LGMG AR65J Use and care manual

LGMG North America Inc.
Operation and Safety Manual
AR65J
Articulated Boom
Mobile Elevating Work Platform
ANSI
△
!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.

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I
Contents
Contents.......................................................................................................I
Foreword....................................................................................................III
Safety Notices........................................................................................... IV
Chapter 1 Safety .........................................................................................1
1.1 Hazards ............................................................................................ 3
1.2 Before Operation, Please Ensure that:.............................................. 3
1.3 Classification of Hazards .................................................................. 3
1.4 Intended Use .................................................................................... 3
1.5 Safety Sign Maintenance.................................................................. 3
1.6 Electric Shock Hazard ...................................................................... 4
1.7 Danger of Tip-over ............................................................................ 4
1.8 General Safety.................................................................................. 5
1.9 Operating Hazards on Slopes........................................................... 6
1.10 Falling Hazard ................................................................................ 6
1.11 Collision Hazard.............................................................................. 7
1.12 Components Damage Hazard......................................................... 7
1.13 Explosion and Fire Hazards ............................................................ 7
1.14 Machine Damage Hazard ............................................................... 8
1.15 Danger of Bodily Injury.................................................................... 8
1.16 Battery Safety ................................................................................. 8
1.17 Locked After Each Use ................................................................... 8
1.18 Personal Fall Protection.................................................................. 9
1.19 Ground Information......................................................................... 9
Chapter 2 Legend .....................................................................................11
Chapter 3 Label.........................................................................................15
Chapter 4 Overall Machine Parameters ....................................................21
Chapter 5 Control Box...............................................................................33
5.1 GCU ............................................................................................... 35
5.2 PCU................................................................................................ 37
Chapter 6 Pre-operation Inspection...........................................................41
6.1 Before Performing This Operation, Ensure that .............................. 43

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6.2 Basic Principles .............................................................................. 43
6.3 Pre-operation Inspection................................................................. 43
Chapter 7 Workplace Inspection ...............................................................45
7.1 No Operation Is Allowed Unless...................................................... 47
7.2 Basic Principles .............................................................................. 47
7.3 Workplace Inspection...................................................................... 47
Chapter 8 Functional Testing.....................................................................49
8.1 Basic Principles .............................................................................. 51
8.2 At GCU ........................................................................................... 51
8.3 On the Platform .............................................................................. 51
Chapter 9 Operating Instructions...............................................................55
9.1 No Operation is Allowed Unless...................................................... 57
9.2 Basic Principles .............................................................................. 57
9.3 Starting the Engine ......................................................................... 57
9.4 Emergency Shutdown..................................................................... 57
9.5 Emergency Power .......................................................................... 58
9.6 Operation on the Ground ................................................................ 58
9.7 Operation on the Platform............................................................... 58
9.8 Platform Overload........................................................................... 60
9.9 Machine Not Level .......................................................................... 60
9.10 Red Guard protective system........................................................ 61
9.11 Low Temperature Start Kit (If Equipped)........................................ 61
9.12 DPF Regeneration (If Equipped)................................................... 62
9.13 System Failure.............................................................................. 64
9.14 After Each Use.............................................................................. 66
Chapter 10 Transportation Instructions......................................................67
10.1 Observing the Regulations............................................................ 69
10.2 Brake Release .............................................................................. 69
10.3 Ensuring Transportation Safety..................................................... 69
10.4 Guidance for Lifting....................................................................... 70

LGMG North America Inc. Operation and Safety Manual
III
Foreword
Thank you for choosing to use this Mobile Elevating Work Platform from LGMG North America. This
machine is designed according to ANSI A92.20-21 and CSA B354.6-17. The information specified in this
manual is intended for the safe and proper operation of this machine for its’ intended purpose.
For maximum performance and utilization of this machine, thoroughly read and understand all the
information in this manual before starting, operating, or performing maintenance on this machine.
Due to continuous product improvements, LGMG North America reserves the right to make specification
changes without any prior notifications. For any updated information, contact LGMG North America.
Ensure all preventive maintenance to the machine is performed according to the interval specified in the
maintenance schedule.
Keep this manual with this machine for reference at all times. When the ownership of this machine is
transferred, this manual shall be transferred with this machine. This manual must be replaced
immediately if it is lost, damaged, or becomes illegible.
This manual is copyrighted material. The reproduction or copy of this manual is not allowed without the
written approval of LGMG North America.
The information, technical specifications and drawings in this manual are the latest available when this
manual is issued. Due to continuous improvement, LGMG North America reserves the right to change
the technical specifications and machine design without notice. If any specifications and information in
the manual are not consistent with your machine, contact the service department of LGMG North
America
△
!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.
All dealers, owners, users, operators, lessors, lessees, and brokers must comply
with appropriate section(s) of applicable A92 standards.

