LGMG SR2669D Service Manual
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LGMG SR2669D Service Manual

Rough terrain mobile elevating work platform
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Service Manual
SR2669D/SR3369D/SR4069D
Rough terrain Mobile
Elevating Work Platform
△
WARNING
!
Before operation and maintenance, the
drivers and maintenance personnel are
required to read this manual thoroughly.
Otherwise, fatal accident may occur. This
manual shall be kept properly for future
reference by the personnel concerned.
LINGONG HEAVY MACHINERY CO.，LTD.

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  • Page 1 Service Manual SR2669D/SR3369D/SR4069D Rough terrain Mobile Elevating Work Platform △ WARNING Before operation and maintenance, the drivers and maintenance personnel are required to read this manual thoroughly. Otherwise, fatal accident may occur. This manual shall be kept properly for future reference by the personnel concerned.
  • Page 2 L I N G O N G H E A V Y M A C H I N E R Y C O . , L T D . Add.: 12F, Building 3, Lushang Olympic City, No. 9777, Jingshi Road, Lixia District, Jinan City, Shandong Province, China Tel: 86-0531-67605017 Technical service: 86-4009666569 Web: www.LGMG.com.cn Sales of accessories:86-0531-67605016...

  • Page 3: Table Of Contents

    Description ..................... 4 2 Product Introduction .................... 7 Machine parameters ..................9 SR2669D (S266900WNK4AH2002) machine parameters ......9 SR3369D (S336900WNK4AH2000) machine parameters ......10 SR4069D (S406900WNK4AH2000) machine parameters ......12 Specification for selection of tightening torque of the lifting platform ..13 Key component moment table ..............
  • Page 4 The platform gate ..................23 Removing the semi-swing gate ............... 23 Installing the semi-swing gate ..............23 Fork assembly ....................25 Removing forks(SR2669D) ..............25 Removing forks(SR3369D) ..............29 Removing forks(SR4069D) ..............34 Assembly the Fork .................. 38 Replacing the fork slider at platform ............46 Replacing the fork slider at chassis ............
  • Page 5 Service Manual of Rough Terrain Mobile Elevating Work Platform Front axle assembly ..................54 Installing the steering rod and steering cylinder ........54 Removing the steering linkage and steering cylinder ......55 Installing the steering knuckle and front motor ........55 Removing the steering knuckle and front axle motor ......
  • Page 6 Service Manual of Rough Terrain Mobile Elevating Work Platform 4 Commissioning ....................71 Safety instructions ..................73 Test of basic functions .................. 74 Start/stop test ..................74 Lifting/lowering function test ..............74 Steering test ................... 74 Horn test ....................75 Drive and brake function test ..............
  • Page 7 Service Manual of Rough Terrain Mobile Elevating Work Platform Test with 1.2 times rated load ..............80 Overload recovery .................. 81 Test with 1.25 times rated load ............... 81 No-load lifting time ..................81 No-load lifting time test ................81 Adjustment of lifting speed..............
  • Page 8 Checking or replacing the scissor arm slider ..........107 Scheduled maintenance ................107 Routine Inspection and Maintenance Intervals ........108 6 Appendix ......................113 Electrical schematic diagram ..............115 SR69D Electrical schematic diagram ............. 115 Hydraulic schematic diagram ..............116 SR2669D、SR3369D Hydraulic schematic diagram ....... 116...
  • Page 9 Service Manual of Rough Terrain Mobile Elevating Work Platform SR4069D Hydraulic schematic diagram ..........117 Diagram of common hydraulic part symbols ..........118 Diagram of common electrical part symbols ..........125 Machine fault codes ................... 129...

  • Page 10: Foreword

    Service Manual of Rough Terrain Mobile Elevating Work Platform Foreword You are welcome to purchase and use the products produced by Lingong Heavy Machinery Co., Ltd. This manual introduces the technical parameter and maintenance adjustment data of Rough terrain elevating work platform, and explains the troubleshooting and maintenance process for qualified professional maintenance personnel.

  • Page 11: Safety Notices

    Service Manual of Rough Terrain Mobile Elevating Work Platform Safety Notices The operator should understand and follow the current national and local safety regulations. If there are no national or local regulations, the safety instructions in this manual shall be applicable. Most accidents are caused by failure to comply with the regulations on the operation and maintenance of the machine.
  • Page 12 Service Manual of Rough Terrain Mobile Elevating Work Platform...

  • Page 13: Safety And Environment

    Service Manual of Rough Terrain Mobile Elevating Work Platform 1 Safety and Environment...
  • Page 14 Service Manual of Rough Terrain Mobile Elevating Work Platform...

  • Page 15: Terms And Definitions

    Service Manual of Rough Terrain Mobile Elevating Work Platform Terms and Definitions Administrator: the entity or individual that directly controls the use and application of the lifting platform, which usually refers to the owner, the renter or the authorized personnel of owner who obtains the control right of the lifting platform;...

  • Page 16: Intended Use

    Lingong Group Jinan Heavy Machinery Co., Ltd. Symbol representation Symbols, color codes and symbolic words used by LGMG products have the following meanings: Safety warning sign - used for warning of potential personal injury. Observe all safety tips after this sign to avoid possible personal injury or death.
  • Page 17 Service Manual of Rough Terrain Mobile Elevating Work Platform Yellow - Indicating a dangerous situation. If not CAUTION avoided, it may cause minor or moderate personal injury. Blue - Indicating a dangerous situation. If not NOTE avoided, it may result in property damage.
  • Page 18 Service Manual of Rough Terrain Mobile Elevating Work Platform...

  • Page 19: Product Introduction

    Service Manual of Rough Terrain Mobile Elevating Work Platform 2 Product Introduction...
  • Page 20 Service Manual of Rough Terrain Mobile Elevating Work Platform...

