended) (s)
170-200
Limit load
340kg/750lbs
Main Boom ascent(s)
70-90
3persons
+100kg/220lbs cargo
Main Boom descent (s)
70-90
Machine weight (kg/lbs)
18000/39683
Boom extension (s)
55-73
Maximum working height (m/ft)
27.9/91.5
Boom retraction (s)
55-73
Maximum platform height (m/ft)
25.9/84.9
Jib boom lift (s)
25-35
Maximum horizontal extension
(m/ft)
23.32/76.5
Jib boom descent (s)
15-25
Driving Speed (Stowed)
(km/h/mph)
4.8±0.25/3±0.25
Platform rotation (s)
13-26
Driving Speed ( Raised or
extended state) (km/h/mph)
0.8±0.05/0.5±0.05
Max.
inclination of
chassis
Along the
boom
4.5°
Machine climbing speed
(retracted state) (km/h/mph)
1.2≤v≤1.5/0.7≤v≤0.9
Orthogonal to
boom
4.5°
Machine climbing speed
(lifting state) (km/h/mph)
0.3≤v≤0.8/0.2≤v≤0.5
Maximum manual force (N)
400
Minimum turning radius (inner
wheel) (m/ft)
3.66/12
Maximum allowable wind speed
(m/s/mph)
12.5/28
Minimum turning radius (outer
wheel) (m/ft)
6.55/21.5
Drive mode
Four wheel drive
Front wheel steering
Theoretical gradeability (no-load
retraction)
45%
Max. braking distance (no-load
retraction)(m/ft)
1≤S≤1.5/3.3≤v≤4.9
2. Main dimensions
Item
Parameter
Item
Parameter
Machine length (mm/in)
12600/496
Wheelbase (front/rear) (mm/in)
2850/112
Machine width (mm/in)
2500/98
Track width (mm/in)
2050/80.7
Machine height (mm/in)
2840/112
Min. ground clearance (middle)
(mm/in)
440/17
Work platform size (length ×
width) (mm/in)
2440×900/96×35
Tire specifications（
Diameter×width）
18-625
3. Engine system
Item
Parameter
Item
Parameter
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