LGMG M2640JE User manual

LGMG North America Inc.
Maintenance Manual
M2640JE
Mast 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.

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LGMG North America Inc. Maintenance Manual
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Contents
Foreword ....................................................................................................... II
Safety Notices .............................................................................................. III
Chapter 1 Maintenance ................................................................................. 1
1.1 Checking the Battery ..................................................................................................3
1.2 Checking the Hydraulic Oil Level ................................................................................4
1.3 PDI Report..................................................................................................................5
1.4 Maintenance Schedule ...............................................................................................5
1.5 Maintenance Inspection Report ..................................................................................6
1.6 PDI Report..................................................................................................................7
1.7 Maintenance Inspection Report ..................................................................................8
1.8 Steps for Checklist A...................................................................................................8
1.9 Steps for Checklist B ................................................................................................10
1.10 Steps for Checklist C ..............................................................................................16
1.11 Steps for Checklist D ..............................................................................................17
1.12 Steps for Checklist E ..............................................................................................22
Chapter 2 Appendix ..................................................................................... 23
2.1 Maintenance items....................................................................................................25

LGMG North America Inc. Maintenance Manual
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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, please contact the service department of LGMG North
America.
△
!WARNING
Only the personnel who have been professionally trained and qualified are allowed
to operate and maintain the machine.
Incorrect operation, maintenance and repair are dangerous and may lead to
personal injury or death.
Before operation or maintenance, please read this manual thoroughly. Otherwise,
do not operate, maintain or repair this machine.
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 operation instructions and precautions in this manual apply only to the
intended use of the machine. If the machine is used for an operation that is out of
the specification herein but not prohibited, always make sure that this operation will
not cause personal injury to yourself or others.
Please operate the machine in strict accordance with the safety requirements in the
manual. The user is responsible for all consequences caused by non-compliance
with the safety requirements of the machine.

LGMG North America Inc. Maintenance Manual
III
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.
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.

LGMG North America Inc. Maintenance Manual
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LGMG North America Inc. Maintenance Manual
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Chapter 1 Maintenance

LGMG North America Inc. Maintenance Manual
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△
! WARNING: Observe the
regulations
The operator can only perform the
regular maintenance items specified
in this manual.
As required by the manufacturer, the
regular maintenance and inspection
shall be performed by the trained
maintenance technicians.
1.1 Checking the Battery
Keeping the battery in good condition is
crucial for superior performance and
safe operation. Improper electrolyte
level or damaged cable or wiring may
cause parts damage and hazards.
△
! CAUTION: If the machine is
equipped with the hermetically sealed
battery or maintenance-free battery,
inspection of electrolyte level is not
required. Otherwise, the electrolyte level
should be checked.
△
! DANGER
Risk of electric shock:
Live-line working may result in serious
personal injury or even death. Be sure
to remove the ring, watch and other
ornaments before the work.
Risk of personal injury:
The battery electrolyte is corrosive.
Avoid touching the spilled electrolyte
with hands or other parts of the body so
as to avoid injuries. Use soda and water
to neutralize the spilled electrolyte.
△
! CAUTION: The following
inspections should be carried out with
sufficient battery power:
Wear protective clothes and
goggles.
Open the upper cover of the rotary
table.
Ensure that the battery cable is
connected firmly, without corrosion.
Remove the battery cover.
Check the battery electrolyte level.
Add distilled water as needed, and
do not add too much.
Refit the cover.
△
! CAUTION: It is necessary to add
the terminal protector and
corrosion-resistant sealant to protect
the battery terminals and cables against
corrosion.

