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DINGLI SL1323-AWD Operator'S Manual Download Page 16

OPERATOR’S MANUAL 

with Maintenance Information

   

Decals 

12 

 

Summary of Contents for SL1323-AWD

Page 1: ...ng Dingli Machinery Co Ltd Sixth Edition August 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 MANUAL ...

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Page 3: ... 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 sup...

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Page 5: ...u read 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...

Page 6: ... to 50kV 3 05 50kV to 200kV 4 60 200kV to 350kV 6 10 350kV to 500kV 7 62 500kV to 750kV 10 67 750kV to 1000kV 13 72 Allow for 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...

Page 7: ...aised use extreme caution to lower the platform For outdoor use machine Do not raise the platform when wind speeds may exceed 12 5 m s If wind speeds exceed 12 5 m s when the platform is raised lower the platform and do not continue to operate the machine Do not operate the machine in strong or gusty winds Do not increase the surface area of the platform or the load Increasing the area exposed to ...

Page 8: ...n the platform or against any part of this machine Do not transport tools and materials 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 ...

Page 9: ...rd 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 and platform decal plate for drive and steer functions Do not operate a machine in the path of any crane or moving overhead machinery unless the controls of the crane have been locked out and or precautions ...

Page 10: ...eak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will 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 Outrigger Safety Do not lower the outriggers unless the machine...

Page 11: ...d Avoid contact with electrical terminals Lockout after Each Use 1 Select a safe parking location firm level surface clear of obstructions and traffic 2 Lower the platform 3 Turn the key switch to the off position and remove the key to secure from unauthorized use 4 Push in the red Emergency Stop buttons to off position 5 Push in the main power switch to off position 6 Chock the wheels ...

Page 12: ...if equipped 2 Platform extension lock handle 10 Outrigger footpads if equipped 3 Platform entry gate 11 Steer tire 4 Platform controls 12 Entry ladder 5 Platform guard rails 13 Fuel tanks behind cover 6 Manual storage containers 14 Non steer tires 7 Platform extensions 15 Ground controls 8 Hydraulic tanks behind cover 16 Safety arm hidden from view ...

Page 13: ...0001 Decal Danger Safety arm 2 8 09310130 Decal Instructions Maximum wheel load 2550kg 4 For SL1323 AWD 09310132 Decal Instructions Maximum wheel load 2800kg 4 For SL1623 AWD 9 09420005 Decal Warning Collision hazard 5 10 09310050 Decal Instructions Tie down point 4 11 09310049 Decal Instructions Lift point 4 12 09410069 Decal Warning Crushing hazard outrigger 4 13 09310134 Decal Instructions Maxi...

Page 14: ... 2 For SL1623 AWD 24 09440007 Decal Caution Max manual force 400N 2 25 09440075 Decal Label Capacity 680kg 2 For SL1323 AWD 09440076 Decal Label Capacity 680kg 2 For SL1623 AWD 26 09940004 Decal Label Summit 2 27 09410073 Decal Caution Restricting access compartment 1 28 09210015 Nameplate Manufacturer serial number 1 29 09410001 Decal Danger Explosion burn hazard 1 30 09310144 Decal Instructions ...

Page 15: ...als 11 1 2 3 4 2 3 4 24 30 31 28 Safety tape Safety tape Safety tape Safety tape 17 20 23 23 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 24 25 26 6 7 8 9 10 11 25 26 6 7 11 10 9 12 13 14 15 16 19 22 21 12 13 9 27 8 9 10 11 11 10 9 12 13 29 17 32 12 13 8 8 18 20 18 ...

Page 16: ...OPERATOR S MANUAL with Maintenance Information Decals 12 ...

Page 17: ...OPERATOR S MANUAL with Maintenance Information Decals 13 ...

Page 18: ...outside 5 2m Turning radius inside 2 04m Ground clearance 22cm Weight See Serial Label Machine weights vary with option configurations Controls Proportional AC outlet in platform Standard Maximum hydraulic pressure functions 240bar Tire size standard tires 33 12 20 Airborne noise emissions 80dB Maximum sound level at normal operating workstations A weighted Gradeability 50 Maximum working slope X ...

Page 19: ... outside 5 2m Turning radius inside 2 04m Ground clearance 22cm Weight See Serial Label Machine weights vary with option configurations Controls Proportional AC outlet in platform Standard Maximum hydraulic pressure functions 240bar Tire size standard tires 33 12 20 Airborne noise emissions 80dB Maximum sound level at normal operating workstations A weighted Gradeability 40 Maximum working slope X...