  • Page 21: Machine Parameters

    Service Manual of Rough Terrain Mobile Elevating Work Platform Machine parameters SR2669D (S266900WNK4AH2002) machine parameters Parameters of machine Item Parameter Item Parameter Rated load (kg/lbs) Fork lifting time (s) 680/1500 35±4 Extended platform rated Fork lowering time (s) 140/310 30±4 load (kg/lbs) Theoretical max.

  • Page 22: Sr3369D (S336900Wnk4Ah2000) Machine Parameters

    Service Manual of Rough Terrain Mobile Elevating Work Platform Speed ratio 48：1 Hydraulic system Item Parameter Type Open Pump displacement (ml/r) Walking Max. working pressure (MPa/psi) 21/3045 system Front motor displacement (ml/r) Rear motor displacement (ml/r) Type Open Pump displacement (ml/r) Lifting system 20/2900 Max.
  • Page 23 Service Manual of Rough Terrain Mobile Elevating Work Platform turning angle Max. travel speed Max. allowed wind 5.5/3.4 12.5/28 (stowed) (km/h/mph) speed (m/s/mph) Max. travel speed 0.5/0.31 (extended) (km/h/mph) Four-wheel drive Drive mode Max. braking distance Front wheel steering 1.5/4.9 (no-load, stowed) (m/ft) Main dimensions Item...

  • Page 24: Sr4069D (S406900Wnk4Ah2000) Machine Parameters

    Service Manual of Rough Terrain Mobile Elevating Work Platform Item Parameter Output voltage (V) Battery Capacity (Ah) Control system Voltage (V) Fluid filling amount Item Parameter Item Parameter Hydraulic oil (L) Engine antifreeze (L) Walking reducer gear Fuel tank capacity (L) 0.68×2 oil (L) Engine oil (L)

  • Page 25: Specification For Selection Of Tightening Torque Of The Lifting Platform

    Service Manual of Rough Terrain Mobile Elevating Work Platform Engine system Item Parameter Item Parameter Model Rated speed (r/min) D1105-EF06e 2500 Displacement (L) Max. torque (Nm) 71.3 Rated power (kW) Emission standard 15.7 EPA Tire4f Transmission system Item Parameter Rated output torque 3390 Walking reducer (Nm)
  • Page 26 Service Manual of Rough Terrain Mobile Elevating Work Platform Tightening torque of metric-threaded oil ports Tightening torque of imperial-threaded oil ports Thread Fitting type Plug Thread Fitting type Plug Pipe Pipe specificatio specificatio Type Type VSTI- Type Type VSTI- diameter diameter n (mm) n (Inch)
  • Page 27 Service Manual of Rough Terrain Mobile Elevating Work Platform after calculation; For Parker joints, the torque is to be selected according to the name and specification, and for ordinary joints, the torque is to be selected according to the thread specification. For example: GE 28 L M ED OMD A3C: GE for straight-through joint, 28 for pipe diameter, L for normal pressure, M for metric thread, ED for E-type elastic seal, OMD for no nut sleeve, A3C for galvanizing;...

  • Page 28: Key Component Moment Table

    Service Manual of Rough Terrain Mobile Elevating Work Platform 3) EW15LOMDA3C: EW represents a right-angle combination fitting. The torque value selected from Table 1 according to 15L is 32 N.m. Table 4: Tightening torque of ordinary bolts (unit: N.m) Nominal diameter of bolt mm Strength grade of Yield strength bolt...

  • Page 29: Service

    Service Manual of Rough Terrain Mobile Elevating Work Platform 3 Service...
  • Page 30 Service Manual of Rough Terrain Mobile Elevating Work Platform...

  • Page 31: Platform

    Service Manual of Rough Terrain Mobile Elevating Work Platform Platform The working platform of the off-road scissor lifting platform is mainly composed of main platform, extended platform, guardrail assembly, semi-swing gate and etc. The exploded view of the working platform is shown in the Fig. below: Fig.

  • Page 32: Removing The Working Platform

    Service Manual of Rough Terrain Mobile Elevating Work Platform Removing the working platform Removing the extended platform △ Caution: Only when the platform is in the stowed position and the extended platform is fully retracted and locked in place can this operation be performed.

  • Page 33: The Main Platform Assembly

    Service Manual of Rough Terrain Mobile Elevating Work Platform Extended platform base plate 3. Blind rivet 4. Bolt shown; 5. Nut 6. Washer Assemble part 15 to parts 10 and 13 with Reference tightening torque of part 4: 12± 1N.m parts 16 and 17, and tighten it;...

  • Page 34: Folding The Working Platform Guardrail

    11. Push the left guardrail of the main platform guardrail inward from the ladder or the ground always The SR2669D/SR3369D/SR4069D platform with hands not putting on the places with risk guardrail system consists of the extension of pinching, and meanwhile prevent the left...

  • Page 35: Assembling The Platform Control Unit (Pcu)

    Service Manual of Rough Terrain Mobile Elevating Work Platform Assembling the platform control unit (PCU) 1. As shown in Fig. 3.7, install the PCU (part 1) onto the bracket (part 2), and tighten it with bolt (part 3). 2. Fix the PCU harness at the bracket. 3.
  • Page 36 Service Manual of Rough Terrain Mobile Elevating Work Platform base plate, and open and close the gate to check that it operates smoothly without seizure, and check that the gate, after being opened, can spring back to its original position freely and can be locked properly and limited reliably.

