DINGLI S0608E Operators Manual With Maintenance Information Download Page 4

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Summary of Contents for S0608E

Page 1: ...tor Drive Part Number SM0110111A_Rev4 0 Zhejiang Dingli Machinery Co Ltd Fourth Edition October 2018 Printing WARNING THE MANUFACTURER SHALL NOT BE HELD LIABLE IN CASE OF FAULTS OR ACCIDENTS DUE TO NEGLIGENCE INCAPACITY INSTALLATION BY UNQUALIFIED TECHNICIANS AND IMPROPER USE OF THE MACHINE DO NOT OPERATE THIS MACHINE UNTIL YOU READ AND UNDERSTAND ALL THE DANGERS WARNINGS AND CAUTIONS IN THIS MANU...

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Page 3: ...1 Owners Users and operators We appreciate your choice of our machine for your application Our number one priority is user safety which is best achieved by our joint efforts We feel that you make a major contribution to safety if you as the equipment users and operators 1 Comply with employer job site and governmental rules 2 Read understand and follow the instructions in this and other manuals su...

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Page 5: ... understand and obey all applicable governmental regulations You are properly trained to safely operate the machine Decal Legend DINGLI product decals use symbols color coding and signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indic...

Page 6: ...platform movement electrical line sway or sag and beware of strong or gusty winds Keep away from the machine if it contacts energized power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off Do not operate the machine during lightning or storms Do not use the machine as a ground for welding Tip over Hazard Occupants equip...

Page 7: ...y S1212E Maximum occupants Indoor use ONLY 3 Platform allowable maximum load 320kg Extension deck allowable maximum load 113kg Maximum capacity S1412 EXC Maximum occupants Indoor use ONLY 2 Platform allowable maximum load 250kg Extension deck allowable maximum load 113kg Platform retracted Platform extended Extension Platform only only Work Area Safety Do not raise the platform unless the machine ...

Page 8: ...ants S0608EH Outdoor 200N 1 Indoor 400N 2 S0808EH Indoor 400N 2 S0812EH Outdoor 400N 2 Indoor 400N 2 S1012EH Outdoor 200N 1 Indoor 400N 2 Model Application manual force Maximum occupants S1212EH Indoor 400N 3 S1412 EHXC Indoor 400N 2 S0608E Outdoor 200N 1 Indoor 400N 2 S0808E Indoor 400N 2 S0812E Outdoor 400N 2 Indoor 400N 2 S1012E Outdoor 200N 1 Indoor 400N 2 S1212E Indoor 400N 3 S1412 EXC Indoor...

Page 9: ...als unless they are evenly distributed and can be safely handled by person s in the platform Do not use the machine on a moving or mobile surface or vehicle Be sure all tires are in good condition air filled tires are properly inflated and lug nuts are properly tightened Crushing Hazard Keep hands and limbs out of scissors Keep hands clear when folding rails Maintain a firm grasp on the platform r...

Page 10: ...extended platform position s when moving the machine Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards when grasping the platform guard rail Operators must comply with employer job site and governmental rules regarding use of personal protective equipment Observe and use color coded direction arrows on the platform controls for drive and steer fun...

Page 11: ...cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain closed and secured during operation Battery Safety Burn Hazard Batteries contain acid Always wear protective clothing and eye wear when working with batteries Avoid spilling or contacting battery acid Neutr...

Page 12: ...0 kg For S1012EH S1012E Each battery must weigh 37 kg The batteries must weigh a minimum of 148 kg For S1212EH S1212E S1412 EHXC S1412 EXC Lifting Hazard Use the appropriate number of people and proper lifting techniques when lifting batteries Lockout after Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Lower the platform 3 Turn the key switch to th...

Page 13: ...ge point 5 Platform guard rails 6 Platform extension release pedal 7 Main platform 8 Platform entry gate 9 Scissor arms 10 Lift cylinder 11 Ground controls on opposite side of machine 12 Entry ladder 13 Brake release pump 14 Non steer tire 15 Battery charger 16 Pothole guard 17 Steer tire 18 Safety arm 1 2 3 4 5 7 8 9 10 6 18 17 11 12 13 14 15 16 ...