Page 20: ...button 3 Overload indicator button 4 Engine start button 5 Engine glow plug button 6 Hour meter 7 Key switch 8 Red Emergency Stop button 9 Platform down button 10 Lift function enable button 11 Emergency lowering down button 12 Platform up button 13 Emergency lowering down enable button 13 12 11 10 9 1 2 3 4 5 6 7 8 ...

Page 21: ... platform position and the platform controls will operate Turn the key switch to the off position and the machine will be off Turn the key switch to the base position and the ground controls will operate 8 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions Turn the red Emergency Stop button clockwise to the on position to operate the machine 9...

Page 22: ...3 Generator select button if equipped 11 Engine start button 4 Engine high speed idle select button 12 Engine lower speed Idle select button 5 Horn button 13 Lift function select button 6 Light if equipped 14 Proportional control handle 7 Outrigger function enable button 15 Thumb rocker switch 8 Outrigger auto level button 16 Function enable switch 7 7 9 10 16 15 14 13 12 11 1 2 3 4 5 6 7 8 7 ...

Page 23: ...ne idle setting Light on indicates lower idle is selected 13 Lift function select button Press this button to activate the lift function 14 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 han...

Page 24: ...OPERATOR S MANUAL with Maintenance Information Control Panel 20 16 Function enable switch Press and hold the function enable switch to enable the drive lift function ...

Page 25: ...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 26: ... improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive motors Wear pads Tires and wheels Engine and related components Limit switches alarms and horn Nuts bolts and other fasteners Platform overload components Platform entry gate Beacon if equipped Safet...

Page 27: ... 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 28: ... 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 29: ... lift function enable button Press and hold the platform up down button Result No function should operate 10 Press and hold the lift function enable button Press and hold the platform up button Result The platform should rise 11 Press and hold the lift function enable button Press and hold the platform down button Result The platform should lower the descent alarm should sound while the platform i...

Page 30: ... blue arrow Result The platform should raise 32 Release the control handle Result The platform should stop raising 33 Press and hold the function enable switch Slowly move the control handle in the direction indicated by the yellow arrow Result The platform should lower The descent alarm should sound while the platform is lowering Test the Steering Note When performing the steer and drive function...

Page 31: ... s immediately tag and remove the machine from service Test the Tilt Sensor Operation Note Perform this test from the ground with the platform controller Do not stand in the platform 44 Fully lower the platform 45 Drive both wheels on one side onto an 12cm block 46 Raise the platform approximately 3 0 m from the ground Result The platform should stop and the tilt alarm will sound at 180 beeps per ...

Page 32: ...Auxiliary Lowering 61 Push and hold the function enable switch and raise the platform approximately 60 cm 62 Push in the red Emergency Stop button to shut off the engine 63 Pull out the red Emergency Stop button to the on position 64 Push and hold the function enable switch Activate the control handle in the direction indicated by the yellow arrow Result The platform should lower Test Outrigger Au...

Page 33: ...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 34: ...on from Ground 1 Turn the key switch to ground control 2 Turn the ground red Emergency Stop button clockwise to the on position 3 Pull out the platform red Emergency Stop button to the on position 4 Start the engine To Position Platform 1 Press the lift function enable button 2 Press the platform up down button to activate the up function or the down function Drive and steer functions are not avai...

Page 35: ...ve speed select switch to the fast drive speed mode To determine the slope grade Measure the slope with a digital inclinometer or use the following procedure You will need Carpenter s level Straight piece of wood at least 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level ...

Page 36: ...ividual outrigger buttons will turn off when all the outriggers are in firm contact with the ground The drive function is disabled while the outriggers are down To control individual outrigger 1 Push and hold one or more outrigger buttons 2 Press and hold the function enable switch Activate the proportional control handle in the direction indicated by the yellow arrow The outriggers will extend an...

Page 37: ...on Operating Instructions 33 3 Turn the key switch to the off position and remove the key to secure from unauthorized use 4 Push in the red Emergency Stop buttons to off position 5 Push in the main power switch to off position 6 Chock the wheels ...

Page 38: ...g the brakes Do not drive the machine on a slope that exceeds the slope or side slope rating See Driving on a Slope in the Operating Instructions section If the slope of the transport vehicle bed exceeds the maximum slope rating the machine must be loaded and unloaded using a winch as described Free wheel Configuration for Winching Chock the wheels to prevent the machine from rolling 2WD models Re...

Page 39: ...e the extension deck s 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 Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items If the railings have been folded down secure them with straps before transpo...