  • Page 37: Fork Assembly

    Service Manual of Rough Terrain Mobile Elevating Work Platform Fork assembly Removing forks(SR2669D) Fig. 3.9 SR2669D Fork assembly Platform pin Slider Third outer arm Third inner arm Lift cylinder rod end pin 3# center pin 3# pin (steering end) 3# pin...
  • Page 38 Service Manual of Rough Terrain Mobile Elevating Work Platform Remove the fasteners that fix the 3# pin from △ ! WARNING Danger of injury the non-steering end of the machine. This procedure requires specific Remove the 3# pin on left and right sides from maintenance skills, lifting equipment and a the non-steering end of the machine using a suitable workshop.
  • Page 39 Service Manual of Rough Terrain Mobile Elevating Work Platform the machine using a soft metal hammer. △ WARNING: Risk of personal injury Remove the third inner arm from the machine. 19. Attach the sling of the traveling crane to the When the fork is being lowered to second outer arms on the left and right sides the safety arm, keep your hand away...
  • Page 40 Service Manual of Rough Terrain Mobile Elevating Work Platform △ WARNING: Risk of crushing. If not properly supported and fixed to the lifting equipment, the ladder may fall off. 32. Attach the sling of the traveling crane to the first outer arm. Do not apply any lifting force. 33.

  • Page 41: Removing Forks(Sr3369D)

    Service Manual of Rough Terrain Mobile Elevating Work Platform Removing forks(SR3369D) Fig. 3.10 SR3369D Fork assembly 5# pin Fourth inner arm 4# center pin Fourth outer Arm 4# pin (non-steering end) 4# pin (steering end) Third inner arm 3# center pin Third outer Arm Lower cylinder rod end shaft 3# pin (non-steering end)
  • Page 42 Service Manual of Rough Terrain Mobile Elevating Work Platform 9. Remove the fasteners that fix the 4# pin from △ WARNING: Danger of injury the non-steering end of the machine. 10. Remove the 4# pin from the non-steering end This procedure requires specific...
  • Page 43 Service Manual of Rough Terrain Mobile Elevating Work Platform If not properly supported during △ WARNING: Risk of crushing removal, the third inner arm may be out If not properly supported during of balance and fall off. removal, the third outer arm may be out 33.
  • Page 44 Service Manual of Rough Terrain Mobile Elevating Work Platform second inner arm. from the moving parts. 46. Remove the fasteners that fix the 2# pin at the 51. Attach the sling of the traveling crane to the lift steering end of the machine. cylinder rod end.
  • Page 45 Service Manual of Rough Terrain Mobile Elevating Work Platform placed on the chassis. connecting the first inner arm to the end of the 59. Remove the cable from the wiring ring of the chassis. Remove the pin. first arm and set it aside. 70.

  • Page 46: Removing Forks(Sr4069D)

    Service Manual of Rough Terrain Mobile Elevating Work Platform Removing forks(SR4069D) Fig. 3.12 SR4069D Fork assembly 6# pin 5# pin (non-steering end) Fifth outer arm Fourth inner arm 5# pin (steering end) 4# center pin Fourth outer arm 4# pin (non-steering end) Upper lift cylinder rod end shaft Upper lift cylinder tube end shaft 4# pin (steering end)
  • Page 47 Service Manual of Rough Terrain Mobile Elevating Work Platform 9. Remove the 5# pin from the non-steering end △ WARNING: Risk of personal of the machine using a soft metal hammer. Remove the fifth outer arm from the machine. injury This procedure requires specific △...
  • Page 48 Service Manual of Rough Terrain Mobile Elevating Work Platform 19. Lift the lift cylinder to a vertical position. 30. Remove the fourth outer arm from the 20. Remove the fasteners that fix the lift cylinder machine. tube end pin. Remove the upper lift cylinder △...
  • Page 49 Service Manual of Rough Terrain Mobile Elevating Work Platform lift cylinder rod end. from the wiring boards of the second to third 42. Remove the fasteners that fix the lower lift arms, and set them aside. cylinder rod end pin. 55.

  • Page 50: Assembly The Fork

    Service Manual of Rough Terrain Mobile Elevating Work Platform to reduce the oil pressure gradually. If not properly supported during Prevent the oil from spraying or ejection. removal, the first inner and outer arms 66. Mark and disconnect the harnesses and may be out of balance and fall off.
  • Page 51 Service Manual of Rough Terrain Mobile Elevating Work Platform a. Use the traveling crane to hoist the cylinder with the mounting holes at the bottom of cylinder aligned with the holes on the first inner arm as shown in Fig.1, fix the cylinder with part 1, and separate the bottom of the cylinder from the inner side of the first inner arm with part 6, as shown in Fig.
  • Page 52 Service Manual of Rough Terrain Mobile Elevating Work Platform Fig. 3.18 Routing the lower cylinder oil pipes Fig. 3.17 Assembling the first and second forks 1. Hose 2. Pressure plate 3. Pipe clamp 4. Bolt 5. 1. Second inner arm assembly 2. Second outer Nut 6.
  • Page 53 QSP200, socket wrench 1/2 18, open-end wrench 16-18 Note: The Articles g, h, I and j below are for assembling of SR2669D third fork. Fig. 3.20 Assembling the third fork and lower cylinder 1. Third outer arm weldment 2. Third inner arm assembly 3.
  • Page 54 Service Manual of Rough Terrain Mobile Elevating Work Platform and the third outer arm, and secure at the attention that the fixing screws are only connecting shaft with retaining ring. required to be manually screwed into the Install parts 16 and 17 to the right side of the mounting holes.
  • Page 55 Service Manual of Rough Terrain Mobile Elevating Work Platform 10. Routing and tying the harness(SR3369D) Note: If the platform power harness needs to be assembled, keep its direction consistent with the PCU harness. 11. Assembling the fourth fork and upper cylinder(SR4069D) Fig.
  • Page 56 Service Manual of Rough Terrain Mobile Elevating Work Platform 13/14/15/16, and tighten it to the specified torque; Tightening torque part 52± 5N.m; Tightening torque of parts 9/11: 52± 5N.m; Tightening torque of part 16: 90± 9N.m; Tools: copper rod, ratchet torque wrench QSP100, socket wrench1/2 18, open-end wrench 16-18 Fig.
  • Page 57 Service Manual of Rough Terrain Mobile Elevating Work Platform and clamp the part 3 on the other side of the required to be manually screwed into the fork with parts 6/7; mounting holes. Fix part 1 and part 2 together with part 8, fix Note: For the location where the wiring the end of part 8 on the outer side of the fork board is installed, only one pin...

