LGMG AR20J User manual

Maintenance manual
AR20J
Articulated Boom
Mobile Elevating Work Platform
△
!WARNING
Before operation and maintenance, the
drivers and service personnel shall
always read and thoroughly understand
all information in this manual. Failure to
do so may result in, fatal accidents or
personal injury.
This manual must be kept with this
machine at all times.
LINGONG HEAVY MACHINERY CO., LTD.

Articulated Boom Mobile Elevating Work Platform
Maintenance Manual
880*1230 mm sixteen format 8 printed sheet
First edition and printed for the first time in April 2023
Lingong Heavy Machinery Co., Ltd.
Add: F12, Building 3 LushangGuoao Plaza, 9777 Jingshi Road,Lixia District, Jinan,
Shandong, 250000,China
Tel: [phone] Technical service: 86-0531-67605017
Web: www.LGMG.com.cn Sales of accessories: 86-0531-67605016

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
I
Contents
Foreword.....................................................................................................II
Safety Notices............................................................................................III
Chapter 1 Maintenance...............................................................................1
1.1 Observing the Regulations................................................................ 3
1.2 Inspection Manual............................................................................. 3
1.3 Check Labels and Decals................................................................. 3
1.4 Every Day or Every 8 Hours ............................................................. 3
1.5 Every 100 Hours............................................................................... 7
1.6 Every 250 Hours............................................................................... 8
1.7 Every 500 Hours............................................................................. 17
1.8 Every 1000 Hours........................................................................... 23
1.9 Every 2000 Hours........................................................................... 24
1.10 Scheduled maintenance ............................................................... 27
1.11 Engine Fault Table ........................................................................ 28
1.12 Engine fault codes........................................................................ 33
1.13 Maintenance Point........................................................................ 41
Chapter 2 Schematic Diagram ..................................................................47

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
II
Foreword
You are welcome to purchase and use the lifting platform produced by LINGONG HEAVY MACHINERY
CO., LTD. This machine is designed according to AS/NZS 1418.10:2011+A1:2017. This manual
introduces the maintenance and other aspects of the mobile elevating work platform.
Getting the best out of your machine is a goal that we pursue together with you, depending on how
familiar you are with it and how carefully and thoroughly it is maintained.
We sincerely hope that you can read through this manual before starting, performing operation and
maintenance for the first time, and be handy about the operation and maintenance introduced therein.
The illustrations and instructions in this manual are correct at the time of publication, but the structure
and performance of our products are constantly improved and perfected. The design, operation and
maintenance instructions are subject to change without notice. Please understand.
For the latest information about the machine and questions about this manual, please consult our
company.
This manual is suitable for mobile elevating work platform. Under no circumstances shall any act or
operation prohibited in this manual be performed. Users shall strictly follow the maintenance interval
specified in this manual and other materials delivered with the product.
This manual should always be kept in the specified location for easy reference. This manual is part of
the machine and should be handed over with it when ownership or use of the machine is transferred. If
the manual is missing, damaged or illegible, please replace it in time!
The copyright of this manual belongs to LINGONG HEAVY MACHINERY CO., LTD., and cannot be
copied or reproduced without the written permission of our company.
△
! WARNING
Operators and maintenance personnel must read, understand and abide by the
safety regulations and operating instructions specified in this manual before
operating and maintaining this machine, otherwise, it may lead to casualties!
Only specially trained and qualified personnel can operate, maintain and repair the
machine.
Improper operation, maintenance and repair are dangerous and may result in injury
or death.
Users shall be familiar with the rated load, and overloading is strictly prohibited. The
users shall be responsible for all the consequences caused by overloading or
unauthorized modification.
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 there is no potential safety
hazard.