LGMG North America Inc. Operation and Safety Manual
IV
Safety Notices
The operator of this machine shall understand and follow the existing safety regulations of state and
local governments. If these are unavailable, the safety instructions in this manual shall be followed.
To help prevent accidents, read and understand all warnings and precautions in this manual before
operation or performing maintenance.
The safety measures are specified in Chapter 1 Safety.
It is impossible to foresee every possible hazard and the safety instructions in this manual may not cover
all safety prevention measures. Always ensure the safety of all personnel and protect the machine
against any damage. If unable to confirm the safety of some operations, contact LGMG North America.
The operation & maintenance prevention measures listed in this manual are only applicable to the
specified uses of this machine. LGMG North America assumes no responsibility if this machine is used
beyond the range of this manual. The user and the operator shall be responsible for the safety of such
operations.
Do not perform any operation forbidden in this manual in any situation.
The following signal words are applicable for identifying the level of safety information in this manual.
△
! DANGER:
An imminent situation, that if not avoided, will result in severe injuries or death. This
is also applicable to situations that will cause serious machine damage, if not
avoided.
△
! WARNING:
A potentially dangerous situation, that if not avoided, may result in severe injuries or
death. This is also applicable to situations that may cause serious machine damage,
if not avoided.
△
! NOTICE:
A situation, that if not avoided, may result in minor or intermediate injury. This is also
applicable to situations that may cause machine damage or shorten machine service
life.

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Chapter 1 Safety

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1.1 Hazards
△
! WARNING: Failure to follow the
instructions and safety rules in this
manual may result in serious injury or
death. Alcoholics, drug addicts, and
those taking reaction inhibiting drugs
are strictly prohibited from
approaching and operating the
machine.
1.2 Before Operation, Please
Ensure that:
1) Equipped with PFPE, such as helmet, seat
belt, safety shoes, goggles, protective
gloves, etc., and in good physical condition.
2) You have understood and implemented the
safety rules for machine operations in this
Operation Manual.
3) Know and understand the rules for safe
operation of the machine before proceeding
to the next step.
4) Always perform the check before the
operation.
5) Always perform a functional test before
use.
6) Check the workplace.
7) Use the machine only for specified
purposes.
8) All applicable laws and regulations shall be
read, understood and complied with.
9) Been trained to operate the machine safely.
1.3 Classification of Hazards
Symbols, color codes and symbolic words used
in LGMG products have the following meanings:
1) Safety warning sign - used to warn of
potential personal injuries. Observe all
safety tips at the back of the sign to avoid
possible personal injury or death.
2) Red indicates a dangerous situation. If it is
not avoided, it will lead to death or serious
injury.
3) Orange indicates a dangerous situation. If
not avoided, it may cause death or serious
injury.
4) Yellow indicates a dangerous situation. If
not avoided, it may cause minor or
moderate personal injury.
5) Blue indicates a dangerous situation. If not
avoided, it may result in property loss.
1.4 Intended Use
The use of this machine is limited to lifting
personnel and their tools and materials to
workplaces at heights and it can be used
indoors and outdoors.
△
! WARNING: It is strictly forbidden
to modify the machine without
permission, carry goods, and hang or
lift articles.
1.5 Safety Sign Maintenance
1) Replenish missing and replace damaged
safety sign.
2) Clean the safety sign with neutral cleaning
agent or clean water.
3) Solvent-based cleaners may damage the