  • Page 58: Replacing The Fork Slider At Platform

    Service Manual of Rough Terrain Mobile Elevating Work Platform intermediate shaft of the fork, and keep the instead of on the ground; reserved harness about 50mm away from the 18. Lifting the fork fork surface. Fix the harness into all the fixing holes on the wiring board with ties, keep the ties on the routing round steel spaced by 300mm, and ensure that the harness does not sag at any...

  • Page 59: Replacing The Fork Slider At Chassis

    Service Manual of Rough Terrain Mobile Elevating Work Platform slideway. △ WARNING: Risk of crushing. 10. Align the holes on the slider assembly with If not properly supported with lifting the holes on the scissor arm. 11. Install the slider pivot and its fasteners. equipment during removal of platform 12.

  • Page 60: Installing The Solenoid Valve

    Service Manual of Rough Terrain Mobile Elevating Work Platform Connect the sling of the crane to the socket wrench 1/2-16mm, ratchet torque walking variable pump for support. Do wrench QSP100, hexagon head socket wrench not lift it. 1/2-8mm Remove the fasteners that connect the walking variable pump to the engine Installing the solenoid valve assembly.

  • Page 61: The Gear Pump

    Service Manual of Rough Terrain Mobile Elevating Work Platform engine, and then tighten them; Tightening torque of part 3: 52± 5N.m; 2. Installing the gear pump (1) Install part 1 to the engine coupling, with the The gear pump gear pump spline shaft well matched with the coupling;...

  • Page 62: Assembling The Engine Intake System

    Service Manual of Rough Terrain Mobile Elevating Work Platform both ends are inserted to the bottom; Assembling the engine intake Connect the part 10 to the air outlet of the air system cleaner and the air inlet of the engine, and then fix it with part 13 after both ends are inserted to the bottom;...

  • Page 63: Assembling The Engine Cooling System

    Service Manual of Rough Terrain Mobile Elevating Work Platform Assembling the engine cooling Removing the engine cooling system system See Fig.3.40 Push out the engine pallet and fix it to prevent it from sliding. Loosen the hose clamps at both ends of part Loosen the hose clamps at both ends of part Attach the radiator assembly to the lifting equipment;...

  • Page 64: Installing The Fuel Tank

    Service Manual of Rough Terrain Mobile Elevating Work Platform the ground as appropriate. Nut 4. Bolt 5. Bolt 6. Bolt 7. Washer Raise the safety arm slightly and rotate it to Support the fuel tank and fix it to appropriate the vertical position.

  • Page 65: Installing The Hydraulic Oil Tank

    Service Manual of Rough Terrain Mobile Elevating Work Platform Therefore, it is recommended that this service Installing the hydraulic oil tank is performed by dealers. The O-rings (if any) of the fittings and/or hoses must be replaced. During installation, all connections must be tightened to the specified torque.

  • Page 66: Assembling Wheels

    Service Manual of Rough Terrain Mobile Elevating Work Platform Raise the machine by 15 cm/5.9in, and place Tightening torque of part 6: 305± 25N.m; a cushion block under the chassis for the tightening torque of self-contained nut of purpose of supporting. motor: 410-540N.m Tools: pneumatic wrench MI-18, pointer torque △...

  • Page 67: Removing The Steering Linkage And Steering Cylinder

    Service Manual of Rough Terrain Mobile Elevating Work Platform cotter pin needs to be bent not less than 180° on the cylinder. to both sides after installation. 3. Remove the fasteners that fix the cylinder rod Connect part 5 to the right-angle joint above end pin.

  • Page 68: Removing The Steering Knuckle And Front Axle Motor

    Service Manual of Rough Terrain Mobile Elevating Work Platform tighten them to specified torque; △ CAUTION: Risk of crushing. 4. Use parts 6, 7 and 8 to assemble part 5 to the If not supported, the chassis may front axle and steering knuckle, and tighten them to specified torque;...

  • Page 69: Assembling The Axle Swing Cylinder

    Service Manual of Rough Terrain Mobile Elevating Work Platform upper king pin; the floating cylinder, clean the paint slag on the mounting surface of valve block, assemble part 8 onto part 1 with part 9 and part 10, and tighten it to the specified torque; (Note: the oil pipe interfaces of valve bodies on both sides should face backward).

  • Page 70: Installing The Reducer

    Service Manual of Rough Terrain Mobile Elevating Work Platform 1. Reducer 2. Screw 3. Washer 4. O-ring Installing the reducer Tightening torque of part 2: 280± 28 N.m. 1. Install the reducer to the left and right Tools: torque wrench QSP420N, hexagon head mounting plates of the rear axle with parts 2 socket wrench 12mm, electric impact wrench and 3 respectively, and tighten it to the...

  • Page 71: Removing The Rear Axle Assembly

    Service Manual of Rough Terrain Mobile Elevating Work Platform wrench 16mm, torque wrench motor and the reducer. When installing the QSP200, AT262 thread locker driving motor to the machine, make sure that demand) the O-ring is in the correct position. 5.

  • Page 72: Removing The Outrigger Cylinder

    Service Manual of Rough Terrain Mobile Elevating Work Platform 2. Install part 4 to the mounting hole on the upper of the outrigger cylinder. Cover the fittings on part of the outrigger cylinder and tighten it; the cylinder. 3. Remove the protective plate which is provided △...

  • Page 73: Other Components

    Service Manual of Rough Terrain Mobile Elevating Work Platform in the Fig. on the right. Fig. 3.53 the hydraulic oil radiator 1. Hydraulic oil radiator 2. Bracket plate Fig. 3.52 Installing the level meter weldment 3. Bolt 4. Washer 5. Nut 6. Bolt 7. 1.

