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OPERATOR’S MANUAL

with Maintenance Information

Schematic

Hydraulic Schematic

S0608-ACE S0808-ACE S0812-ACE

SV2

SV1

120bar

RV1

SV3

CV1

Pump

Tank

Filter

Function valve

Steer cylinder

Platform loading

(Option)

Lift

cylinder

Lower valve

Sensor

RV1=130bar(JCPT0808AC)

RV1=160bar(JCPT1008AC)

RV1=210bar(JCPT1012AC)

FR1

RV2

Filter

(S0608-ACE)

(S0808-ACE)

(S0812-ACE)

Содержание S06-HAE

Страница 1: ...Motor Drive Part Number SM0120117A_Rev1 2 Zhejiang Dingli Machinery Co Ltd First Edition July 2021 Printing WARNING THE MANUFACTURER SHALL NOT BE HELD LIABLE IN CASE OF FAULTS OR ACCIDENTS DUE TO NEG...

Страница 2: ...OPERATOR S MANUAL with Maintenance Information Version of the Record i Version of the Record Version Number Create Date SM0120117A_Rev1 0 2021 03 SM0120117A_Rev1 1 2021 04 SM0120117A_Rev1 2 2021 07...

Страница 3: ......

Страница 4: ...og 103 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...

Страница 5: ......

Страница 6: ...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 ident...

Страница 7: ...trical current Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Voltage Phase to Phase Minimum Safe Appr...

Страница 8: ...mum occupants Outdoor use 1 Platform allowable maximum load 230kg Extension deck allowable maximum load 113kg Maximum capacity S0608 ACE Maximum occupants Indoor use 2 Maximum occupants Outdoor use 1...

Страница 9: ...latform controls to free a platform that is caught snagged or otherwise prevented from normal motion by an adjacent structure All personnel must be removed from the platform before attempting to free...

Страница 10: ...battery must weigh 28 kg The batteries must weigh a minimum of 112 kg For S06 HAE ACE S0608 HAE ACE S0808 HAE ACE S0812 HAE ACE Each battery must weigh 30 kg The batteries must weigh a minimum of 120...

Страница 11: ...fall protection If occupant s of the platform are required to wear personal fall protection equipment PFPE due to job site or employer rules PFPE equipment and its use shall be in accordance with the...

Страница 12: ...the lead acid battery charger The lead acid battery cannot by the lithium battery charger Do not use the machine as a ground for welding Explosion and Fire Hazard Do not operate the machine or charge...

Страница 13: ...y the lithium battery charger Pressure relief valves are used as breathable plugs If open the pressure relief valves the battery will be destroyed The battery must always be kept clean and dry in orde...

Страница 14: ...educe the service life while lower temperatures reduce the available capacity 45 C is the upper limit temperature and is not permissible as an operating temperature The rated temperature range of lith...

Страница 15: ...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...

Страница 16: ...pockets 2 8 09310003 Decal Instructions Tie down point 4 9 09310002 Decal Instructions Lift point 4 10 09310233 Decal Instructions Maximum wheel load 710kg 4 11 09310064 Decal Notice Main power switch...

Страница 17: ...OPERATOR S MANUAL with Maintenance Information Decals 12 S06 HAE ACE 12 14 13 10 15 5 12 10 15 6 8 9 7 19 20 8 9 9 8 10 21 22 1 5 1 2 3 4 9 8 7 10 11 17 18 12 Safety tape 17 18 1 1 16 16...

Страница 18: ...OPERATOR S MANUAL with Maintenance Information Decals 13 S06 HAE ACE...

Страница 19: ...l Capacity 320kg 1 S1212 HAE ACE 09440038 Decal Label Capacity 250kg 1 S1412 HAE ACE 7 09440005 Decal Warning Use indoors only 1 S0808 HAE ACE S1212 HAE ACE S1412 HAE ACE 8 09430003 Decal Danger Keep...

Страница 20: ...0808 HAE 09640151 Decal Label S0812 ACE 2 S0812 ACE 09640152 Decal Label S0812 HAE 2 S0812 HAE 09640153 Decal Label S1012 ACE 2 S1012 ACE 09640154 Decal Label S1012 HAE 2 S1012 HAE 09640155 Decal Labe...

Страница 21: ...ANUAL with Maintenance Information Decals 16 12 15 13 13 5 15 1 2 3 4 5 1 1 1 6 14 15 17 8 19 20 13 9 13 19 20 22 23 11 12 11 8 9 10 11 12 10 11 12 8 9 8 9 16 7 21 Safety tape 8 18 18 S0608 HAE ACE S1...