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
III
Safety Notices
Operators should understand and follow the current national and local safety regulations, and use the
safety instructions in this manual if there are no corresponding regulations.
Most accidents are caused by the user's violation of the regulations on machine operation and
maintenance. To avoid accidents, please read, understand and comply with all requirements,
precautions and warnings in this manual and machine labels before operation and maintenance.
This manual is not a training manual for lifting platform operators! All operating instructions are for
professionals who have received lifting platform relevant training.
Since it is impossible to foresee all possible hazards and accidents, the safety instructions in this manual
cannot include all safety precautions, and other existing safety risks must be taken into account in the
actual operation. If a procedure or operation not recommended in this manual is used, the operator must
carry out a risk assessment and must ensure the safety of himself and others and that no damage is
done to the machine. If the safety of some operations is not certain, please contact our company or
dealer.
If the content of this manual is inconsistent with the standards or laws and regulations issued by the local
government or authorities, please enforce the stricter policy.
The operation and maintenance precautions given in this manual are only applicable to the specified use
of this machine. If the machine is used outside the specified purpose, our company will not assume any
responsibility, and all responsibilities shall be borne by the user and the operator.
In any instance, the prohibited operations in the manual cannot be carried out.
The following markers are used to identify safety information in this manual:
△
! DANGER - Indicating any dangers that, if not avoided, will cause serious injury
or even death, and also serious machine damage.
△
! WARNING - Indicating any dangers that, if not avoided, may cause injury,
serious injury or even death, and also serious machine damage.
△
! CAUTION - Indicating dangers that, if not avoided, may cause minor or
moderate injury, and also machine damage or shortened machine service life.

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
IV

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
1
Chapter 1 Maintenance

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
2

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
3
1.1 Observing the
Regulations
1) You are properly trained and qualified to
operate and maintain the machine safely.
2) All safety regulations in this manual,
workplace safety regulations and
applicable government laws and
regulations must be read, understood and
complied.
3) Equipped with PPE, such as helmet, seat
belt, safety shoes, goggles, protective
clothing, insulating gloves, insulating shoes,
etc., and in good physical condition.
4) When maintenance and repair procedures
are being performed, many dangers
indicated in the Operation Manual will also
become potential safety hazards.
5) Scheduled maintenance and repair can
only be completed by trained and qualified
maintenance technician.
6) Dispose of waste materials in accordance
with government regulations and workplace
regulations.
7) Only parts and consumables approved by
the LGMG can be used.
8) Always perform functional tests after
maintenance.
1.2 Inspection Manual
It's necessary for safe equipment operation to
keep operation manual and maintenance
manual in good condition.An illegible or missing
manual will not provide the necessary safety
and operational information for the safe
operation.
1) Make sure that the operation manual and
maintenance manual are complete in the
file box.
2) Check each page of the inspection manual
to ensure that it is legible and in good
condition.
3) Put the manual into the file box after use.
△
! CAUTION: If the manual needs to
be replaced, please contact the LGMG
service personnel.
1.3 Check Labels and Decals
It is necessary for safe operation of equipment
to keep all safety and description labels and
decals in good condition. The label warns the
operator and staff of many possible hazards
during use of this equipment. It also provides
the user with operation and maintenance
information. The illegible label cannot warn the
staff of steps or dangers, which may also lead to
unsafe operation.
Refer to the label section of this operation
manual to check whether all label are where
they shall be.
Check the clarity and damage of all label and
immediately replace any damaged or illegible
label.
△
! CAUTION: If you need to replace
the label, please contact the LGMG
service personnel.
1.4 Every Day or Every 8
Hours
1.4.1 Check for Damaged and Loose or
Missing Part
Perform this step every 8 hours or every day.
Daily equipment status checks will be necessary
for safe equipment operation and good
equipment performance. Incorrect positioning
and repair damage, and loose or missing parts
may lead to unsafe operating conditions.
1) Check the damage of the whole equipment
and incorrect installation or loss of parts,
including:
Electrical components, wiring and cable