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1.2 Checking the Hydraulic Oil
Level
Proper hydraulic oil level is crucial in
operating the machine. If the hydraulic
oil is at an improper level, the hydraulic
components will be damaged. Through
a daily inspection, the inspector can
determine the hydraulic oil level change
which indicates that the hydraulic
system is faulty.
△
! CAUTION: This procedure shall be
performed when the machine is
retracted.
1) Visually check the oil level sight glass on the
side of the hydraulic tank.
Result: The hydraulic oil level should be at the
scale of the tank.
2) Add the oil as needed, and do not add too
much.
△
! CAUTION: Please add hydraulic oil
according to the operating environment
and temperature, as described below:

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Inspection interval
Inspection item
Daily or every 2 h
A
Monthly or every 25 h
A+B
Quarterly or every 50 h
A+B+C
Semiannually or every 100 h
A+B+C+D
Yearly or every 200 h
A+B+C+D+E
Biennially or every 400 h
A+B+C+D+E+F
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.
1.3 PDI Report
1) PDI report covers all PDI items.
2) PDI report should be prepared for every PDI
item. Fill in the report and save it as required.
1.4 Maintenance Schedule
The daily, quarterly, semiannually, yearly and
biennially inspection must be carried out as
scheduled. The product maintenance schedule
and PDI report are subdivided into five items: A, B,
C, D, E. The inspection steps are shown in the left
table.
△
! CAUTION:
Working hours shall prevail for the
maintenance cycle.
Key
Y=Yes
N=No
R=Repaired
Pass/fail
PDI report
Y
N
R
Operation
inspections
completed
Maintenance items
completed
Function tests
completed
Model
Serial number
Date
Owner
Inspection unit (printed)
Signature of inspector
Title of inspector
Inspection company

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The steering knuckle and slewing
bearing should be lubricated
monthly to ensure that the
equipment meets the operating
requirements.
1.5 Maintenance Inspection Report
1) Maintenance inspection report
covers all maintenance inspection
items.
2) Maintenance inspection report
should be prepared for every
maintenance inspection item. After
the inspection, the report should be
retained for at least 4 years, or as
specified by the employer,
workplace and government laws and
regulations.

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1.6 PDI Report
1.6.1 Basic Principles
1) Dealers are obliged to complete PDI.
2) Priority should be given to PDI before each
product is delivered. PDI is to find out if there
are any obvious problems with the
equipment before it is put into use.
3) Damaged and modified equipment is never
allowed to be used. Once damage or
inconsistencies in equipment delivery are
found, the machine must be marked and
stopped immediately.
4) Equipment repairs must be performed by a
certified technician, in accordance with the
manufacturer's specifications and the
requirements in this manual.
1.6.2 Instructions
1) Refer to the Operating Manual on the
equipment.
2) PDI consists of operation inspections,
maintenance items and function tests.
3) Record the results in a table. Fill in the
appropriate table after each item is
completed according to the instructions in the
Operating Manual.
4) If the result of any inspection is "N", stop the
equipment, and conduct repair and recheck.
Key
Y=Pass
N=Fail
R=Repaired
Checklist A
Y
N
R
A-1 Checking the manuals and
labels
A-2 Pre-operation inspection
A-3 Function test
After 25 h
A-4 30-day maintenance
Checklist B
Y
N
R
B-1 Checking the battery
B-2 Checking the wires
B-3 Checking the tires and
hubs
B-4 Checking the emergency
stop switch
B-5 Key switch
B-6 Horn
B-7 Drive and brake
B-8 Drive speed in retraction
state
B-9 Drive speed in lifting state
B-10 Visually checking
hydraulic oil
Checklist C
Y
N
R
C-1 Platform overload system
C-2 Checking the wire rope
Checklist D
Y
N
R
D-1 Checking reducer gear oil
D-2 Checking the mast slider
D-3 Replacing the hydraulic
filter
D-4 Replacing the hydraulic
tank breather cap
D-5 Checking the lifting chains
D-6 Lubricate the lifting chains
Checklist E
Y
N
R
E-1 Testing and changing
hydraulic oil