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safety sign. Do not use solvent-based
cleaners to clean the safety sign.
1.6 Electric Shock Hazard
△
! WARNING: This machine is not
insulated and does not provide shock
protection when in contact with or near
wires, power supplies or electrical
equipment.
1) Please maintain a sufficient safe distance
from the wires, power supplies and power
equipment in accordance with applicable
laws and regulations and the following
table.
Voltage
Required safety
distance
0-50 KV
3.05m/10ft
50 KV-200 KV
4.60m/15ft
200 KV-350 KV
6.10m20ft
350 KV-500 KV
7.62m/25ft
500 KV-750 KV
10.67m/35ftft
750 KV-1,000 KV
13.72m/45ft
△
! CAUTION: The influence of
strong wind or gust on the movement
of the platform, the swing and
relaxation of wires should be
considered.
2) If the machine comes into contact with live
wires, immediately keep away from the
machine.
3) Before cutting off the power supply of wires,
it is forbidden for personnel to come in
contact with or operate the machine.
4) Do not operate and use the machine in
case of lightning or storm.
5) Do not use the machine as a ground wire
during welding.
1.7 Danger of Tip-over
1) The total weight of the personnel,
equipment and materials on the platform
shall not exceed the maximum bearing
capacity of the platform.
2) Never overload the platform.
3) Only when the machine is on solid, flat
ground can the boom be raised and
extended.
4) If the platform is overloaded, the buzzer will
alarm. Please reduce the platform load first.
5) When the platform is raised, the speed of
the machine shall not exceed 0.8 km/h/0.5
mph.
6) The tilt sensor cannot be considered as a
level indicator. The buzzer on the rotary
table will only sound when the machine is
heavily tilted.
7) If the buzzer sounds when the platform is
lifted, be very careful, as the Machine not
level indicator lamp will come on and the
drive function will not be available in both
directions. First determine the state of the
boom on the slope, as shown below. Then
lower the boom as follows before moving
the machine to a solid, level ground. Do not
rotate the boom when lowering.

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If the buzzer sounds when the platform goes
uphill
①Lower the primary boom
②Lower the secondary boom
③Retract the primary boom
If the buzzer sounds when the platform goes
downhill
①Retract the primary boom
②Lower the secondary boom
③Lower the primary boom
8) Do not raise the boom when the wind
speed may exceed 12.5 m/s/28 mph. If the
wind speed exceeds 12.5 m/s/28 mph after
the boom is raised, lower the boom and do
not continue to operate the machine.
9) Do not operate the machine in strong wind
or gust. Do not increase the surface area of
the platform or load. Increasing the area
exposed to the wind will reduce the stability
of the machine.
10) When the platform is tripped, stuck, or other
nearby objects hinder its normal movement,
do not use the PCU to operate the machine.
If you intend to operate the machine by
using the GCU, you must operate it after all
personnel have left the platform.
11) Always follow your national traffic
regulations.
12) Be very careful and reduce the speed when
the machine is driven on a surface with
crushed stone, unstable or slippery or near
a hole or on a steep slope in the stowed
state.
13) When the boom is raised, the machine
cannot be driven on uneven terrain,
unstable surfaces or other dangerous
conditions, or near these areas.
14) Do not push or pull any object outside the
platform. The maximum allowable manual
force of the machine is 400 N.
15) The machine cannot be used as a crane.
16) Do not place, tie down or hang loads on
any part of the machine.
17) Do not push machine or other objects with
boom.
18) When the vehicle goes downhill, please
operate in the low speed range, and it is
forbidden to go downhill at high speed.
19) When the vehicle is driving on a slope, it is
forbidden to use the emergency stop
switch.
1.8 General Safety
1) The machine cannot be operated with the
hood open.
2) Do not allow boom to approach or touch
any objects.
3) All sensors such as those for angle,
inclination, weighing shall not be changed
or disabled.