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
4
Hydraulic hose, joint, valve block, hydraulic
cylinder
Fuel and hydraulic tank
Sliders
Tires and hubs
Engine and related components
Limit switches, horns
Nuts, bolts and other fasteners
Indicator lamps and alarms
Drive shafts
Check the entire machine to find:
Cracks in weld or structural parts
Whether the chassis is deformed or open
weld
Dent or damage to the machine
Ensure that all structural parts and other
key components are complete and all
relevant fastener and pin are in the correct
position and tightened
Scheduled maintenance
In extremely cold, dusty or humid working
environment, more frequent lubrication and
maintenance than specified in "scheduled
maintenance" is required. During maintenance,
the maintenance items listed in the original
requirements shall be repeated.
For example, when proceeding the
maintenance item for 500 working hours, the
maintenance items listed for every 250 working
hours and every 100 working hours shall be
carried out at the same time.
1.4.2 Check the Hydraulic Oil Level and
Hydraulic Oil Leaks
Check the hydraulic oil level every 8 hours or
every day.
△
! CAUTION: Perform this step
when the arm rod is in the stowed
position.
Park the machine on a flat ground. The arm
rod shall retract to the stowed position.
Figure 1-1 Hydraulic oil dipstick
Check the oil dipstick on the hydraulic oil
tank. The liquid level shall be within the M
range as shown in Figure 1-1. If the liquid
level is lower than M, the hydraulic oil shall
be filled. Select the hydraulic oil grade
according to the temperature.
Grade
Brand
Rando MV32
Chevron
△
!CAUTION: Do not top off with
incompatible hydraulic fluids.
Hydraulic fluids may be incompatible
due to the differences in base additive
chemistry. When incompatible fluids
are mixed, insoluble materials may
form and deposit in the hydraulic
system, plugging hydraulic lines,
filters, control valves and may result in
component damage.
Check for hydraulic oil leaks every 8 hours or
every day.
△
! CAUTION: Danger of personal
injury: Spilled hydraulic oil can
penetrate and burn the skin, Goggles

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
5
and protective gloves must be worn.
The leakage of high-pressure oil may not
be visible to eyes. Cardboard or wood chip
shall be used as a tool to check for
hydraulic oil leakage. It is forbidden to
confirm it by hand. Check oil droplets or oil
residues on the following components:
Hydraulic tank, filter, pump, hydraulic
cylinder, motor, reducer, valve block,
hydraulic pipe
Check oil droplets or oil residues in the
following areas:
Rear of arm rod, fly jib, upper of rotary table,
upper and lower of drive chassis, ground
area under equipment
1.4.3 Check for Engine Oil Level
△
!Do not operate on running
engines!
No smoking and open fires!
Be careful when contacting with high
temperature engine oil. Danger of
scalding!
△
! When operating on the oil system,
pay attention to the surface cleaning.
Carefully clean all areas involved. Blow
wet parts with compressed air.
△
! Please observe the safety
regulations for engine oil and relevant
local regulations. Dispose of spilled
engine oil and filter elements as
required. Waste oil cannot penetrate
into the ground.
△
!Test run shall be carried out after
each operation. At the same time, pay
attention to the sealing and lubricating
oil pressure, and then check the
engine oil level.
Check the engine oil level every 8 hours or
every day.
Insufficient or excessive engine oil may cause
damage to the engine. The engine oil level can
only be checked when the engine is placed
horizontally and closed. If the engine is hot,
close the engine and check the engine oil level
5 minutes later. Check it immediately if the
engine is cooled.
V2403-CR-E5:
V2403-E3:
Figure 1-2
1. Oil measuring rod
2. Oil filler plug
1) Pull out the oil measuring rod and clean it
with a piece of clean and fiber-free cloth.
2) Insert the oil measuring rod into the bottom.