Page 14: ...H S0812E 09440016 Decal Label Capacity 320kg 1 S1012EH S1012E 09440017 Decal Label Capacity 320kg 1 S1212EH S1212E 09440038 Decal Label Capacity 250kg 1 S1412 EHXC S1412 EXC 7 09440005 Decal Warning Use indoors only 1 S0808EH S0808E S1212EH S1212E S1412 EHXC S1412 EXC 8 09210015 Nameplate Manufacturer serial number 1 9 09310001 Decal Instructions Forklift pockets 2 10 09310003 Decal Instructions T...

Page 15: ... 4 S1212EH S1212E S1412 EHXC S1412 EXC 18 09640030 Decal Cosmetic S0608EH 2 S0608EH 09640031 Decal Cosmetic S0608E 2 S0608E 09640032 Decal Cosmetic S0808EH 2 S0808EH 09640033 Decal Cosmetic S0808E 2 S0808E 09640034 Decal Cosmetic S0812EH 2 S0812EH 09640035 Decal Cosmetic S0812E 2 S0812E 09640036 Decal Cosmetic S1012EH 2 S1012EH 09640037 Decal Cosmetic S1012E 2 S1012E 09640038 Decal Cosmetic S1212E...

Page 16: ...Label E Tech 2 S0608E S0808E S0812E S1012E S1212E S1412E 09940004 Decal Label Summit 2 S0608EH S0808EH S0812EH S1012EH S1212EH S1412 EHXC 20 09410005 Decal Danger Do not alter or disable limit switch 1 21 09310004 Decal Instructions Emergency lower 1 22 09410003 Decal Warning Inspected and operation properly 1 ...

Page 17: ...OPERATOR S MANUAL with Maintenance Information Decals 13 Safety tape 1 2 3 4 5 1 1 1 6 8 9 10 11 13 14 15 17 19 20 12 16 9 10 11 12 19 20 17 16 21 22 23 16 10 11 10 11 14 12 12 5 7 14 18 18 ...

Page 18: ...OPERATOR S MANUAL with Maintenance Information Decals 14 ...

Page 19: ...OPERATOR S MANUAL with Maintenance Information Decals 15 ...

Page 20: ...atform Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Maxim...

Page 21: ...tform Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Maximu...

Page 22: ...tform Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Maximu...

Page 23: ...tform Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Maximu...

Page 24: ...atform Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Maxim...

Page 25: ...n platform Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction M...

Page 26: ...form Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Maximum...

Page 27: ...orm Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Maximum ...

Page 28: ...tform Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Maximu...

Page 29: ...tform Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Maximu...

Page 30: ...atform Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Maxim...

Page 31: ...platform Standard Maximum hydraulic pressure functions 240 bar System voltage 24 V Tire size Φ381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Max...

Page 32: ... controls will operate 2 Platform up down switch Move the switch up and the platform will raise Move the switch down and the platform will lower 3 Circuit breaker When the current was overloaded the circuit breaker will cut off the circuit 4 Overload indicator light Light on indicates when overloaded 5 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all ...

Page 33: ...9 Platform Control Panel 1 Thumb rocker switch 2 Drive function select button 3 Drive speed button 4 Red Emergency Stop button 5 LED readout screen 6 Horn button 7 Lift function select button 8 Proportional control handle 9 Function enable switch 9 8 7 6 5 1 2 3 4 ...

Page 34: ...ivate the lift function 8 Proportional control handle Lift function Press and hold the function enable switch to enable the lift function on the platform control handle Move the control handle in the direction indicated by the blue arrow and the platform will raise Move the control handle in the direction indicated by the yellow arrow and the platform will lower The descent alarm should sound whil...

Page 35: ...discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unauthorized variation fro...

Page 36: ...manifolds Battery pack and connections Drive motors Wear pads Tires and wheels Ground strap Limit switches alarms and horn Nuts bolts and other fasteners Platform overload components Platform entry gate Beacon if equipped Safety arm Platform extension s Scissor pins and retaining fasteners Platform control joystick Brake release components Pothole guard Check entire machine for Cracks in welds or ...