  • Page 74: Installing The Dc Power Switch

    Service Manual of Rough Terrain Mobile Elevating Work Platform 9. Install part 14 to the part 2, fasten the upper 3. Install part 7 into the filter inlet and outlet part with parts 15 and 7, and the lower part is respectively, and tighten it to the specified shared with the radiator.
  • Page 75 Service Manual of Rough Terrain Mobile Elevating Work Platform Fig. 3.56 battery 1. Battery 2. Locking angle steel 3. Threaded rod 4. Washer 5. Nut Reference tightening torque of part 5: 12± 1N.m; Tools: electric impact wrench 51082, long socket wrench 1/2-13mm...

  • Page 76: Valve Group

    Service Manual of Rough Terrain Mobile Elevating Work Platform Valve group Installing the spool 1. Immerse the spool in clean oil to lubricate the O-ring. 2. Manually screw in the spool until it reaches the top of the O-ring, and then adjust the torque to meet specification requirements.

  • Page 77: Walking Control Valve

    Service Manual of Rough Terrain Mobile Elevating Work Platform Restricting steering control oil 12-1 Check valve 40-45 flow direction Restricting oil return direction of 12 -2 Check valve 40-45 lift system and outrigger 13-1 Solenoid valve Controlling floating 27.1 13-2 Solenoid valve Controlling right floating 27.1...

  • Page 78: Lower Lift Cylinder Control Valve

    Service Manual of Rough Terrain Mobile Elevating Work Platform as required Distributing front/rear motor Flow diverter/combiner valve 99-104 flow as required Controlling brake and Pressure relief valve 33.9 governor pressure Controlling front axle motor Throttle valve 33.9 flow Controlling high-speed oil Solenoid valve 70-81 inlet...

  • Page 79: Lower Cylinder Valve Block

    Service Manual of Rough Terrain Mobile Elevating Work Platform Enabling one-way flow of Check valve 40-45 hydraulic oil Controlling the lowering Proportional solenoid valve 34-41 speed Damper Limiting the maximum Overflow valve assembly pressure of the lifting 40-45 system Coil Plug 11-12 O-ring...

  • Page 80: Pressure Sensor On Lifting Control Valve

    Service Manual of Rough Terrain Mobile Elevating Work Platform Name Function Pressure Torque (Nm) Enabling one-way flow of Check valve 40-45 hydraulic oil Controlling the lowering Proportional solenoid valve 34-41 speed Damper Limiting the maximum Overflow valve assembly pressure of the lifting 40-45 system Coil...

  • Page 81: Schematic Diagram Of Location Of Main Appliances

    Service Manual of Rough Terrain Mobile Elevating Work Platform Schematic diagram of location of main appliances For example SR2669D： Fig. 3.62 Main electrical location map...
  • Page 82 Service Manual of Rough Terrain Mobile Elevating Work Platform...

  • Page 83: Commissioning

    Service Manual of Rough Terrain Mobile Elevating Work Platform 4 Commissioning...
  • Page 84 Service Manual of Rough Terrain Mobile Elevating Work Platform...

  • Page 85: Safety Instructions

    Service Manual of Rough Terrain Mobile Elevating Work Platform and the instructions in the table below to maintain Safety instructions a sufficient safety distance from wires, power Before commissioning, please make sure to supplies, and electrical equipment. refer to the Operation and Maintenance Manual, Voltage Required safety familiarize yourself with the relevant safety...

  • Page 86: Test Of Basic Functions

    Service Manual of Rough Terrain Mobile Elevating Work Platform Control criteria: The platform is lowered, and Test of basic functions the lowering alarm sounds. Start/stop test 4. Use PCU. Turn on the lifting joystick switch as Ground control mode: Turn the key to GCU indicated by the blue arrow;...

  • Page 87: Horn Test

    Service Manual of Rough Terrain Mobile Elevating Work Platform CAUTION: The tester shall stand in the middle able to stop steadily on any slope climbed by of the platform and face toward the steering end of the machine under test. No-load test Horn test Outrigger leveling...

  • Page 88: Relief Pressure Test

    Service Manual of Rough Terrain Mobile Elevating Work Platform increase or decrease the pressure as Relief pressure test appropriate until the pressure is consistent System with the target value; Keep the position of the Allen wrench unchanged, and tighten the fastening nut of the lift relief valve;...

  • Page 89: Inclination Calibration

    Service Manual of Rough Terrain Mobile Elevating Work Platform machine on the absolute level platform again; Inclination calibration 2. Adjustment method: Press the emergency stop button of the platform control unit. Press and hold “AUTOLEVEL” and the outrigger extend button at the upper left corner at the same time, as shown on the right.

  • Page 90: Left-And-Right 2

    Service Manual of Rough Terrain Mobile Elevating Work Platform Left-and-right 2° Fig. 4.13 Fore-and-aft 3° 1. Run the machine forwards and backwards to Fig. 4.14 Left-and-right 2° a 3° slope separately, ensuring the machine is 1. Run the machine to move its left and right completely on the slope;...

  • Page 91: Idle Load

    Service Manual of Rough Terrain Mobile Elevating Work Platform Idle load Rated load Fig. 4.15 Idle load calibration 1. Turn on the emergency stop switches of PCU and GCU, press UP and DOWN buttons with both hands simultaneously, and turn the key to the GCU position;...

  • Page 92: Overload Function

    Fig. 4.19 Test with 1.2 times rated load DOWN buttons to adjust the options, and then Height for Model press the enable switch to enter the PLAT overload alarm SR2669D 0.90m/2.95ft OVERLOAD ON mode.Select ON mode SR3369D 1.00m/3.28ft SR4069D 1.10m/3.61ft by operating the enable switch to enable the overload function.