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Daily or every 2 h
A
Monthly or every 25 h
A+B
Quarterly or every 50 h
A+B+C
Semiannually or every
100 h
A+B+C+D
Yearly or every 200 h
A+B+C+D+E
Biennially or every 400 h
A+B+C+D+E+F
Afterwards, mark the R column.
1.7 Maintenance Inspection Report
△
! CAUTION:
Record each inspection in a report.
Select the appropriate checklist
according to the inspection items.
Check the appropriate box after
each inspection.
Learn how to perform the inspection
step by step.
If the inspection result is "N", mark
and stop the equipment, and
conduct repair and recheck. After
the repair, check the “R” column. ①
PDI②Operation inspections
completed③Maintenance items
completed④Function tests
completed
1.8 Steps for Checklist A
A-1
Checking the manuals and labels
Keeping the operation and maintenance manuals
intact is the key to safe operation. Each
equipment is supplied with manuals, which are
stored in the box on the platform. Manuals with
faint handwriting or missing pages do not provide
enough information to ensure safe operation.
In addition, be sure that all safety labels are in

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good condition. The labels warn the operator of
safety hazards associated with the use of the
machine. They also provide the user with
operation and maintenance information. Blurred
labels will not serve as a warning and may lead to
a hazardous operating environment.
1) Check that the operation and maintenance
manuals are in the box on the platform.
2) Check that the manuals are legible and
complete.
Result: The manuals match the model, and all
manuals are legible and complete.
Result: The manuals do not match the model, or
they are illegible or incomplete. Stop the machine
before manual replacement.
3) Check if the labels are illegible or damaged
against the label inspection chart carefully.
Result: All labels are complete, legible and intact.
Result: Some labels are missing, illegible or
damaged. Stop the machine before the label
replacement.
4) Put the manuals back to the original place
after use.
Notice: To replace the manuals or labels, please
contact LGMG.
A-2
Pre-operation inspection
Completing the pre-operation inspection is crucial
for safe operation of the machine. The
pre-operation inspection is completed by visual
inspection before the machine is operated. This
inspection is used to identify any obvious
problems with the machine prior to function test
and also to determine if routine maintenance
procedures should be performed.
The complete inspection procedure can be found
in the "Pre-operation Inspection" section of the
Operating Manual.
A-3
Function test
Completing the function test is crucial for safe
operation of the machine. Function test is used to
find any functional defects in the machine before
it is put into operation. A defective machine
should not be used. As soon as a functional
defect is found, the machine should be marked
and stopped immediately.
The complete procedure can be found in the
"Function Test" section of the Operating Manual.
A-4
30-day maintenance
The 30-day maintenance is a one-time
maintenance after the first 30 days or 25 hours of
machine operation. After this step, proceed to the
maintenance items on the checklist.
Perform the following maintenance:
For example:
1) B-3 Checking the tires and hubs

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1.9 Steps for Checklist B
B-1
Checking the battery
This inspection shall be performed once every 25
h or every month, whichever comes first.
Keeping the battery in good condition is crucial for
superior performance and safe operation of the
machine. Improper electrolyte level or damaged
cable or connector may cause parts damage and
hazards.
△
! WARNING: Risk of electric shock
Live-line working may result in serious
personal injury or even death. Be sure
to remove the ring, watch and other
ornaments before the work.
△
! WARNING: Risk of personal injury
The battery electrolyte is corrosive.
Avoid touching the spilled electrolyte
with hands or other parts of the body so
as to avoid injuries. Use soda and water
to neutralize the spilled electrolyte.
1) Wear protective clothes and goggles
properly.
2) Open the upper cover of the rotary table.
3) Ensure that the battery cable connectors are
not corroded.
△
! CAUTION: Adding terminal
protectors or applying anti-corrosion
sealant may avoid corrosion of the
battery cable connectors.
4) Ensure that the battery and cables are fixed
securely.
5) Fully charge the batteries and maintain the
charge for at least 24 hours.
△
! CAUTION: Steps 6-12 do not apply
to maintenance-free batteries and
hermetically sealed batteries.
6) Open the battery cell cover(s), check the
specific weight with a specific gravity
hydrometer and record the value.
7) Check ambient temperature and adjust the
specific liquid gravity of each battery
according to the instructions in the following
steps.
Increase the specific liquid gravity by 0.004
per 5°C, if the temperature is higher than
27°C.
Decrease the specific liquid gravity by 0.004
per 5°C, if the temperature is lower than
27°C.
Result: The specific liquid gravity of each
battery is greater than 1.277 after the
adjustment. Fully charge the battery and turn
to Step 11.
Result: If the specific liquid gravity of each