Page 37: ... if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Be aware of and avoid the following hazardous situations Drop offs or holes Bum...

Page 38: ... machine as it was intended Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service The operator must follow the step by step instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qu...

Page 39: ...ole guards have not deployed sounds at 180 beeps per minute The alarm that goes off when the machine is not level sounds at 180 beeps per minute An optional automotive style horn is also available 10 Turn the key switch to off or platform position 11 Move up and hold the platform up down switch Result No function should operate 12 Turn the key switch to ground control position 13 Move up and hold ...

Page 40: ...uld lower The descent alarm should sound while the platform is lowering Test the Steering Note When performing the steer and drive function tests stand in the platform facing the steer end of the machine 29 Press the drive function select button The indicator light should turn on 30 Press and hold the function enable switch on the control handle 31 Depress the thumb rocker switch on top of the con...

Page 41: ...o them 43 Raise the platform approximately 2m from the ground Result The platform should stop and the tilt alarm will sound at 180 beeps per minute The platform controls LED readout should display LL 44 Press the drive function select button 45 Press and hold the function enable switch on the control handle 46 Move the control handle in the direction indicated by the blue up arrow then move the co...

Page 42: ...rrow and then move the control handle in the direction indicated by the yellow down arrow Result The drive function should not work in either direction 55 Press and hold the function enable switch on the control handle 56 Depress the thumb rocker switch on top of the control handle in the direction identified by the blue and white arrow on the control panel Result The steer function should not wor...

Page 43: ...o used to perform some relatively straightforward calculations on subsystem to determine the overall PL of the system Reliability data diagnostic coverage DC the system architecture Category common cause failure and where relevant requirements for software are used to assess the PL to comply with PLr of SRP CS in Clause 5 11 of EN 280 The Operating Instructions section provides instructions for ea...

Page 44: ... Press the lift function select button 2 Press and hold the function enable switch on the control handle 3 Move the control handle according to the markings on the control panel To Steer 1 Press the drive function select button 2 Press and hold the function enable switch on the control handle 3 Turn the steer wheels with the thumb rocker switch located on the top of the control handle To Drive 1 P...

Page 45: ...e Run 3 6 m Rise 0 3 m 0 3 m 3 6 m 0 083 x 100 8 3 If the slope exceeds the maximum slope or side slope rating the machine must be winched or transported up or down the slope See Transport and Lifting section Operation from Ground with Controller Maintain safe distances between operator machine and fixed objects Be aware of the direction the machine will travel when using the controller Battery Le...

Page 46: ...tep or the ground 9 From the rear step or from the ground remove the left rear main deck wire lock pins 10 Fold down the left rail assembly Keep hands clear of pinch points 11 Replace the removed pin back into rear rail bracket 12 Remove the right rear main deck wire lock pins 13 Fold down the right rail assembly Keep hands clear of pinch points 14 Replace the removed pin back into rear rail brack...

Page 47: ...All Motion 36 Low Battery Alert Warning Only 42 Platform Left Turn Switch ON at power up Message Warning Only 43 Platform Right Turn Switch ON at power up Message Warning Only 46 Platform Joystick Enable Switch ON at power up Fault Disable Platform Control 47 Platform Joystick not in neutral at power up Message Warning Only 52 Drive Forward Coil Fault Disable Lifting and Driving 53 Drive Reverse C...

Page 48: ... Controller Left Drive Motor Fault Controller Dependent 77 Motor Controller Right Drive Motor Fault Controller Dependent 78 Pump Motor Short Fault Disable Lifting and Driving 79 Left Drive Motor Short Fault Disable Lifting and Driving 80 Over 80 Load Warning Warning Only 81 Right Drive Motor Short Fault Disable Lifting and Driving 82 Left Brake Coil Fault Disable Lifting and Driving 83 Right Brake...

Page 49: ...K consider replacing the Joystick or PCU 46 Platform Joystick Enable Switch ON at power up Fault Ensure that nothing is holding the Enable switch closed Also check the neutral zone parameters If OK consider replacing the Joystick or PCU 47 Platform Joystick not in neutral at power up Message Make sure that the Joystick is in the neutral upright position Check the neutral zone parameter setting in ...