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4) Boom or platforms must not be bound to
adjacent objects.
5) Do not modify this machine without the
prior written permission of the manufacturer.
Installing additional devices for placing
tools or materials on platform, pedals or
guardrails will increase the weight and
surface area of the platform.
6) Ladders or scaffolding shall not be placed
in the platform or against any part of the
machine.
7) Only tools and materials that are evenly
distributed and can be safely moved by
people on the platform can be transported.
8) Do not use machines on moving or shaky
surfaces or on vehicles.
9) Do not place hands and arms close to
areas with danger of cutting or smashing.
10) Do not change or damage any component
that may affect the safety and stability of
the machines.
11) Key part affecting the stability of the
machine shall not be replaced with part of
different Spec.
12) Ensure that all tires are in good condition
and the nuts are properly tightened. Do not
replace the original tire with a tire of
different Spec.
13) The ambient temperature for the use of the
machine shall be -20 ℃~ 40 ℃, and the
relative humidity should not be greater than
90% (at 20 ℃).
14) Ensure that this manual is kept in the file
box in the platform.
15) Total vibration value to which the hand/arm
system is subjected does not exceed 2.5
m/s². Highest root mean square value of
weighted acceleration to which the whole
body is subjected does not exceed 0.5 m/s².
1.9 Operating Hazards on
Slopes
Do not drive the machine on a slope that
exceeds the maximum uphill, downhill or side
slope rated value of the machine. Slope rating is
only applicable to machines in stowed state.
The maximum slope rating when the boom is
stowed is as follows
Item
Parameters
AR65J
Platform in
downhill
direction
45%(24°)
Platform in uphill
direction
30%(17°)
Platform side
slope
25%(14°)
△
! CAUTION: Slope rating is limited
by ground condition and traction.
Refer to Driving on Slopes in the
Operating Instructions section of this
manual.
△
! Danger of Sliding Slope:
When the machine is working on a
slope exceeding the maximum and
rated gradation, a slip may occur.
A slip may lead to death or serious
injury.
1.10 Falling Hazard
1) During the operation, the staff on the
platform must wear PFPE, such as helmet,
safety belt and safety shoes according to
the site needs, and use, inspect, and

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7
regularly replace them according to the
manufacturer's instructions.
△
! WARNING: Seat belt hooks must
be fixed to approved rope fixing points,
and only one hook can be tied to each
rope fixing point.
2) Do not sit, stand or climb on the protective
fence of the platform. Stand stably on the
platform floor at all times.
3) Never get on or get off the platform when
the platform is raised.
4) When the platform is lifted, it is not allowed
to climb down from the boom.
5) Keep the platform floor free of debris,
sundries, grease and other slippery
substances.
6) Please close the entrance door before
operation.
7) Do not enter or leave the platform unless
the machine is tucked up.
1.11 Collision Hazard
1) Exercise good judgment and planning
when operating machines on the ground.
Keep a safe distance between the operator,
the machine and the object.
2) When starting or operating the machine,
pay attention to the sight range and the
existence of blind spots.
3) When rotating the rotary table, pay
attention to the position of the boom and
rotary table swing tail.
4) Check the work area to avoid obstacles or
other possible dangers overhead.
5) Beware of the squeezing danger when
grasping the platform fence.
6) When there are no people and obstacles in
the lower area, the boom can be lowered.
7) Limit travel speed according to ground
conditions, congestion level, slope,
personnel position and any other factors
that may cause collision.
8) The machine cannot be operated on the
route of any crane or mobile overhead
machinery unless the crane controller is
locked or precautions have been taken to
prevent any potential collision.
9) Do not operate the machine dangerously or
playfully.
10) Users must abide by the user rules,
workplace rules and government rules for
personal protection equipment.
11) Attention shall be paid to the direction of
driving and steering function.
1.12 Components Damage
Hazard
1) Do not use any battery or charger greater
than 12 V to start the engine.
2) Do not use the machine as a ground wire
during welding.
3) Do not use the machine where magnetic
fields may exist.
1.13 Explosion and Fire
Hazards
1) Do not operate the vehicle where it is
dangerous or where flammable or
explosive gases or particles may be
present.
2) Do not start up the engine if liquefied
petroleum gas (LPG), gasoline, diesel, or
other explosive substances are present.
3) Do not refuel the machine when the engine
is running.
4) Only refuel the machine in open and
well-ventilated places far away from sparks,
open flames, burning cigarettes, etc.