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11
battery is lower than 1.250, turn to Step 8.
8) Charge the battery in a balanced way or fully
charge the battery and maintain the charge
for at least 6 hours (preferably 24 hours).
9) Open the battery cell cover(s), check the
specific weight with a specific gravity
hydrometer and record the value.
10) Check ambient temperature and adjust the
specific liquid gravity of each battery
according to the instructions in the following
steps.
Increase the specific liquid gravity by 0.004
per 5°C, if the temperature is higher than
27°C.
Decrease the specific liquid gravity by 0.004
per 5°C, if the temperature is lower than
27°C.
Result: the specific liquid gravity of each
battery is greater than 1.277 after the
adjustment. Fully charge the battery and turn
to Step 11.
Result: the specific liquid gravity difference
between the battery cells is greater than 0.1
or the specific liquid gravity of more than one
battery cell is less than 1.217. In such case,
please replace the battery.
11) Check the battery acid level. If needed,
replenish with distilled water until the white
buoy floats to the top. Do not overfill.
12) Install the vent caps and neutralize any
electrolyte that may have spilled.
△
! CAUTION: The following steps
apply to all batteries.
13) Check the battery charger plug and wire
insulation for excessive wear and damage,
and replace them in time if necessary.
14) Connect the battery charger to AC power
supply of 100-240V, 50-60HZ correctly.
Result: The charger charges the battery.
Result: The audible alarm of the charger is
triggered and the indicator lamp flashes. Check
and correct the connection of fuse and charger.
Ensure that the charger works normally and
charges the battery.
△
! CAUTION:
For good effect, please select the wire of
appropriate length. The overall length of
wire shall not exceed 15 m.
To know more problems on charger
operation, please contact the after-sales
service department of LGMG.
B-2
Checking the wires
This inspection shall be performed once every 25
h or every month, whichever comes first.
Keeping the wires in good condition is crucial for
safe operation and superior performance of the
machine. Failure to find and replace the burned,
scratched, corroded or bent wires will lead to an

LGMG North America Inc. Maintenance Manual
12
unsafe operating environment, causing damage
to the machine parts.
△
! DANGER: Risk of electric shock/
explosion
Contact with live circuits may cause
serious personal injury or death. Do not
wear rings, watches or other ornaments.
1) Press the red emergency stop buttons on
PCU and GCU.
2) Turn the key switch to “OFF” position.
3) Turn off the main power switch.
4) Check if the ground wire under the chassis is
missing or damaged.
5) Check for burnt, scratched, corroded, bent or
loose wires in the followings areas:
GCU box
Hydraulic valve group
Battery pack
Guard plate of front cover of chassis
6) Check for burnt, scratched, corroded, bent or
loose wires in the chassis and mast areas.
7) Check for burnt, scratched, corroded, bent or
loose wires in the following areas:
Mast
ECU to platform
Harness connectors connected to the
platform
8) Check the free coating of insulating oil
applied to the following parts:
Harness connectors between ECU and PCU.
9) Check the electrical contactor for:
Excessive pitting
Excessive burn
B-3
Checking the tires and hubs
This inspection shall be performed once every 25
h or every month, whichever comes first.
Keeping the tires and hubs in good condition is
crucial for safe operation and superior
performance of the machine. Any failure of the
tires and hubs may cause rollover of the machine.
If the failure isn’t found or eliminated in time, the
machine parts will be damaged.
1) Check the tire tread and side for scratch,
crack, puncture and other abnormal wear.
2) Check the hub for damage, bending and
crack.
3) Check if the rim bolts are tightened to the
torque of 110-130 N.m.
B-4
Checking the emergency stop function
1) This inspection shall be performed once
every 25 h or every month, whichever comes
first.
2) Normal emergency stop function is crucial for
safe operation of the machine. If abnormal,
the red emergency stop button will not be
able to cut off the power supply and stop the