Page 50: ...onnections and tighten or clean Check the voltage to the ECU and PCU 69 High Neutral Current The MC is sensing current in the motors when there should not be This could occur anytime the MC thinks the brakes are on and the motors are still turning This message sometimes comes just before other faults but should be ignored in those cases 70 Steering Input Out of Range There is an inappropriate volt...

Page 51: ...heck the coil itself to see if it is open or shorted 84 Motor Post shorted Check the connections of the controller and motor Make sure the wiring is not shorted 85 Brake Release Switch On Check the wires to brake release switch or look for a stuck switch 86 Brake Release Not Stowed Check if the platform is below down limit height Check the down limit switch and connections 87 Brake Release Need Sw...

Page 52: ...e plates Do not overfill prior to the charge cycle 6 Replace the battery vent caps 7 Connect the battery charger to a grounded AC circuit 8 The charger will indicate when the battery is fully charged 9 Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill Dry Battery Filling and Charging Instructions 1 Remove ...

Page 53: ...s the maximum slope rating the machine must be loaded and unloaded using a winch as described Brake Release Operation For the Hydraulic Motor Drive Model 1 Chock the wheels to prevent the machine from rolling 2 Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions 3 Push in the black brake release knob to open the brake valve 4 Pump th...

Page 54: ...e the extension deck s Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Use the tie down points on the chassis for anchoring down to the transport surface Use a minimum of four chains or straps Use chains or straps of ample load capacity If the railings have been folded down secure them with straps before transpo...

Page 55: ...ne with a Forklift Be sure the extension deck controls and component trays are secure Remove all loose items on the machine Fully lower the platform The platform must remain lowered during all loading and transport procedures Use the forklift pockets located on both sides of the ladder Position the forklift forks in position with the forklift pockets Drive forward to the full extent of the forks R...

Page 56: ...chine using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine There are two lifting points on each end of the machine Adjust the rigging to prevent damage to the machine and to keep the machine level Center of gravity Model X Axis Y Axis S0608EH S0608E 90 5 cm 56 5cm S0808EH S0808E 80 6cm 57 6cm S0812EH S0812E 89cm 64 4cm S1012EH S1012E ...

Page 57: ...ch type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have ...

Page 58: ...hall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in this manual Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after...

Page 59: ...ine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist A Y N R A 1 Inspect the manuals and decals A 2 Pre operation inspection A 3 Check the Batteries A 4 Check the Hydraulic Oil Level A 5 Function tests Perform after 40 hours A 6 30 day service Perform every 100 hours A 7 Grease steer yokes Checklist ...

Page 60: ...e that the operator s manual is present and complete in the storage container on the platform 2 Examine the pages of manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and the manual are legible and in good condition Result The operator s manual is not appropriate for the machine or the manual is not in good condition or is ill...

Page 61: ... A 3 Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain...

Page 62: ... following table Model Scale line L S0608EH S0608E S0808EH S0808E S0812EH S0812E 15 S1012EH S1012E S1212EH S1212E 17 5 S1412 EHXC S1412 EXC 19 2 Add oil if necessary Do not overfill Original Hydraulic oil specifications L HV46 Customers shall choose the appropriate hydraulic oil according to the ambient temperature used Example L HV32 or L HV68 A 5 Perform Function Tests Completing the function te...

Page 63: ...ease the Steer Yokes DINGLI requires that this procedure be performed every 100 hours of operation Regular application of lubrication to the steer yokes is essential to good machine performance and service life Continued use of an insufficiently greased steer yoke will result in component damage 1 Open the steer yoke cover 2 Locate the grease add hole on the top of the steer yoke 3 Pump multipurpo...

Page 64: ...harge the batteries Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize Models without maintenance free or sealed batteries 6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 7 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows ...

Page 65: ...heck each battery pack and verify that the batteries are wired correctly 14 Inspect the battery charger plug and pigtail for damage or excessive insulation wear Replace as required 15 Connect the battery charger to a properly grounded 110 230V 50 60 Hz single phase AC power supply Result The charger should operate and begin charging the batteries Result If simultaneously the charger alarm sounds a...