Страница 22: ...OPERATOR S MANUAL with Maintenance Information Decals 17 S0608 HAE ACE S1412 HAE ACE...

Страница 23: ...OPERATOR S MANUAL with Maintenance Information Decals 18...

Страница 24: ...Maximum hydraulic pressure functions 180 bar System voltage 24 V Tire size 323 100 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value doe...

Страница 25: ...um hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not...

Страница 26: ...m hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not...

Страница 27: ...m hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not...

Страница 28: ...m hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not...

Страница 29: ...um hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not...

Страница 30: ...imum hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does n...

Страница 31: ...Maximum hydraulic pressure functions 180bar System voltage 24 V Tire size 323 100 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does...

Страница 32: ...hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not e...

Страница 33: ...hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not e...

Страница 34: ...um hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not...

Страница 35: ...m hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not...

Страница 36: ...um hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not...

Страница 37: ...um hydraulic pressure functions 240 bar System voltage 24 V Tire size 381 127 mm Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not...

Страница 38: ...tery capacity maximum 225Ah Maintenance free No S1012 ACE S1012 HAE standard Voltage 6VDC Type 6TB220 Quantity 4 Battery capacity maximum 220Ah Maintenance free Yes S1012 ACE S1012 HAE optional Voltag...

Страница 39: ...HAE S0808 ACE S0808 HAE S0812 ACE S0812 HAE optional Voltage 24VDC Type TFL24 180 DL3 Quantity 1 Battery capacity maximum 180AH Maintenance free Yes S1012 ACE S1012 HAE S1212 ACE S1212 HAE S1412 ACE S...

Страница 40: ...e red Emergency Stop button to the on position to operate the machine 3 Menu up button 4 Menu down button 5 Menu enter button 11 Key switch Turn the key switch to the platform position and the platfor...

Страница 41: ...Platform Control Panel 1 Function enable switch 6 Drive function select button 2 Thumb rocker switch 7 Drive speed button 3 Proportional control handle 8 LED readout screen 4 Horn button 9 Red Emerge...

Страница 42: ...unction on the platform control handle Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will move in the direction that the blue arrow points M...

Страница 43: ...iscover 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 requi...

Страница 44: ...anifolds 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 gat...

Страница 45: ...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...

Страница 46: ...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 te...

Страница 47: ...sounds at 180 beeps per minute An optional automotive style horn is also available 10 Do not press the function enable button 11 Press the platform up or platform down button Result No function should...

Страница 48: ...d 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 machin...

Страница 49: ...them 44 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 4...

Страница 50: ...ote The ultrasonic sensor system includes an ultrasonic sensor and its installation accessories which are fixed on the platform controller bracket to detect obstacles directly above to prevent the mac...

Страница 51: ...le ensuring that the ultrasonic sensor moves in line with the obstacle Result When the platform control is 1 5m away from the obstacle the platform will stop the lift function the alarm should continu...

Страница 52: ...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 cau...

Страница 53: ...dle 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...

Страница 54: ...ansported 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...

Страница 55: ...onsists of three fold down rail section for the extension deck and three sections for the main deck All sections are held in place by four wire lock pins 1 Fully lower the platform and retract the pla...

Страница 56: ...els do not limit the lift function 3 When the Ultrasonic sensor platform control panel is 1 5 meters away from the obstacle zone the lift function is disabled and the alarm will be constant After the...

Страница 57: ...bles All Motion 09 GPS Communication Fault Warning Only 10 MC Communication Fault Warning Only 11 BMS Communication Fault Warning Only 12 Chassis Up or Down Switch ON Disable Chassis Control 18 Pothol...

Страница 58: ...d Disable Lifting and Driving UP Platform up limit position Warning Only 102 Restore Parameters to Default Warning Only 103 Battery is draining Warning Only 104 Motor Controller Fault Warning Only 105...

Страница 59: ...RGE Controller Dependent 1062 2062 3062 TH PROTECTION Controller Dependent 1065 2065 3065 MOTOR TEMPERAT Controller Dependent 1066 2066 3066 BATTERY LOW Controller Dependent 1074 2074 3074 DRIVER SHOR...

Страница 60: ...END Controller Dependent 1174 2174 3174 OFFSET SPD SENS Controller Dependent 1175 2175 3175 SPEED FB ERROR Controller Dependent 1176 2176 3176 HOME SENS ERR XX Controller Dependent 1177 2177 3177 COI...

Страница 61: ...BRAKE RUN OUT Controller Dependent 1205 2205 3205 EPS RELAY OPEN Controller Dependent 1206 2206 3206 INIT VMN HIGH Controller Dependent 1207 2207 3207 INIT VMN LOW Controller Dependent 1208 2208 3208...