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13
machine, causing hazards.
①Turn the key switch to GCU position,
and screw out the red emergency stop
buttons of GCU and PCU.
②Set the red emergency stop button of
GCU to “OFF” position.
③Operate the machine with the GCU.
Result: The machine does not work.
④Turn the key switch to PCU position, and
screw out the red emergency stop
buttons of GCU and PCU.
⑤Set the red emergency stop button of
PCU to “OFF” position.
⑥Operate the machine with the PCU.
Result: The machine does not work.
△
! CAUTION: All operations of the
machine can be stopped by the red
emergency stop button of GCU, even
though the key switch is set to PCU
position.
B-5
Testing the key switch
1) This inspection shall be performed once
every 25 h or every month, whichever comes
first.
2) Normal key switch is crucial for safe
operation of the machine. The machine may
be operated by the GCU or PCU, which is
switched through the key switch. Failure of
the switch may cause hazards.
①Screw out the red emergency stop
buttons of GCU and PCU.
②Turn the key switch to PCU position.
③Check the lifting and lowering function of
the GCU.
Result: The machine does not work.
④Turn the key switch to GCU position.
⑤Check the lifting and lowering function of
the PCU.
Result: The machine does not work.
⑥Turn the key switch to “OFF” position.
Result: The machine does not work.
B-6
Testing the horn
1) This inspection shall be performed once
every 25 h or every month, whichever comes
first.
2) The horn is used by the platform personnel to
warn the ground personnel. Abnormal horn
cannot warn the ground personnel of
hazards or unsafe conditions.
①Turn the key switch to PCU position, and
screw out the red emergency stop
buttons of GCU and PCU.
②Press the horn button.

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14
Result: The horn sounds.
B-7
Testing the drive and brake function
1) This inspection shall be performed once
every 25 h or every month, whichever comes
first.
2) Correct braking is crucial for safe operation.
Steady braking without delay, jolt or
abnormal noise is required.
3) The braking function test must be carried out
with the machine placed on a solid, level and
unobstructed ground and in retraction state.
①Draw a reference test line on the ground.
②Turn the key switch to PCU position, and
screw out the red emergency stop
buttons of GCU and PCU.
③Lower the platform to the retraction
position.
④Press the drive function activation button.
Then the indicator lamp comes on.
⑤Take one point (such as the contact
point between the wheel and the ground)
on the machine as the mark for visual
inspection of misalignment with the
reference test line.
⑥Run the machine at the highest speed,
and release the joystick immediately
when the reference point goes beyond
the reference test line on the ground.
⑦Measure the distance between the
reference point and the reference test
line.
Result: The machine stops within the specified
braking distance. The machine meets the
requirement and no action is required.
Result: The machine does not stop within the
specified braking distance. Replace the brake
and repeat the above process starting from step 1
△
! CAUTION:
The brake must be effective within the
permissible gradeability range of the
machine.
B-8
Testing the drive speed in retraction state
1) This inspection shall be performed once
every 25 h or every month, whichever comes
first.
2) Normal drive function is crucial for safe
operation. The drive function shall enable the
machine to respond to the operator quickly
and steadily. No delay, jolt or abnormal noise
shall occur during normal operation and
traveling.
3) The drive test must be carried out with the