Page 66: ...se to the on position Pull out the platform red Emergency Stop button to the on position 4 Raise the platform until the distance of the two sets of scissor at least 0 5m 5 Lift the safety arm move it to the center of the scissor arm and rotate up to a vertical position 6 Lift the upper safety arm move it to the center of the scissor arm and rotate down to a vertical position for JCPT1412 JCPT1612B...

Page 67: ...d 66Nm B 4 Test the Emergency Stop DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation As a safety feature selecting and operating...

Page 68: ...atform control 3 Check the platform up down function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Check the machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the off position Result No function should operate B 6 Test the Automotive style Horn if equipped DINGLI...

Page 69: ... clockwise to the on position Pull out the platform red Emergency Stop button to the on position 3 Lower the platform to the stowed position 4 Press the drive function select button a a drive function select button 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 6 Bring the machine to top drive speed before reaching the test lin...

Page 70: ...rt and finish lines by marking two lines on the ground 12 2 m apart 2 Turn the key switch to platform control Turn the ground red Emergency Stop button clockwise to the on position Pull out the platform red Emergency Stop button to the on position 3 Lower the platform to the stowed position 4 Press the drive function select button a a drive function select button 5 Choose a point on the machine i ...

Page 71: ...urn the key switch to platform control Turn the ground red Emergency Stop button clockwise to the on position Pull out the platform red Emergency Stop button to the on position 3 Press the lift function select button a b a lift function select button b drive function select button 4 Press and hold the function enable switch on the joystick 5 Raise the platform approximately 2 m from the ground 6 P...

Page 72: ...and finish lines by marking two lines on the ground 12 2 m apart 2 Turn the key switch to platform control Turn the ground red Emergency Stop button clockwise to the on position Pull out the platform red Emergency Stop button to the on position 3 Lower the platform to the stowed position 4 Press the slow speed select button a a slow speed select button 5 Choose a point on the machine i e contact p...

Page 73: ...the test See E 1 Test or Replace the Hydraulic Oil B 12 Inspect the Hydraulic Tank Cap Venting System DINGLI requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist A free breathing hydraulic tank cap is essential for good machine performance and service life A dirty or clogged cap may cause the machin...

Page 74: ...r quarterly whichever comes first Maintaining the limit switches is essential to safe operation and good machine performance Operating the machine with a faulty limit switch could result in reduced machine performance and a potentially unsafe operating condition Perform these procedures with the machine on a firm level surface that is free of obstructions Down Limit Switch 1 Remove the platform co...

Page 75: ...d and the steer and drive functions operate Replace the down limit switch 15 Press the lift function select button Raise the platform approximately 0 3 m Result The LED readout screen will show code 18 and an alarm sounds The machine is functioning properly Result The LED readout screen does not show code 18 and the alarm does not sound Replace the down limit switch 16 Raise the platform until the...

Page 76: ...r and drive functions operate Adjust or replace the level sensor Pothole Limit Switches 33 Lower the platform to the stowed position Move the machine onto a firm level surface 34 Place a wooden block approximately 5 cm tall under the right pothole guard 35 Press the lift function select button Attempt to raise the platform approximately 2 4m Result The pothole guard contacts the block and does not...

Page 77: ...the scissor arm and rotate up to a vertical position 3 Lift the upper safety arm move it to the center of the scissor arm and rotate down to a vertical position for JCPT1412 JCPT1612B 4 Lower the platform until the safety arm rests securely on the link Keep clear of the safety arm when lowering the platform Crushing hazard Keep hands clear of the safety arm when lowering the platform 5 Open the li...

Page 78: ...sensor which is adjustable and located at the barrel end of the lift cylinder is used to determine when the hydraulic lift cylinder requires too much pressure to support the load inside the platform When this occurs the overload pressure sensor will send a signal to the ECU which will not allow the machine to function until the extra weight is removed from the platform The angle sensor located in ...

Page 79: ...res of the up limit switch 14 Fully raise the platform Release the toggle switch Result The alarm should not sound The system is functioning correctly Result The alarm sounds The system is not functioning correctly Troubleshoot the limit switch limit switch wire harness or limit switch mount bracket or the platform overload system needs to be calibrated 15 Lower the platform until the distance of ...