Страница 62: ...RV EV Controller Dependent 1233 2233 3233 POWERMOS SHORTED Controller Dependent 1234 2234 3234 DRV SHOR EV Controller Dependent 1235 2235 3235 CTRAP THRESHOLD Controller Dependent 1236 2236 3236 CURRE...

Страница 63: ...g temperature 3 Disables All Motion 4005 Low discharging temperature 2 Lift and Drive speed limit 4006 High discharging temperature 3 Disables All Motion 4007 Low discharging temperature 2 Lift and Dr...

Страница 64: ...and Drive speed limit 4030 Discharge cell voltage low 3 Disables All Motion 4031 Charge cell voltage low 2 Lift and Drive speed limit 4032 Charge cell voltage low 3 Disables All Motion 4033 Cell volta...

Страница 65: ...the entire charging cycle Maintenance free battery 3 Connect the battery charger to a grounded AC circuit 4 The charger will indicate when the battery is fully charged Standard Battery 5 Remove the ba...

Страница 66: ...harge the battery 5 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 Note In order to achieve an optimal s...

Страница 67: ...imum 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...

Страница 68: ...machine must be towed do not exceed 4 0 km h Securing to Truck or Trailer for Transit Always chock the machine wheels in preparation for transport Retract and secure the extension deck s Turn the key...

Страница 69: ...e 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...

Страница 70: ...he 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 mach...

Страница 71: ...to turn off the main power switch key switch and emergency stop switch fully charge In order to ensure that these batteries stay ready for operation the following charging procedures must be applied T...

Страница 72: ...electrode should be insulated when stored e g cover with protective cover to ensure that no metal part is exposed to prevent short circuit 5 If there are more than 10 groups of batteries in centralize...

Страница 73: ...h 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...

Страница 74: ...all 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 P...

Страница 75: ...y inspection receives an N tag and remove the machine 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 Checklis...

Страница 76: ...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...

Страница 77: ...ial to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Note This check is not required f...

Страница 78: ...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 f...

Страница 79: ...arge 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...

Страница 80: ...ttery charger Apply to S1012 S1212 S1412 Hydraulic Motor AC Motor Drive a 12V batteries b power switch c fuse d battery charger Suitable for lithium batteries 13 The connection between the electrode a...

Страница 81: ...rs Note If you have any further questions regarding the battery charger operation please contact the DINGLI Service Department B 2 Inspect the Electrical Wiring DINGLI requires that this procedure be...

Страница 82: ...ower the platform to the stowed position and turn the machine off B 3 Inspect the Tires and Wheels including castle nut torque DINGLI requires that this procedure be performed every 250 hours or quart...

Страница 83: ...osition Result No machine functions should operate Note The red Emergency Stop button at the ground controls will stop all machine operation even if the key switch is switched to platform control B 5...

Страница 84: ...ate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when not fully operational Perform this procedure with the machi...

Страница 85: ...on jerking and unusual noise over the entire proportionally controlled speed range Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Create start and finis...

Страница 86: ...reference point on the machine crosses the start line 9 Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to specifications B 10 Test...

Страница 87: ...he 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...

Страница 88: ...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 Perfo...

Страница 89: ...the LED readout screen shows code 18 an alarm sounds and the platform will lift to 2 4m or beyond The machine is functioning properly Result The pothole guard contacts the block and does not fully dep...

Страница 90: ...ressure transducer and the platform height sensor provide the GCON with necessary information to determine the load in the platform Note The overload system will not measure loads at or below the heig...

Страница 91: ...draulic Tank Breather Cap DINGLI requires that this procedure be performed every 500 hours or semi annually whichever comes first The hydraulic tank is a vented type tank The breather cap has an inter...

Страница 92: ...c chassis deck For S06 HAE ACE Result The measurement is 23mm or more Proceed to step 2 Result The measurement is less than 23 mm Replace both wear pads For S0608HAE ACE S1412HAE ACE Result The measur...

Страница 93: ...th hot oil may cause severe burns 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 th...

Страница 94: ...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...

Страница 95: ...ting 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...

Страница 96: ...A B B SV5 CV3 D3 D2 D1 D4 SV4 SV3 P M T BRK L S2 S1 LB B RB RV3 SV2 RV2 CB1 CV2 CV1 RV1 EC1 ORF7 ORF3 SV1 ORF1 ORF2 ORF5 ORF4 80bar Tank Filter Function valve Steer cylinder Platform loading Option L...

Страница 97: ...EC1 ORF7 ORF3 SV1 ORF1 ORF2 ORF5 ORF4 120bar Tank Filter Function valve Steer cylinder Platform loading Option Lift cylinder Lower valve Sensor Hand pump Motor Brake SV4 SV3 P M T BRK L S2 S1 1 5mm 2...