  • Page 93: Overload Recovery

    Target lifting time for SR2669D model: overload information clearing. 64± 4(s); Test with 1.25 times rated load Target lifting time for SR3369D model: 39±...

  • Page 94: Adjustment Of Lifting Speed

    Service Manual of Rough Terrain Mobile Elevating Work Platform 35± 4(s); decrease the drive speed; 4) Press the enable switch to set the speed. 2. Lowering time: After measuring the lifting time, Adjustment of lowering speed operate the machine reversely with the same method to measure the lowering time;...

  • Page 95: Outrigger Limit Test(Idle Load)

    Service Manual of Rough Terrain Mobile Elevating Work Platform 2. Extend the two front or rear outriggers simultaneously to the limit state, and maintain this state for half a minute; 3. After the two front or rear outriggers are extended to the limit state, perform automatic Fig.

  • Page 96: Function Test

    Service Manual of Rough Terrain Mobile Elevating Work Platform others are placed on a flat ground; times and then return to normal, and the fork 3. Floating test criteria: The four wheels can will continue to descend. touch the ground simultaneously after falling Anti-pinch function position requirement: When into the pit;...

  • Page 97: Outrigger Function

    Service Manual of Rough Terrain Mobile Elevating Work Platform for deactivation); the GCU, find the load inspection function 2. If the function is deactivated, activate it option, and verify whether the function is through the function button; activated ("On" for activation, Off" for 3.

  • Page 98: Lifting Height For Overload Alarm

    0.9m/2.95ft for SR2669D model,1m/3.28ft for same time to lift the platform; or press the SR3369D,and 1.1m/3.61ft for SR4069D；...
  • Page 99 Service Manual of Rough Terrain Mobile Elevating Work Platform leveling, turn the start switch to the upper b） Press the travel function button, press the control position, start the engine, press and enable button on the PCU, and push the hold the outrigger automatic leveling button, enable joystick forward or backward at the press and hold the enable switch, and...
  • Page 100 Service Manual of Rough Terrain Mobile Elevating Work Platform...

  • Page 101: Maintenance

    Service Manual of Rough Terrain Mobile Elevating Work Platform 5 Maintenance...
  • Page 102 Service Manual of Rough Terrain Mobile Elevating Work Platform...

  • Page 103: Checking The Safety Manual

    △ Wear washer To replace any manual, please  Tire and wheel  contact the service personnel of LGMG. Engine and its relevant parts Checking the labels and signs  Limit switch and horn  Nut, bolt and other fasteners It is essential to keep all safety and ...

  • Page 104: Checking The Gcu

    Service Manual of Rough Terrain Mobile Elevating Work Platform deformation or sealing-off Result: The engine shall be shut down, and all  the machine for dent or damage functions shall not be enabled.  that all structural parts and other key Checking the PCU components are intact and all relevant Turn the key switch to PCU position.

  • Page 105: Checking The Battery

    Service Manual of Rough Terrain Mobile Elevating Work Platform  GCU box goggles, protective gloves and protective clothes  Hydraulic valve group if necessary. Avoid touching the spilled electrolyte  Battery wire with hands or other parts of the body. Use soda ...

  • Page 106: Checking The Tires And Wheel Hubs

    Checking the hydraulic tank charge the battery, only the charger approved vent cap by LGMG can be used. This inspection shall be performed once The battery with white electric eye may not every 8h or every day whichever comes first.

  • Page 107: Checking The Hydraulic Filter

    Service Manual of Rough Terrain Mobile Elevating Work Platform engine is shut down. △ Risk of personal injury. Replacement of the return filter element of the Splashed hydraulic oil will penetrate and hydraulic tank: burn the skin. Implement this step once every 550h or Check for hydraulic oil sediments, droplets every six months whichever comes first.

  • Page 108: Replacing The Air Filter Of The Hydraulic Tank

    Service Manual of Rough Terrain Mobile Elevating Work Platform Check the seal of the filter cover, and 1. Stop the machine on a flat ground. Retract the replace it when necessary. platform. Install a new high pressure filter element, 2. Check the oil level sight glass on the hydraulic and tighten it.

  • Page 109: Checking The Oil Level Of The Reducer

    Service Manual of Rough Terrain Mobile Elevating Work Platform 2. Remove the oil drain plug from the hydraulic the level gauge. Ensure that the hydraulic oil doesn’t overflow. tank. 11. Remove the possibly splashed hydraulic oil. 12. Open the ball valves on the hydraulic tank. △...

  • Page 110: Changing The Reducer Gear Oil

    Service Manual of Rough Terrain Mobile Elevating Work Platform 5. Repeat this step for each reducer. If the coolant beyond the specified interval is used, the cooling system will be clogged Changing the reducer gear oil and the engine will be damaged. The coolant The first maintenance shall be performed shall be changed at the specified interval.

  • Page 111: Changing Engine Oil And Replacing Oil Filter

    Service Manual of Rough Terrain Mobile Elevating Work Platform the engine is hot, shut it down, and after 5 minutes, and local regulations. Dispose of spilled oil check the oil level. If the engine is cold, check the and filter elements as specified. Ensure that oil level immediately.

  • Page 112: Checking Fuel Leaks

    Service Manual of Rough Terrain Mobile Elevating Work Platform Unscrew the oil drain plug to drain the old wrench of the filter element after manual oil. tightening.do nont srew it too tight to avoid Install a new seal ring on the oil drain plug, oil leakage.

  • Page 113: Bleeding The Fuel System

    Service Manual of Rough Terrain Mobile Elevating Work Platform △ frequent in case of extremely dirty working Caution: environment. Carefully clean all areas involved. Dry the Apply a thin layer of fuel to the gasket and wet parts with compressed air. tighten the strainer in place by hand.

  • Page 114: Checking The Coolant Level

    Service Manual of Rough Terrain Mobile Elevating Work Platform 1. Open the positioning plate (3). for a very short time. 2. Take off the filter cover (4) and unscrew the Carefully open the cover of the cooling outer element (2). system.