Page 80: ...ulic tank is a vented type tank The breather cap has an internal air filter that can become clogged or over time can deteriorate If the breather cap is faulty or improperly installed impurities can enter the hydraulic system which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove and discard the hydraulic tank breather cap 2 Install a n...

Page 81: ...sure the distance between the number one arm cross tube and the chassis deck at the ground controls side of the non steer end of the machine Result The measurement is 34mm or more Proceed to step 2 Result The measurement is less than 34mm Replace both wear pads a wear pad b arm cross tube c chassis deck 2 Measure the distance between the number one arm cross tube and the chassis deck at the batter...

Page 82: ...urns The hydraulic tank return filter is mounted on the bracket between the function manifold and the hydraulic power unit 1 Clean the area around the oil filter Remove the filter with an oil filter wrench 2 Apply a thin layer of oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand 4 Use a permanent ink marker to write the date and number of hours from the hour...

Page 83: ...y 2 Open the power unit module tray 3 Remove the oil drain plug at bottom 4 Drain all of the oil into a suitable container 5 Tag and disconnect the hydraulic tank return line from the hydraulic filter head and remove the line from the tank Cap the fitting on the filter head 6 Tag and disconnect the hydraulic pump inlet line and remove the line from the tank Cap the fitting on the pump 7 Remove the...

Page 84: ...tting onto the hydraulic filter head and torque 15 Fill the tank with hydraulic oil until the fluid is full in the hydraulic tank Do not overfill 16 Activate the pump to fill the hydraulic system with oil and bleed the system of air Component damage hazard The pump can be damaged if operated without oil Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system...

Page 85: ...m S1 S2 P M T BRK RV1 SV1 FR RV4 CV2 RV3 CV1 1 1mm SV4 SV3 D3 D2 D1 D4 L P41 P42 CV2 1 5mm Lower valve NBCY 1001A 11 235bar 3 45bar Tank Pump 5802 4 12 Valve 5805 0116R Hand pump 5805 0412 960020A10 Platform loading Option Steer cylinder Lift cylinder 120bar RV2 130bar S0608EH RV2 160bar S0808EH RV2 210bar S0812EH ...

Page 86: ...1B 11 120bar 235bar 3 45bar RV2 150bar S1012EH RV2 190bar S1212EH 180bar Pump 5802 4 12 Valve 5805 0116R Tank Platform loading Option Steer cylinder Lift cylinder Upper lift cylinder Hand pump 5805 0412 960020A10 SV2 1mm 1mm S1 S2 P M T BRK RV1 SV1 FR RV4 CV2 RV3 CV1 1 1mm SV4 RV5 CV2 0 9mm 1 5mm SV3 D3 D2 D1 D4 L P41 P42 ...

Page 87: ... FR RV4 CV2 RV3 CV1 1 1mm SV4 SV3 D3 D2 D1 D4 L P41 P42 RV5 CV2 0 6mm 1 0mm Lower valve NBCY 1001A 11 Lower valve NBCY 1001B 11 120bar 235bar 3 45bar Pump 5802 4 12 Valve 5805 0116R Tank Platform loading Option Steer cylinder Lift cylinder Upper lift cylinder Hand pump 5805 0412 960020A10 180bar RV2 220bar ...

Page 88: ...c 84 S0608E S0808E S0812E 120bar RV1 130bar S0608E RV1 160bar S0808E RV1 210bar S0812E Lift cylinder Platform loading Option Steer cylinder P M SV2 FRRV1 SV1 S1 S2 L T Tank Pump 5802 3 2 14 Function valve DPH 0918 10 1mm 1mm 1 5mm Lower valve NBCY 1001A 11 ...

Page 89: ...S1212E Upper lift cylinder Tank Pump 5802 4 12 Function valve DPH 0918 10 1mm 1mm 1 5mm 0 9mm 120bar Lower valve NBCY 1001A 11 Lower valve NBCY 1001B 11 RV1 150bar S1012E RV1 190bar S1212E Platform loading Option Steer cylinder Lift cylinder T P M SV2 FRRV1 SV1 S1 S2 L ...

