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LGMG AR65J Maintenance Manual

Articulated boom mobile elevating work platform
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Maintenance Manual
LGMG North America Inc. Maintenance Manual
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
LGMG North America Inc.
△
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.
This page left blank intentionally
Contents
AR65J
Articulated Boom
ANSI

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Summary of Contents for LGMG AR65J

  • Page 1: Table Of Contents

    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..............

  • Page 2: Foreword

    Foreword LGMG North America Inc. Maintenance Manual 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.

  • Page 3: Safety Notices

    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...
  • Page 4 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.

  • Page 5: Chapter 1 Maintenance

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

  • Page 6: Observing The Regulations

    LGMG North America Inc. Maintenance Manual LGMG North America Inc. Maintenance Manual 1.1 Observing the 8) Always perform functional tests after maintenance. Regulations 1.2 Inspection Manual 1) You are properly trained and qualified to operate and maintain the machine safely.
  • Page 7 ! CAUTION: If you need to replace ● Electrical components, wiring and cable ● the label, please contact the LGMG service personnel. Hydraulic hose, joint, valve block, hydraulic LGMG North America Inc. Maintenance Manual cylinder ●...
  • Page 8 Goggles and protective gloves must be worn. Rando MV32 Chevron LGMG North America Inc. Maintenance Manual No smoking and open fires! ● The leakage of high-pressure oil may not be △ visible to eyes. Cardboard or wood chip...
  • Page 9 2) Insert the oil measuring rod into the bottom. 3) Pull out the oil measuring rod and read the value of engine oil level. LGMG North America Inc. Maintenance Manual 4) The engine oil level shall always be between Dispose of spilled fuel and filter...

  • Page 10: Every 100 Hours

    ! Perform this step when the Coolant must have a specified concentration of engine is turned off. △ LGMG North America Inc. Maintenance Manual cooling system protectant! stationary can the belt drive operation Please observe the safety regulations for be carried out.

  • Page 11: Every 250 Hours

    Figure 1-4 Slewing mechanism increase the frequency of filling grease. 1. Slewing bearing 2. Oil pipe LGMG North America Inc. Maintenance Manual evenly to the surface of the exposed piston 1.5.2 Grease the Exposed Piston Rod rod using lint-free wipers.
  • Page 12 Check electric eye status every three months (maintenance-free lead-acid battery) Explosion Hazard! As shown in Figure 1-5, check the battery hydrometer color: LGMG North America Inc. Maintenance Manual White Insufficient electrolyte. Please shut down the machine and stop using it.
  • Page 13 Check tire nut torque battery, only the charger approved Type Torque by the LGMG can be used. AR65J 595±55N.m ● Do not replenish the battery with white eyes. Replace the battery. ● LGMG North America Inc. Maintenance Manual 1.6.4 Check the Clearance Between the...
  • Page 14 ! CAUTION: To drain or fill oil and 1.6.5 Visual Inspection of Hydraulic Oil check the oil level, the drive axle must LGMG North America Inc. Maintenance Manual be level and installed on the vehicle. Check main reducer oil level...
  • Page 15 Improper oil level in the reducer will reduce the horizontal position, remove the plug to performance of the equipment, and continuous check whether the oil level is at the lower use will lead to component damage. LGMG North America Inc. Maintenance Manual...
  • Page 16 1) Slewing reducer oil level inspection Minimum temperature <- 30°C 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.
  • Page 17 LGMG North America Inc. Maintenance Manual 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.
  • Page 18 ! Be sure to pay attention to the element. cleanliness of the external surface LGMG North America Inc. Maintenance Manual 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.

  • Page 19: Every 400 Hours

    Danger of scalding! engine oil level. When operating on the oil system, LGMG North America Inc. Maintenance Manual It is available in the first 50 hours, and the engine oil and filter shall be replaced every 400 hours or half a year. (If the ambient temperature continues to be below -10℃...
  • Page 20 2. Remove with a filter wrench (Tighten with The following steps apply to engine V2403- - your hand) △ LGMG North America Inc. Maintenance Manual regulations for fuel and relevant local regulations. Dispose of spilled fuel and △ ! The engine must be shut down! filter elements in accordance with national regulations.