  • Page 115: Checking The Engine Belt

    Service Manual of Rough Terrain Mobile Elevating Work Platform Add the coolant to the Max. mark or to the Visually check all pulleys for damage. limit position. Replace the damaged components. Turn on the possible heater and adjust it to Reinstall the protective device if necessary.

  • Page 116: Engine Dtcs

    Service Manual of Rough Terrain Mobile Elevating Work Platform Engine DTCs Fault diagnosis of Kubota engine 1. It is difficult to start the engine Fault cause Action Thick fuel hard to flow Check the fuel tank and fuel filter. Remove water, dust and other impurities. Because all fuel will be filtered by the fuel filter, if there is water or other foreign matter in the fuel filter, please clean the fuel filter with kerosene.
  • Page 117 Check whether the clearance of engine bearings is within the factory specifications. 4. The color of exhaust gas is abnormal Fault cause Action Damaged fuel regulating Contact the service personnel of LGMG. device Inferior fuel Choose quality fuel. Please use No. 2-D diesel only.
  • Page 118 Service Manual of Rough Terrain Mobile Elevating Work Platform head gasket Improper fuel injection Adjust to the right timing timing Unsuitable engine oil Use the specified fuel. DTCs of Kubota engine J1939-73 Description of DTC Error identification DTC setting parameter Coolant temperature sensor Sensor/harness open, or voltage: not less than 4.9V...

  • Page 119: Checking Or Replacing The Scissor Arm Slider

    Service Manual of Rough Terrain Mobile Elevating Work Platform Checking or replacing the scissor arm slider Perform this step every 1000 hours or every year, whichever comes first. 1. The quality of wear-resistant slider of scissor arm is critical to the safe operation of the machine.

  • Page 120: Routine Inspection And Maintenance Intervals

    Service Manual of Rough Terrain Mobile Elevating Work Platform Routine Inspection and Maintenance Intervals △ Note: The working hours are based on the engine working time, and the operation cycle is calculated from the date of production. Maintenance Period Maintenance Routine Level 1 Level 2...
  • Page 121 Service Manual of Rough Terrain Mobile Elevating Work Platform the water regularly for cleaning It can be cleaned Clean or replace the air for at Clean the air cleaner outer element every 250h or when the indicator alarms, and it cleaner outer element and most 5 is forbidden to clean the air cleaner inner element...
  • Page 122 Service Manual of Rough Terrain Mobile Elevating Work Platform Check if the battery ● terminals are loose or rusted Check if the system ● ● ● ● ● pressure is normal Check if the lifting pressure ● ● ● ● ●...
  • Page 123 Service Manual of Rough Terrain Mobile Elevating Work Platform Check the platform, fork ● and chassis for deformation or open weld Check if the vehicle paint ● falls off Check if the safety ● identification is true or stained Lubricate the steering ●...
  • Page 124 Service Manual of Rough Terrain Mobile Elevating Work Platform...

  • Page 125: Appendix

    Service Manual of Rough Terrain Mobile Elevating Work Platform 6 Appendix...
  • Page 126 Service Manual of Rough Terrain Mobile Elevating Work Platform...

  • Page 127: Electrical Schematic Diagram

    Service Manual of Rough Terrain Mobile Elevating Work Platform Electrical schematic diagram SR69D Electrical schematic diagram...

  • Page 128: Hydraulic Schematic Diagram

    Service Manual of Rough Terrain Mobile Elevating Work Platform Hydraulic schematic diagram SR2669D、SR3369D Hydraulic schematic diagram...

  • Page 129: Sr4069D Hydraulic Schematic Diagram

    Service Manual of Rough Terrain Mobile Elevating Work Platform SR4069D Hydraulic schematic diagram...

  • Page 130: Diagram Of Common Hydraulic Part Symbols

    Service Manual of Rough Terrain Mobile Elevating Work Platform Diagram of common hydraulic part symbols (1) Hydraulic pump, hydraulic motor and hydraulic cylinder Name Symbol Description Name Symbol Description Hydraulic General Detailed pump symbol symbol Non- adjustable One-way one-way One-way rotation, bounce fixed...
  • Page 131 Service Manual of Rough Terrain Mobile Elevating Work Platform One-way flow, one- Fixed displaceme One-way rotation, nt hydraulic action fixed pump-motor displaceme Turbocharg Two-way flow, two- Variable Pump- displaceme rotation, Continuous motor nt hydraulic variable action pump-motor displaceme nt, external oil drain Unidirection al rotation,...
  • Page 132 Service Manual of Rough Terrain Mobile Elevating Work Platform pressure co internal oil ntrol drain External control of air Gas-liquid pressure, * Control Locking pilot hydraulic method for device pressure co internal unlocking ntrol control, external oil drain Electro- Hydraulic hydraulic external Bounce...
  • Page 133 Service Manual of Rough Terrain Mobile Elevating Work Platform Double- acting adjustable Press-pull electromag type netic operation (torque motor, etc.) Rotary motion Handle type electrical control device One-way Feedback General pedal type control symbol The position is detected Two-way Electrical Feedback potentiometer pedal type...
  • Page 134 Service Manual of Rough Terrain Mobile Elevating Work Platform General Direct- symbols or Two-way acting, Unloading direct-acting relief valve external oil valve unloading drain valve Unloading General valve symbols or Pilot Pressure direct- electromag reducing acting netic p1>p2 valve pressure unloading reducing valve...
  • Page 135 Service Manual of Rough Terrain Mobile Elevating Work Platform four-way proportional valve Two- position Normally Two- four-way closed position proportional two-way valve solenoid valve Normally Four-way open servo valve Two- Four-way position electro- Level 2 Reversing three-way hydraulic valve solenoid servo valve valve Two-...
  • Page 136 Service Manual of Rough Terrain Mobile Elevating Work Platform tank Pipe end Local oil With air above the drain or cleaner liquid level return Pressurized oil tank or Three oil closed oil tank circuits (7) Fluid regulator General Filter Air cleaner symbol Filter with pollution...