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1.14 Machine Damage Hazard
1) A machine that have been damaged or
faulty shall not be used.
2) The machine shall not be used where
strong magnetic fields, strong ionization
and radioactive radiation may exist.
3) Before every shift, the pre-operation
inspection of the machine shall be strictly
carried out and all functions shall be tested.
The damaged or faulty machine shall be
marked immediately and the operation shall
be stopped.
4) Ensure that all inspections and
maintenance have been carried out as
specified in this manual.
5) Ensure that all labels are located properly
and easily identified.
1.15 Danger of Bodily Injury
1) Please do not operate the machine when
the hydraulic oil leaks. Hydraulic oil leakage
may penetrate or burn the skin, and the
goggles and protective gloves must be
worn when checking the hydraulic
oil leakage.
2) Incorrect contact with any components
under the hood will result in serious injury,
and only trained maintenance personnel
can open the hood for overhaul. The hood
can be opened by the operator for
inspection only when the pre-run inspection
is carried out. All hoods must remain closed
during operation.
3) It is forbidden to carry out maintenance
work when the equipment hydraulic system
is under pressure.
4) Always operate the machine in a
well-ventilated area to avoid of carbon
monoxide poisoning.
1.16 Battery Safety
Danger of Burns
1) Lead-acid battery contains acid. Wear
protective clothing and protective glasses
when maintaining battery.
2) Avoid spillage or contact with acidic
substances in the battery. Use soda and
water to neutralize spilled battery acid.
3) When cleaning the vehicle, it is forbidden to
directly flush and wash the battery and
other electrical components.
4) Disconnect the main power switch when
transporting, repairing or parking the
vehicle for a long time.
Explosion Hazard
1) Sparks, flames and lit cigarettes are
prohibited from getting close to the battery.
The battery can release explosive gases.
2) Do not touch battery terminals or cable
clamps with tools that may cause sparks.
Electric Shock/Burn Hazard
1) Check cables, wires and wiring daily for
damage. Replace damaged items before
operation.
2) Avoid electric shock due to contact with
battery terminals. Remove all rings,
watches and other accessories.
1.17 Locked After Each Use
1) Choose a safe parking place, which can be
a solid level ground without obstacles and
avoid places where transportation is busy.
2) Retract and lower the boom to the stowed
position.
3) Rotate the rotary table so that the boom is
located between the two tire of the rear
axle.
4) Turn the key switch to the "off" position and

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9
remove the key to avoid unauthorized use.
5) Cushion the wheel with a wedge.
6) Cut off the power when the machine is
repaired or not used for a long period.
1.18 Personal Fall Protection
1) The personal fall protection equipment
(PFPE) is required when this machine is
operated.
2) Personnel on the platform must wear a seat
belt or use safety facilities that comply with
government regulations. Tie the lanyard to
the lanyard fixing point of the platform.
3) Users must abide by user rules, workplace
rules and government rules regarding the
use of personal protection equipment.
4) All PFPEs must comply with the
corresponding government regulations and
must be inspected and used according to
the PFPE manufacturer's instructions.
1.19 Ground Information
△
! WARNING: Rollover and personal
injury will be caused under severe
working conditions and complex and
unsafe ground conditions, and stable
ground conditions and good working
conditions can ensure the normal
operation of the machine; therefore
before operation, verify that the
ground in the working area is safe and
strong enough to support the machine.
△
! DANGER: Rollover and personal
injury may occur under the following
conditions:
On steep slopes or in caves;
When there are protrusions,
obstacles or debris on the ground;
On the inclined surface;
On the unstable or smooth surface;
Near the mining area where the soil
foundation is soft soil;
On saturated soil or frozen soil;
On suspended floor;
On kerbs and road edges;
On surface support that is not
strong enough to withstand the full
load of the machine;
Under other possible unsafe
situations.
Tire specification:
Model
Drive wheel
load-5km/h
（kg/lbs）
Maximum static
load（kg/lbs）
AR65J
5300/11684
7000/15432

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Chapter 2 Legend

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△
! CAUTION: The product structure diagram of AR65J is shown here. For other
models, please refer to this diagram.
Fig. 2-1 Side view of complete vehicle
No.
Description
No.
Description
1
Counterweight
6
PCU
2
Front axle
7
Jib
3
Rear axle
8
Base boom
4
Lanyard fixing point
9
Tower boom
5
Platform
10
Engine side

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