  • Page 21: Every 500 Hours

    B: Close state 4) Apply a thin layer of diesel to the seal ring 1) Close the fuel filter handle. LGMG North America Inc. Maintenance Manual of the new filter. 2. Hydraulic tank air filter 5) Screw in a new filter manually until seal fit and tighten it.
  • Page 22 Name Torque date on the Filter Replacement Record. Main return pipe LGMG North America Inc. Maintenance Manual ⑦ Use GCU to operate any arm rod function. Replacing the high pressure filter element is essential for the good performance and service △...
  • Page 23 LGMG North America Inc. Maintenance Manual 595±55N.m Tightening torque of bolt 2: 190±19N.m 1.8.4 Replacement of Engine Oil and Filter △...
  • Page 24 (If the ambient temperature continues to be below -10℃ (14゜F) or the temperature of Figure 1-22 LGMG North America Inc. Maintenance Manual 8) Warm up and run the engine. 1. Oil drain plug 1) Warm up and run the engine.
  • Page 25 The following steps apply to engine the seal performance. V2403-CR-E5. △ LGMG North America Inc. Maintenance Manual A qualified fire extinguisher shall be △ ! There is danger of explosion and placed in an easily accessible place.
  • Page 26 1. Drain plug due to dirt in the fuel. △ △ LGMG North America Inc. Maintenance Manual pipeline when the engine is Replacement of the Fuel filter running. ! The engine must be shut down! △...

  • Page 27: Every 1000 Hours

    Check the fixing and wearing of the wear- resistant slider once every 1000 hours or every year, whichever comes first. LGMG North America Inc. Maintenance Manual between the slider and the arm rod is 1) The slider is located on the surface and inner...
  • Page 28 Fill the lower edge of the reducer of drive axle filler port with the specified oil. 4. Tighten the plug. LGMG North America Inc. Maintenance Manual 5. Work on each close-to-wheel reducer in the same way. Change the oil of gear box...

  • Page 29: Every 2000 Hours

    Dirty hydraulic oil and filter may affect the performance of the machine, and if not replaced, may cause damage to the parts. Hydraulic oil and filter shall be replaced more Figure 1-30 LGMG North America Inc. Maintenance Manual...
  • Page 30 cleaning oil. ) Name 9) Clean foreign matter adsorbed by the ring magnet. 10) Install a new suction filter. △ Sunction filter plate 11) Install the suction filter plate. 12) Install the ring magnet, drain flange and Bolt drain plug. Ring magnet ! CAUTION: When installing drain Drain plug...

  • Page 31: Scheduled Maintenance

    △ LGMG North America Inc. Maintenance Manual 5) Close the cooler cover. ! Risk of part damage. Do not start Filling of the Coolant the engine or use the emergency 1) Carefully open the cover for the cooling power unit when the suction filter of system.

  • Page 32: Engine Fault Table

    1.12 Engine Fault LGMG North America Inc. Maintenance Manual Table V2403-E3 Fault Cause Measures When it is difficult to start Thick fuel hard to flow Check the fuel tank and fuel filter. the engine Remove water, dust and other impurities. Because all fuel will be...
  • Page 33 When output is insufficient Insufficient compression The valve is in poor condition or the ring, LGMG North America Inc. Maintenance Manual Valve leaks. piston and bushing are excessively worn, leading to insufficient compression. Replace them with new ones.
  • Page 34 Check the lubricating oil system. After every 2 oil changes, be sure to replace the oil filter element. LGMG North America Inc. Maintenance Manual Check whether the clearance of engine bearings is within the factory specifications.
  • Page 35 Check the temperature with a temperature sensor thermometer and replace it if necessary. Faulty or leaking cylinder head gasket Replace parts. Improper fuel injection timing Adjust to the right timing Unsuitable engine oil Use the specified fuel. V2403-CR-E5 LGMG North America Inc. Maintenance Manual...
  • Page 36 Fault Cause Measures When it is difficult to start Fuel is thick and doesn't flow. Check the fuel tank, and remove the engine water, dirt and other impurities. Check the fuel filter cartridge and replace it if necessary. Engine oil becomes thick in oils different viscosities,...
  • Page 37 Check to see if the engine bearing clearances are within factory specs. Check the function of the relieve valve in the lubricating system. LGMG North America Inc. Maintenance Manual Check pressure switch. Check filter base gasket Engine warning lamp lights up.