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
6
3) Pull out the oil measuring rod and read the
value of engine oil level.
4) The engine oil level shall always be
between MIN and MAX!
5) Fill up to the maximum liquid level if
necessary.
1.4.4 Check for Fuel Leakage
Visually check for fuel leakage every 8 hours or
every day.
△
! The engine must be shut down!
No smoking and open fires!
Be careful when contacting high
temperature fuel!
Please observe the safety regulations
for fuel and relevant local regulations.
Dispose of spilled fuel and filter
elements in accordance with national
regulations. The fuel cannot seep into
the ground.
Visually check for fuel leakage every 8
hours or every day.
△
! There is danger of explosion and
fire. The fuel of the engine is
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,
spark, flame, and burning tobacco. A
qualified fire extinguisher shall be
placed in an easily accessible place.
△
! There is danger of explosion and
fire. If fuel leaks, prevent any additional
person from entering the area or
operating the equipment. Repair the
leakage immediately.
1.4.5 Check for Engine Air Filter
Check the maintenance indicator for the air filter
every 8 hours or every day.
Figure 1-3
△
! Perform this step when the
engine is turned off.
Check the maintenance indicator of the air filter.
When the transparency of the indicator turns red,
filter element needs to be maintained and
cleaned or replaced.
When the primary filter element is cleaned more
than 5 times or the filter element has been
damaged, the primary filter element needs to be
replaced.
Under ordinary conditions, open the dust
discharge valve once a week; When used in
dusty places, open it once a day, which can
remove large particles of dust and something
dirty.
1.4.6 Check for Coolant Liquid Level
Check the coolant liquid level every 8 hours or
every day.
△
! The coolant at high temperature
has the risk of scald.

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
7
The cooling system is under pressure! The
cover can only be opened in the cooling state.
Coolant must have a specified concentration of
cooling system protectant!
Please observe the safety regulations for
coolant and relevant local regulations.
Dispose of the spilled coolant as specified,
without leaving it on the ground.
Never run the engine without coolant, even if it's
a very short time.
1) Carefully open the cover for the cooling
system.
2) The coolant liquid level shall always be
between min and max! Fill up to the
maximum liquid level if necessary.
1.4.7 Check for Engine Belt
△
! Only when the engine is
stationary can the belt drive operation
be carried out.
△
! There is danger of burn. Be
cautious of high-temperature engine
components. Contact with them may
cause serious burn.
1) Visually inspect whether all belt drives for
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.
1.5 Every 100 Hours
1.5.1 Slewing Bearing and Slewing
Gear Lubrication
Fill the slewing bearing and slewing gear with
grease every 100 hours. Regular lubrication of
slewing bearings is necessary to maintain good
equipment performance and service life.
Incorrect lubrication can lead to component
damage.
Figure 1-4 Slewing mechanism
1. Slewing bearing
2. Oil pipe
3. Grease nipple
4. Adjusting bolt
5. Lock nut
6. Fixing bolt
As shown in Fig. 1-4, find the grease filler 3
next to the slewing reducer, connect the
greaser, and rotate the rotary table several
times while filling grease until the grease
overflows from the upper and lower fixing
surfaces of the slewing bearing. Grease
grade: lithium base grease 2#.
Check the lubrication of slewing bearing
gear and slewing reducer gears, clean the
gear surface if necessary, and apply the
grease again.