Page 90: ...tic 86 S1412 EXC Platform loading Option Steer cylinder Lift cylinder Upper lift cylinder Tank Pump 5802 4 12 Function valve DPH 0918 10 1mm 1mm 1 0mm 0 6mm 120bar Lower valve NBCY 1001A 11 Lower valve NBCY 1001B 11 RV1 220bar P M SV2 FRRV1 SV1 S1 S2 L T ...

Page 91: ...5A 9B 12C 11B 10B 12B 12A 11C 4B 11A 3C 6B 3A 1C 1B 9A 8A 8B 8C 6C 7A 6A 7B 7C 3B GND 13 BK 16 GND 12 BK 16 GND 11 BK 16 GND 5 BK 16 GND 4 BK 16 GND 3 BK 16 GND 6 BK 16 B BK 14 B1 YV7 YV5 YV6 YV1 YV3 YV4 8A 2 BN GN 16 8A 3 BN GN 16 JS1 SB4 S2 SB5 SB6 SB7 SB8 B3 CAN_H CAN_L SB3 PCU ECU 2 1 B2 1 2 3 1 2 3 C A B TILT AS1 LS1 SA2 YV2 HL2 YV8 BK 2 BK 2 RD 2 HM B J1 J3 M B 2 1 MC1 M1 GND 10 BK 16 RD 2 G...

Page 92: ... 12B 12A 11C 4B 11A 3C 6B 3A 1C 1B 9A 8A 8B 8C 6C 7A 6A 7B 7C 3B GND 13 BK 16 GND 12 BK 16 GND 11 BK 16 GND 5 BK 16 GND 4 BK 16 GND 3 BK 16 GND 6 BK 16 B BK 14 B1 YV7 YV5 YV6 YV1 YV3 YV4 8A 2 BN GN 16 8A 3 BN GN 16 JS1 SB4 S2 SB5 SB6 SB7 SB8 B3 CAN_H CAN_L SB3 PCU ECU 2 1 B2 1 2 3 1 2 3 C A B TILT AS1 LS1 SA2 YV2 HL2 YV8 BK 2 BK 2 RD 2 HM B J1 J3 M B 2 1 MC1 M1 GND 10 BK 16 RD 2 GND 1 BK 16 RD 2 B...

Page 93: ... 11B 12B 12A 11C 4B 11A 3C 6B 3A 3B 10C 9C 10A 8C 6C 9A 4C 7A 5B 5C 8A 6A 7B 7C 8B GND 2 BK 18 GND 7 BK 18 GND 8 BK 18 GND 9 BK 18 数字指示 ECU 10C GN VT 16 9C BU RD 16 10A GN BU 16 8C WH VT 16 6C BN GY 16 9A BN BK 16 4C GN WH 16 7A BN WH 16 5B GN RD 16 5C BN YE 16 8A 1 BN GN 16 8A 2 BN GN 16 1 2 Hourmeter HM 6A VT YE 16 7B WH BU 16 7C WH BU 16 8B BN RD 16 B BK 14 BK 2 YV1 YV3 YV4 B1 GND 3 BK 16 GND ...

Page 94: ...or M N N P R SQ2 Lift Down Limit Switch Lift Up Limit Switch 12C GN BU 18 11B BU RD 18 12B BN WH 18 12A BN GY 18 11C GN VT 18 4B WH VT 18 11A GN YE 18 3C GN RD 18 6B WH BU 18 3A BN YE 18 3B BN BK 18 10B 1 WH BU 16 10B WH BU 16 9B WH BK 16 12C GN 20 11B WH 20 12A BN GY 16 12B BN WH 16 11C GN VT 18 WH GN 22 WH GN 22 BU 20 RD 20 3A BN 18 BK 22 B BK 20 BU 20 GND 3 BK 16 GND 2 BK 16 1B 1C 2B 2C 4A 5A 9...

Page 95: ...OPERATOR S MANUAL with Maintenance Information Inspection and Repair Log 91 Inspection and Repair Log Date Comments ...

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