  • Page 38: Engine Fault Codes

    Head gasket defective or Replace parts water leakage 1.13 Engine fault LGMG North America Inc. Maintenance Manual codes V2403-E3 Inspection item DTC set parameter Oil Pressure Error Oil pressure switch Despite rpm，oil pressure switch is on Engine overheat Overheat of engine...
  • Page 39 Charging failure 523738 Alternator L terminal is Open circuit，short circuit, 0V while engine is or damage of harness running LGMG North America Inc. Maintenance Manual Speed sensor pulse 523740 Engine speed sensor Less than correct gear pulse abnormal tooth number...
  • Page 40 below 0.2 V IAT Sensor Integrated Sensor/harness open or IAT sensor integrated MAF Sensor: High shorted to +B sensor voltage: above 4.85 V PLV Emergency Open PLV emergency open PLV is opened in emergency; Engine speed is greater than 700 min-1 (rpm) High Rail Pressure Actual pressure above the Rail pressure sensor is...
  • Page 41 No.1 Cylinder Injector Harness open circuit; Harness or injector coil open circuit Harness/Coil Open Circuit Injector coil open circuit LGMG North America Inc. Maintenance Manual No.3 Cylinder Injector Harness open circuit; Harness or injector coil open circuit Harness/Coil Open Circuit Injector coil open circuit No.4 Cylinder Injector...
  • Page 42 Sensor/harness open or DOC inlet temperature Sensor 0: High shorted to +B sensor (T0) voltage: above 4.92 V LGMG North America Inc. Maintenance Manual Battery Voltage: Low Harness open circuit, short The battery voltage circuit or damage; identified by the ECU in...
  • Page 43 No QR (IQA) Data 523538 QR data not written Area of QR data on EEPROM is vacant ECU Flash-ROM Error Flash ROM error ● Checksum error ● Delete error ● Write error ● Read error ECU CPU (Master IC) Error 1077 CPF and/or IC failure Critical CPU and/or IC errors...
  • Page 44 Accelerator Position Sensor Short circuit to ground Accelerator position 1: High outside sensor/harness sensor 1 voltage below 4.8 V LGMG North America Inc. Maintenance Manual Accelerator Position Sensor Sensor/harness shorted to Accelerator position 2: Low ground or open sensor 2 voltage below 0.3V...
  • Page 45 Intake Throttle Lift Sensor: High 523582 Intake throttle lift sensor high Intake throttle lift sensor voltage: above 4.848 V LGMG North America Inc. Maintenance Manual Emission Deterioration 3252 DOC is heated up due to T1 - T0 ≥ 250℃ (482℉) unburned fuel...
  • Page 46 (1508℉) Excessive PM3 3701 PM accumulation level 3 PM accumulation above trigger level Regeneration level = 3 Excessive PM4 3701 PM accumulation level 4 PM accumulation above trigger level Regeneration level = 4 Excessive PM5 3701 PM accumulation level 5 PM accumulation above trigger level Regeneration level = 5...
  • Page 47 No “C1 cache" request CAN TSC1 Frame Error 523596 CAN_TSC1 communication initiated for 3 interruption consecutive times after the override LGMG North America Inc. Maintenance Manual control request (non-0x00) is issued CAN EBC1 Frame Error 523598 CAN_EBC1 CAN EBC1 frame timeout communication interruption 1.14 Maintenance...
  • Page 48 Clean the air cleaner outer element every 250h or when the It can be the air cleaner indicator alarms, and it is forbidden to clean the air cleaner inner cleaned for outer element at most 5 element and times inner element LGMG North America Inc. Maintenance Manual generally.
  • Page 49 Change coolant Every 2000h or every two years, whichever comes first. ● ● ● ● Check the fixing of the battery terminals and apply grease to the electrodes (if necessary) ● ● ● ● ● Re-tighten the drive shaft bolt ●...
  • Page 50 Every day harness connector is contaminated and damaged. Check if the PCU Every day wire harness is extruded or broken. LGMG North America Inc. Maintenance Manual Check whether Every day the wiring of angle sensor and length sensor, tilt sensor...
  • Page 51 (self-sealing filter) Check whether Every day the oil pipe fixing clip is LGMG North America Inc. Maintenance Manual loose Check the oil level Every day hydraulic of hydraulic tank oil Rando MV32 when oil level is below "M"...
  • Page 52 Whether the Every day bolts, nuts and other fasteners of the whole machine are loose and make abnormal noise Check whether the Every day structural parts of the whole machine have cracks and whether LGMG North America Inc. Maintenance Manual...
  • Page 53 ● ● ● Tire steering lubrication ● ● ● ● ● Front and rear axle slewing lubrication ● ● ● ● ● Drive shaft lubrication ● ● Platform weighing structure lubrication 1.14.3 Machine LGMG North America Inc. Maintenance Manual Lubrication...
  • Page 54 The slewing lubrication points of the front and rear axles The lubricating point of the drive shaft The lubricating point for slewing bearing Slewing bearing and slewing gear contact surface Platform weighing structure lubrication LGMG North America Inc. Maintenance Manual...

  • Page 55: Chapter 2 Schematic Diagram

    LGMG North America Inc. Maintenance Manual Chapter 2 Schematic Diagram...
  • Page 56 LGMG North America Inc. Maintenance Manual LGMG North America Inc. Maintenance Manual AR65J Hydraulic schematic diagram...
  • Page 57 LGMG North America Inc. Maintenance Manual AR65J Electrical schematic diagram (V2403-CR-E5)
  • Page 58 LGMG North America Inc. Maintenance Manual AR65J Electrical schematic diagram (V2403-E3)
  • Page 60 AR65J Articulated Boom Mobile Elevating Work Platform Maintenance Manual First Edition –March 2023 1445 Sheffler Drive...
  • Page 61 Chambersburg, PA. 17201 Toll Free: 833.288.LGMG (5464) Local Phone: 717.889.LGMG (5464) Email: sales@lgmgna.com www.lgmgna.com...

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