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
8
△
! CAUTION: If there is too much
dust in the working environment,
increase the frequency of filling
grease.
1.5.2 Grease the Exposed Piston Rod
If storing the machine for a long time with the
piston rod exposed, carry out the maintenance
monthly; if not, carry it out quarterly.
Component requiring maintenance:
Tower boom lift cylinder.
Grease specification:
Lithium-based grease and hydraulic oil mix, with
the ratio of lithium-based grease to hydraulic oil
as 3:1.
Maintenance procedure:
1) Apply the mix evenly onto lint-free wipers.
2) Fully raise the tower boom and apply the
mix evenly to the surface of the exposed
piston rod using lint-free wipers.
3) Fully lower the tower boom and fully raise it.
Then wipe the residual mix off the piston
rod using lint-free wipers.
1.6 Every 250 Hours
1.6.1 Check the Air Filter of Hydraulic
Tank
This inspection is carried out every 250 hours or
quarterly, whichever comes first.
A hydraulic tank cap with smooth ventilation is
essential for achieving good mechanical
performance and service life. Dirty or clogged
vent caps may lead to poor performance of the
machine. Inspection shall be carried out
frequently in the harsh working environment.
①Remove the vent cap from the hydraulic
tank cover.
②Ventilation check.
Result: air can pass through the vent cap.
Result: if the air cannot pass through the vent
cap, clean or replace the vent cap. Continue
with Step 3.
Note: when checking the ventilation of the
hydraulic oil tank cap, the air shall be able to
pass freely.
③Clean the tank vent cap carefully with a
mild solvent and dry it with low pressure
compressed air. Repeat step 2.
④Install the hydraulic tank vent cap.
1.6.2 Check the Battery
Check the battery once every 250 hours or
quarterly, whichever comes first.
△
! DANGER:
Explosion Hazard!
Danger of Electric Shock!
Burn Danger!
When operating, keep away from fireworks and
remove all rings, watches and other accessories.
Wear goggles, protective gloves and protective
clothing if necessary. Avoid touching the spilled
electrolyte with hands or other parts of the body,
and neutralize spilled electrolyte with baking
soda.
Good battery condition is critical to machine
performance and safe operation. Unsuitable
voltage or damaged cable and wiring may
cause damage to components and create
dangerous conditions.
Check maintenance-free lead-acid battery:
Check whether the battery lock lever is
stable.
Check the wiring of the battery cable, which
shall be secure and free from corrosion.
Check whether the electrolyte is leaking

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
9
and whether the battery is dry and clean.
Check electric eye status every three months
(maintenance-free lead-acid battery)
As shown in Figure 1-5, check the battery
hydrometer color:
Figure 1-5 Battery Hydrometer
Color of
electric
eye
Meaning and processing method
White
Insufficient electrolyte. Please shut
down the machine and stop using
it.
Black
Under voltage or damage
Green
Measure the voltage of each
battery. If the voltage is lower than
11 V, it indicates that the battery is
damaged (open circuit or short
circuit);
The voltage is between 12.4 V-12.7
V, indicating that the battery is in
good condition
Table 1-1 Color and description of battery
hydrometer
If the battery hydrometer color is green and
the voltage is above 12V, but it cannot work
normally, please ask the trained
maintenance personnel who have obtained
the corresponding qualifications to further
test the battery.
Battery recharge:
Before charging, disconnect the
negative connection of the battery first,
and then the positive connection of the
battery.
Before replenishing electricity, clean the
end column and remove the oxide scale
on the surface.
△
!NOTE: If an external power
supply is required to charge the
battery, only the charger approved
by the LGMG can be used.
Do not replenish the battery with
white eyes. Replace the battery.
When wiring after charging,
connect the positive wire first
and then the negative wire.
△
! NOTICE: Adding a terminal
protector and an anti-corrosion sealant
will help remove corrosion caused to
battery terminals and cables.
1.6.3 Check the Tire and Nut Torque
This inspection is carried out every 250 hours or
quarterly, whichever comes first.
Maintaining the tire and hub in good condition is
essential for the safe operation and good
performance. Failure of tire and hub may cause
the machine to roll over. If not find the failure
and repair it in time, it will also cause damage to
the machine parts.
Filled tire and solid tire do not need inflation.
1) Check the tire tread and sides for scratches,
cracks, piercing and other abnormal wear.
2) Check the hub for damage, bending and
cracking.
Check tire nut torque
Type
Torque
Hydrometer