Page 40: ...e platform Be sure the extension decks controls and covers are secure Remove all loose items on the machine Determine the center of gravity of your machine 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 mac...

Page 41: ...ion Report The pre delivery preparation report contains checklists for each 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 M...

Page 42: ...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 43: ... Y N R A 1 Manuals and decals A 2 Pre operation inspect A 3 Check the Batteries A 4 Check the Engine Oil Level A 5 Check the Hydraulic Oil Level A 6 Check the Engine Coolant Level A 7 Function tests A 8 Engine maintenance Perform after 40 hours A 9 30 day service Perform after 50 hours A 10 Engine maintenance Perform every 250 hours A 11 Filter separator A 12 Engine maintenance Checklist B Y N R B...

Page 44: ... 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 ille...

Page 45: ... Manual on your machine A 3 Check the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine 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 in...

Page 46: ...0 Oil type cold conditions 0W 20 A 5 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems Perform this procedure with the platform in the stowed posi...

Page 47: ...tions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 8 Perform Engine Maintenance Engine specifications require that this procedure be ...

Page 48: ...t damage Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Note Perform this procedure with the engine off 1 Release the latches on the engine tray and fully slide the engine tray out 2 Insert a 15cm screwdriver or rod into the ...

Page 49: ...uel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately A 12 Perform Engine Maintenance Engine specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Required maintenance procedures and additional engine information is available in the engine operator s manual ...

Page 50: ...ntenance free or sealed batteries 5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 6 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 5 5 C above 26 7 C Subtract 0 004 from the reading of each cell for every 5 5 C below 26 7 C Result...

Page 51: ...pinched wires could result in unsafe operating conditions and may cause component damage Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the underside of the chassis for damaged or missing ground strap s 2 Inspect the following areas for burnt chafed corroded and loose wires Ground con...

Page 52: ...rn the safety arm to the stowed position 12 Lower the platform to the stowed position and turn the machine off B 3 Check the Exhaust System Dingli requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause co...

Page 53: ... on the engine tray and fully slide the engine tray out 3 Insert a 15cm screwdriver or rod into the engine tray hole located near the engine tray roller wheels to prevent the engine tray from moving 4 Locate and open the engine RPM test socket dust cover put the RPM sensor into the hole and tighten 5 Connection tachometer and sensor communication lines 6 When starting the engine idling speed meter...

Page 54: ...m lug nut torque lubricated 127 4Nm B 7 Check the Oil Level in the Drive Hubs Dingli requires that this procedure be performed every 250 hours or quarterly whichever comes Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 9...

Page 55: ...rn the key switch to the off position Result The engine should stop and no functions should operate B 9 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 mac...

Page 56: ...afe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Mark a test line on the ground for reference 2 Start the engine from the platform controls 3 Choose a point on the machine i e contact patch of a tire as a vis...

Page 57: ... at full speed and note the time when the machine reference point passes over the finish line The time is less than 7 2 sec B 13 Test the Drive Speed Raised Position Dingli requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operat...

Page 58: ...ions may require oil changes to be performed more often Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil B 15 Perfo...

Page 59: ...g a suitable lifting device place an appropriate test weight equal to the maximum platform capacity in the center of the platform floor Result The overload alarm at the platform controls should not sound indicating a normal condition Result The overload alarm at the platform controls sounds Calibrate the platform overload system 5 Add an additional weight to the platform not to exceed 30 of the ma...

Page 60: ...ance 56 Result All ground control functions should operate 11 Turn the key switch to platform controls and start the engine from platform controls 12 Test all machine functions from the platform controls Result All platform control functions should operate ...

Page 61: ...ds 4 Measure the thickness of each platform scissor arm wear pad at the non steer end of the machine Result The measurement is 8 mm or more Result The measurement is less than 5 16 inch 8 mm Replace both wear pads D 2 Check the Free wheel Configuration Dingli specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel conf...

Page 62: ... with minimum effort 12 Engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Raise the machine and remove the blocks Lower the machine Collision hazard Failure to engage the drive hubs could result in death or serious injury and property damage D 3 Replace the Drive Hub Oil Dingli specifications require that this procedure be performed every 1000 ...

Page 63: ... 59 D 4 Perform Engine Maintenance Engine specifications require that this procedure be performed every 1000 hours or annually whichever comes first Required maintenance procedures and additional engine information is available in the engine operator s manual ...

Page 64: ...ectrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 1 Disconnect the battery pack from the machine 2 Open the cover 3 Remove the oil drain plug...

