LGMG AR65J User manual

LGMG North America Inc.
Maintenance 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.
This page left blank intentionally
LGMG North America Inc. Maintenance Manual
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 400 Hours............................................................................. 14
1.8 Every 500 Hours............................................................................. 17
1.9 Every 1000 Hours ........................................................................... 22
1.10 Every 2000 Hours ......................................................................... 24
1.11 Scheduled maintenance................................................................ 26
1.12 Engine Fault Table ........................................................................ 27
1.13 Engine fault codes ........................................................................ 32
1.14 Maintenance Point........................................................................ 40
Chapter 2 Schematic Diagram ..................................................................47
I
LGMG North America Inc. Maintenance Manual 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.
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LGMG North America Inc. Maintenance Manual
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.
III
LGMG North America Inc. Maintenance Manual IV

LGMG North America Inc. Maintenance Manual
Chapter 1 Maintenance
1

LGMG North America Inc. Maintenance Manual 2
LGMG North America Inc. Maintenance Manual
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 ●
Hydraulic hose, joint, valve block, hydraulic
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LGMG North America Inc. Maintenance Manual
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
and protective gloves must be worn.
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LGMG North America Inc. Maintenance Manual
●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.
3) Pull out the oil measuring rod and read the
value of engine oil level.
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LGMG North America Inc. Maintenance Manual
4) The engine oil level shall always be between
MIN and MAX!
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.
The cooling system is under pressure! The
cover can only be opened in the cooling
state.
Coolant must have a specified concentration of
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LGMG North America Inc. Maintenance Manual
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