  • Page 137: Diagram Of Common Electrical Part Symbols

    Service Manual of Rough Terrain Mobile Elevating Work Platform General Temperatur symbol e sensor General Coupling symbol Coupling Amplifier Flexible coupling (10) Pipeline, pipeline joints and connectors Pressure The two pipeline and Cross pipelines are Pipeline return pipeline crossed and pipeline unconnected pipelines...
  • Page 138 Service Manual of Rough Terrain Mobile Elevating Work Platform Combinatio Composite n knob button switch voltage Emergency circuit stop button breaker Controller Key- operated operating button switch Coil Thermal operating element device Thermal relay Normally Normally open main closed contact contact Contactor Normally...
  • Page 139 Service Manual of Rough Terrain Mobile Elevating Work Platform Normally closed Normally contact closed which is instantaneou contact disconnected Normally open contact Overvoltag which is e coil closed with delay Normally closed Undervolta contact which is ge coil disconnected with delay Voltage Normally relay...
  • Page 140 Service Manual of Rough Terrain Mobile Elevating Work Platform Three- phase Generator transformer Generator Voltage tachometer transformer generator Transformer Signal lamp Current (indicator transformer lamp) Lamp Plug Plug and Lighting lamp Connector socket Sock et XS...

  • Page 141: Machine Fault Codes

    Service Manual of Rough Terrain Mobile Elevating Work Platform Machine fault codes GCU display PCU display Description Solution 0x01 Internal ECU Fault GCU error Replace the GCU. Check the wiring, and if the wiring is intact, replace the platform/ground 0x02 Platform ECU Fault Communication error control unit respectively to determine if the platform/ground...
  • Page 142 Service Manual of Rough Terrain Mobile Elevating Work Platform Chassis DOWN 0x18 Chassis Down Sw Fault switch pressed during Check the switch and wiring power-on Left turn switch on Check the switch and replace the 0x19 Left Turn Switch Fault PCU pressed during power-on Right turn switch on...
  • Page 143 Service Manual of Rough Terrain Mobile Elevating Work Platform Right rear outrigger switch on PCU Check the switch and replace the 0x24 Right Rear Outrig Sw Flt pressed during power-on Auto level switch on Check the switch and replace the 0x25 AutoLevel Switch Fault PCU pressed during power-on...
  • Page 144 Service Manual of Rough Terrain Mobile Elevating Work Platform Lift-down solenoid Check the line and replace the 0x37 Down Coil Fault valve open circuit solenoid valve. Right turn solenoid Check the line and replace the 0x38 Right Turn Coil Fault valve open circuit solenoid valve.
  • Page 145 Service Manual of Rough Terrain Mobile Elevating Work Platform Left front outrigger 0x4B LFLIMIT SWCLOSEFAULT Check the travel switch and harness NC contact fault Left front outrigger 0x4C LFLIMIT SWOPENFAULT Check the travel switch and harness NO contact fault Left rear outrigger NC 0x4D LRLIMIT SWCLOSEFAUL Check the travel switch and harness contact fault...
  • Page 146 Service Manual of Rough Terrain Mobile Elevating Work Platform 0x59 DPF Fault Lv5 DPF level 5 alarm Operate the engine after-treatment RegeneratonNeeded activated system High/low-speed Check the line and replace the 0x5A 2Speed Coil Fault solenoid valve open solenoid valve. circuit Bypass solenoid Check the line and replace the...
  • Page 147 Service Manual of Rough Terrain Mobile Elevating Work Platform Refer to the engine maintenance manual 0X65 Beacon Fault Engine fault Do troubleshooting based on SPN and FMI Check the engine connector or Engine intake 0x66 BPSCDNP sensor, or refer to the engine pressure sensor fault maintenance manual Check the engine connector or...
  • Page 148 Service Manual of Rough Terrain Mobile Elevating Work Platform Check engine connector or sensor, ECU temperature 0x71 TECUSRC or refer to the engine maintenance sensor fault manual Check engine connector or sensor, 0x72 INJVLVCYL1 Injector 1 fault or refer to the engine maintenance manual Check engine connector or sensor, 0x73 INJVLVCYL2...
  • Page 149 Service Manual of Rough Terrain Mobile Elevating Work Platform Check engine connector or sensor, 0x7D ENGMCAS Camshaft signal loss or refer to the engine maintenance manual Check engine connector or sensor, 0x7EENGMCRS Crankshaft signal loss or refer to the engine maintenance manual Check engine connector or sensor, DEC1 message T50...
  • Page 150 Service Manual of Rough Terrain Mobile Elevating Work Platform CAN received frame Check engine connector or sensor, 0x89 FRMMNGERC1DR ERC1DR data size or refer to the engine maintenance error manual Check engine connector or sensor, ETC1 message data 0x8A FRMMNGETC1 or refer to the engine maintenance length error manual...
  • Page 151 Service Manual of Rough Terrain Mobile Elevating Work Platform Check engine connector or sensor, CANTOTSC1VE data 0x95 FRMMNGTSC1VE or refer to the engine maintenance size error manual Check engine connector or sensor, CANTOTSC1VR data 0x96 FRMMNGTSC1VR or refer to the engine maintenance size error manual Check engine connector or sensor,...
  • Page 152 Service Manual of Rough Terrain Mobile Elevating Work Platform Check engine connector or sensor, 0xA1 BATTVLTGERR High battery voltage or refer to the engine maintenance manual Check engine connector or sensor, 0xA2 ENGOVERHEAT Engine overheating or refer to the engine maintenance manual Check engine connector or sensor, 0xA3...

This manual is also suitable for:

Sr3369dSr4069d

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