Page 65: ...ifications require that this procedure be performed every 3000 hours Required maintenance procedures and additional engine information is available in the engine operator s manual E 4 Perform Engine Maintenance Engine specifications require that this procedure be performed every 4000 hours Required maintenance procedures and additional engine information is available in the engine operator s manua...

Page 66: ... replace the platform 26 26 Right Turn switch Fault Platform Right Turn Switch ON at power up Check the switch replace the platform 27 27 Drive Enable Sw Flt Platform Drive Enable Switch ON at power up Check the switch replace the platform 28 28 Off Neutral Drive Joystick Platform Joystick not in neutral ON at power up Check the switch replace the platform 31 31 Platform Choke Sw Fault Platform Ch...

Page 67: ...iring replace the valve 54 54 Up Coil Fault Power FET channel DOWN fails check the wiring replace the valve 55 55 Down Coil Fault Power FET channel RT fails check the wiring replace the valve 56 56 Right Turn Coil Fault Power FET channel LT fails check the wiring replace the valve 57 57 Left Turn Coil Fault Power FET channel LT fails check the wiring replace the valve 58 58 Brake Coil Fault Power ...

Page 68: ...annel RIGHT REAR OUTRIGGER fails check the wiring replace the valve 85 85 Outrigger Ext Coil Fit Power FET channel EXTEND OUTRIGGER fails check the wiring replace the valve 86 86 Outrigger Ret Coil Fit Power FET channel RETRACT OUTRIGGER fails check the wiring replace the valve 95 95 Machine Type Fauit Wrong Machine Type Selected Reinstall Machine Type OL 98 Platform Overload Platform Overload Fau...

Page 69: ...0 J 230bar 140bar 100bar W S W S W S W S Functi on valve 5805 0234 Accumulator NXQA L2 5 20 A LF Outrigger RF Outrigger RR Outrigger LR Outrigger Left Steer Cylinder Right Steer Cylinder Lower lift Cylinder Lift Counterpoise Valve 5805 0934S TP2 L1 L2 S1 LEV1 S2 LEV2 TP1 P AUXP PV1 CP1 RV1 CP2 SV1 CV1 ORF1 SV2 CR1 CR2 SV1a SV1b SV2a SV2b SV3 SV3a SV3b FR1 SV4 SV6 SV5 SV7 5805 0613 5805 0613 5805 0...

Page 70: ...CP1 RV1 CP2 SV1 CV1 ORF1 SV2 CR1 CR2 SV1a SV1b SV2a SV2b SV3 SV3a SV3b FR1 SV4 SV6 SV5 SV7 5805 0613 5805 0613 5805 0613 5805 0613 TP1 T P2 TP1 TP2 W S W S W S W S Function valve 5805 0234 Accumulator NXQA L2 5 20 A LF Outrigger RF Outrigger RR Outrigger LR Outrigger Left Steer Cylinder Right Steer Cylinder Lower lift Cylinder Upper lift Cylinder Lift Counterpoise Valve 5805 0934S Lift Counterpois...

Page 71: ...r 240bar L B E D 1 2 3 4 5 S A BRK T X1 A B Pump 5801 46 12 Oil cooler 5899 1312 Filter 5899 0711 Oil return valve 59 97011 Drive Valve 5805 0113 BRK T X1 A B BRK T X1 A B BRK T X1 A B 24bar SV8 SV9 RV1 HS1 LS1 ORF6 FD2 ORF3 ORF4 ORF5 FD3 FD1 ORF2 ORF1 a b LF Motor 5803 38 11 Filter WU 100 80 J Tank RF Motor 5803 38 11 RR Motor 5803 38 11 LR Motor 5803 38 11 ...

Page 72: ...wer Relay E Stop Switch KA 6 Emergency Lowering Relay 208b GN RD 16 204c YE 13 001A RD 13 KA2 Ignition HM HourM eter KA3 Preheat Relay K A1 Horn Relay K A4 Fan Relay H2 A larm 208b WH 20 GND8 BK 20 GND9 B K 16 2 1 211b WH VT 16 002 RD 16 211B WH 20 GND9 BK 16 209c RD 13 GND9 BK 16 001A RD 13 GND9 BK 16 GND7 BK 20 B K 16 RD 16 1 2 015 RD BU 16 003a RD BU 16 003c RD BU 16 003c RD BU 16 Outrigger Ext...

Page 73: ...OPERATOR S MANUAL with Maintenance Information Inspection and Repair Log 69 Inspection and Repair Log Date Comments ...

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