Страница 98: ...lift cylinder Lower valve Upper lift cylinder Lower valve Sensor Hand pump Motor Brake Motor Brake SV4 SV3 P M T BRK L S2 S1 LB B RB RV3 SV2 RV2 CB1 CV2 CV1 RV1 EC1 ORF7 ORF3 SV1 ORF1 ORF2 ORF5 ORF4 1...

Страница 99: ...enance Information Schematic 94 Hydraulic Schematic S06 ACE IN SV3 CV1 Pump Tank Filter Function valve Steer cylinder Platform loading Option Lift cylinder Lower valve Sensor FR1 RV2 150bar Filter P M...

Страница 100: ...8 ACE S0808 ACE S0812 ACE P M SV2 SV1 S1 S2 L T 120bar RV1 IN SV3 CV1 Pump Tank Filter Function valve Steer cylinder Platform loading Option Lift cylinder Lower valve Sensor RV1 130bar JCPT0808AC RV1...

Страница 101: ...SV1 S1 S2 L T 120bar RV1 Filter Function valve Steer cylinder Platform loading Option Lower lift cylinder Lower valve Lower valve Upper lift cylinder Sensor IN SV4 CV1 RV2 FR1 RV2 Filter RV1 150bar JC...

Страница 102: ...10 BK 18 A54 BK 18 10 54 RD 5 KM1 Pw In GN 18 Pw Out RD 18 A29 WH 20 29 102 BN 20 101 BN 20 GS1 003 1 RD 20 8 1 2 7 5 4 3 CANL1 3 GN 20 CANH1 3 YE 20 B RD 18 12 11 10 9 8 7 6 5 4 3 2 1 A11 WH 20 11 LO...

Страница 103: ...Pothole Switch Beacon Lift Down Limit Switch Angle Sensor Pressure Sensor Power_Key Power_Key PCU Power PCU Power Left Pothole Switch Beacon Power Power Right Pothole Switch Lift Down Switch Controlle...

Страница 104: ...e High speed valve Controller Power Pressure Sensor Pressure Sensor Hourmeter RD 5 KM1 Pw In GN 18 Pw Out RD 18 GND 1W WH 18 CANH1 4 YE 18 CANL1 4 BU 18 4 3 1 2 5 GN 18 RD 18 WH 18 YE 18 BU 18 4 3 1 2...

Страница 105: ...55 A56 BK 18 56 P 12A WH 20 12 A A21 WH 20 21 A21 WH 20 002 1G RD 20 P 03A RD 20 002 1B RD 20 002 1F RD 20 A24 WH 20 A47 WH 20 A20 WH 20 A32 WH 20 1 2 1 2 CANH1 5 YE 20 CANL1 5 GN 20 002 2 RD 16 002 2...

Страница 106: ...8 WH 20 GND 2A BK 20 1 2 3 4 5 GND BK 14 002 2C RD 20 A29 WH 20 SQ3 A29 WH 20 A29 WH 20 29 102 BN 20 101 BN 20 003 1 RD 20 8 1 2 7 5 4 3 CANL1 3 GN 20 CANH1 3 YE 20 LOCK BU 20 1 4 3 2 FU4 10A BATT BAT...

Страница 107: ...2 2B RD 20 A26 WH 20 A23 WH 20 GND 2B BK 20 A21 WH 20 GND 2 BK 18 A18 WH 20 GND 2A BK 20 1 2 3 4 5 GND BK 14 002 2C RD 20 A29 WH 20 SQ3 A29 WH 20 A29 WH 20 29 102 BN 20 101 BN 20 003 1 RD 20 8 1 2 7 5...

Страница 108: ...A BF B P 22A WH 20 P 05A BU 18 P 25A BN 20 P 13A WH 20 P 14A WH 20 4 1 3 2 BU 20 BU 20 P A06 RD 20 A07 WH 20 SQ2 GND 1R BK 18 GND GND A10 BK 18 A54 BK 18 10 54 A30 WH 20 30 A30 WH 20 BK 5 175A B P 10A...

Страница 109: ...WH 20 GND 2 BK 18 A18 WH 20 GND 2A BK 20 1 2 3 4 5 L N PE GND BK 14 GB1 002 2C RD 20 A29 WH 20 SQ3 A29 WH 20 A29 WH 20 29 RD 2 C E L K D F M 24V BMS 102 BN 20 101 BN 20 C CANL GN 20 C CANH YE 20 V CA...

Страница 110: ...OPERATOR S MANUAL with Maintenance Information Schematic 105 Inspection and Repair Log Date Comments...

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