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
10
AR20J
595±55N.m
1.6.4 Check the Clearance Between the
Slewing Bearing and the Slewing
Reducer
This inspection is carried out every 250 hours or
quarterly, whichever comes first.
The rotary table shall rotate smoothly without
jam and pause. Measure the backlash
between slewing bearing gear and slewing
reducer with feeler gauge. The backlash shall
be between 0.2-0.3mm. If it is out of the range,
please adjust it.
Figure 1-6 Slewing mechanism
1. Slewing bearing
2. Oil pipe
3. Grease nipple
4. Adjusting bolt
5. Lock nut
6. Fixing bolt
Loosening fixing bolt 6 and lock nut 5
Turn adjusting bolt 4 to adjust reducer
position
Measure slewing bearing gear and slewing
reducer gear backlash with feeler gauge
If the clearance is between 0.2-0.3 mm,
tighten lock nut 5 and tighten fixing bolt 6
Measure the backlash between slewing
bearing gear and slewing reducer gear
again to verify that requirements are met.
Tighten the fixing bolt 6, torque:
595±55N•m.
1.6.5 Visual Inspection of Hydraulic Oil
This inspection is carried out every 250 hours or
quarterly, whichever comes first.
Collect a hydraulic oil sample and place it in a
transparent container. The operation of the
visual inspection of hydraulic oil is as follows:
Color: the oil color should be transparent
and light honey.
Appearance: the oil should be clear and not
cloudy, and the viewing angle should not be
visibly distorted when viewing through the
sight glass or container. Without particles,
foreign matter or other contaminants.
The hydraulic oil can be checked by smell
(the smell of "hot" can be smelled, but not
"burnt" smell) or friction between fingers (It
should be sticky without any graininess).
If all the hydraulic oil passes the above
inspection, continue maintenance at
predetermined intervals. If the hydraulic oil fails
in any of the above checks, the hydraulic oil
must be tested.
1.6.6 Check the Oil Level of the Drive
Axle Main Reducer and Close-to-wheel
Reducer
This inspection is carried out every 250 hours or
quarterly, whichever comes first.
△
! CAUTION: The vehicle must be
parked on a level, solid ground before
operation. Place a cushion block under
the tire to prevent the machine from
moving.

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
11
△
! CAUTION: To drain or fill oil and
check the oil level, the drive axle must
be level and installed on the vehicle.
Check main reducer oil level
Figure 1-7
1. Filler port/sight port
2. Drain port
3. Breather
Carefully clean breather 3 and the
surrounding area.
Remove plug 1 and check if the oil level is
at the lower edge of the filler port, otherwise
add oil.
Tighten the plug.
Act on each main reducer in the same way.
Check close-to-wheel reducer oil
Figure 1-8
4. Filler port/sight port/drain port
Turn the wheel so that the plug 4 is in the
highest position, and partially loosen it to
release the pressure that may exist.
Turn the wheel so that the plug 4 is in a
horizontal position, remove the plug to
check whether the oil level is at the lower
edge of the filler port, otherwise add oil and
tighten the plug.
Work on each close-to-wheel reducer in the
same way.
1.6.7 Check the Transfer Case Oil Level
This inspection is carried out every 250 hours or
quarterly, whichever comes first.
Figure 1-9
1. Filler port/sight port
2. Drain port
3. Breather
Carefully clean breather 3 and the
surrounding area.
Remove plug 1 and check if the oil level is
at the lower edge of the filler port, otherwise
add oil.
Tighten the plug.

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
12
1.6.8 Check the Oil Level of the
Slewing Reducer
This inspection is carried out every 250 hours or
quarterly, whichever comes first.
Improper oil level in the reducer will reduce the
performance of the equipment, and continuous
use will lead to component damage.
1) Slewing reducer oil level inspection
Figure 1-10 Slewing reducer
1. Filler port 2. Sight port
Remove the plug 2 on the reducer side and
check the oil level, as shown in Figure.
Result: the oil level should be the same as sight
port 2 height.
When it is needed, please add gear oil
through filler port 1 until the oil level is the
same as the bottom height of sight port 2.
Apply pipe thread sealant to the plug and
install the plug into the reducer.
Replace lubricant after the first 50h of use,
then every 1,000 h or yearly, whichever
comes first.
The gear oil recommended is as the following
table
Item
Condition
Grade
API Gl-5
Gear
oil
30°C < Minimum
temperature
85W/140
-10°C < Minimum
temperature <30°C
85W/90
-30°C <Minimum
temperature <-10°C
80W/90
Minimum temperature
<-30°C
75W
1.6.9 Check the Wires
This inspection is carried out every 250 hours or
quarterly, whichever comes first.
It is important for safe operation and good
machine performance to keep the wires in good
conditions. Failure to find and replace the
burn-out, scratched, corroded or bent wires will
result in unsafe operating conditions and
damage to the parts.
Risk of electric shock/explosion
Contact with live circuits may cause serious
injury or death. Do not wear rings, watches or
other jewelry.
1) Check the following areas for burn-out,
scratched, corroded, bent or loose wires:
Engine wiring harness
All wire harness connectors to ground
control box
All wire harness connectors to platform
control box
Hydraulic manifold wiring
2) Check whether all wire harness connectors
are coated with insulating grease:
Ground control unit
Platform control unit
Harness connectors
Sensor
1.6.10 Adjustment of Belt Tension
V2403-E3

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
13
Figure 1-11
1. Fan belt
2. Bolt and nut
V2403-CR-E5
Figure 1-12
1. Fan belt
2. Bolt and nut
Apply moderate thumb pressure to belt between
the pulleys.
If tension is incorrect, loosen the alternator
mounting bolts and, using a lever placed
between the alternator and the engine block,
pull the alternator out until the deflection of the
belt falls within acceptable limits.
Replace fan belt if it is damaged.
Proper fan belt tension
A deflection when the
belt is pressed in the
middle of span.
7 to 9 mm
under load of 10 kg
1.6.11 Cleaning or Replacement of Air
Filter
Clean it every 250 hours or quarterly and
replaced it for every 1000 hours or every year,
whichever comes first.
△
! Do not operate on running
engines!
△
! Be sure to pay attention to the
cleanliness of the external surface
when operating on the engine suction
system, and close the suction inlet
when necessary. The old filter
elements are handled in an
environmentally friendly manner.
Cleaning of air filter
△
! Do not clean the filter element (4)
with gasoline or high temperature
liquid.
If the primary element is stained heavily, replace
it soon. At this time, replace the secondary
element too.
The secondary element should be removed only
if it is to be replaced.
To protect the engine, do not remove the
secondary element in servicing the primary
element.

Maintenance Manual of Articulated Boom
Mobile Elevating Work Platform
14
Figure 1-13
1. Air cleaner body
2. Dust cup
3. Secondary element（If equipped）
4. Primary element
5. Evacuator valve
Make sure the hooking clip for the element is
tight enough. If it is loose, dust and dirt may be
sucked in wearing down the cylinder liner and
piston ring earlier and thereby resulting in poor
power output.
Do not excessively service the air cleaner
element. Over-service may cause dirt to enter
the engine causing premature wear. Use the
dust indicator as a guide on when to service.
1) Open the hooking clip.
2) Remove the filter cover (2) and screw off
the filter element (4).
3) Filter element (4): For slight contamination,
purge with dry compressed air (maximum
205 Kpa) from inside to outside for cleaning
(general cleaning times are no more than 5
times);
Replace it in case of serious contamination.
Replacement of the Safety Filter Tube of the
Air Filter
△
! Never clean the safety filter tube
(3).
1) Screw off the Primary element (4) and the
Secondary element (3).
2) Install the new Secondary element.
3) Install the filter element (4), place the outer
cover (2) and fix it with the hooking clip.
1.7 Every 400 Hours
1.7.1 Replacement of Engine Oil and
Filter
The following steps apply to engine V2403-
-E3.
△
! Do not operate on running
engines!
No smoking and open fires!
Be careful when contacting with high
temperature engine oil.
Danger of scalding!
△
!When operating on the oil system,
pay attention to the surface cleaning.
Carefully clean all areas involved.
Blow wet parts with compressed air.
△
!Please observe the safety
regulations for engine oil and relevant
local regulations. Dispose of spilled
engine oil and filter elements as
required. Waste oil cannot penetrate
into the ground.
△
! Test run shall be carried out after
each operation. At the same time, pay
attention to the sealing and lubrication
oil pressure, and then check the