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Maintenance

1. Upper lift Cylinder Platform y Overload E steer Cylinder b Pd Xf 5 1 Pump X T N Filter ES 7 Tank o 61 OPERATOR S MANUAL with Maintenance Information Schematic Hydraulic Schematic 9 5 2100 AMWP11 2100 Upper lift Cylinder Platform Overload Option Upper lift Cylinder steer Cylinder X SP1 62 Schematic OPERATOR S MANUAL with Maintenance Information
2. 14 AMWP9 5 2100 1 9424127 Crushing Hazard look im Ehe direction of movement 2 Keep clear of absbruetians 3 Kaep al body paris made plato during operation Failure t follow instructions result in dealh nr senus injury Falling Hazard Keep both Fee platform 2 Dra climb aid or sland on plalfprm guard rasis 3 Enaura eniramce area i Propel rity closad 4 use planks ladders of Hem platform io get added reach 5 All guard rails must be proporty inziallad during operation Falling fram plationm could cause death or serious injury 5424127 3 9424133 Tip over Hazard 1 Do mot excagad pigtlorm raised capacity or rabod ef paaple Eveenly diadribula land 2 mot expase t winds or honrontial forces 3 Machine must on Term and level surface balore p ntlarm 4 reot raise plalform when on unavan er aot turac chiding Ficka ballari curs scaffolds of ximil r d t 5 mat more machane naar drap offa holes nr oer hazards 6 Make sure operating surface will support the machine 7 all ans imn go
3. 12 40 D 2 1 Platform entry mid rail 8 Motor Pump Reservoir Unit located under the cover and not 2 Platform controls displayed 3 Platform 9 Ground Control 4 Front Wheel 10 Cover 5 Chassis 11 Masts Assembly 6 Pothole device 12 Platform guard rails 7 Rear Wheel OPERATOR S MANUAL with Maintenance Information Decals Decal Inspection Use the pictures on the next page to verify that all decals are legible and in place Below is a numerical list with quantities and descriptions For AMWP8 1100 AMWP9 5 1100 Description Qty 1 9424127 Warning Crushing Hazard Falling Hazard 2 9414111 Caution Max Manual Force 200N 3 9424125 Warning Tip over Hazard 4 9324011 Label Platform entry operating instructions 5 9314011 Lanyard Anchorage 9124015 Platform Console Panel 7 9424123 Warning Tip over Hazard 9424121 Electrocution Hazard 9 9423013 Warning Crushing hazard 10 9424119 Danger Tip over Hazard 9424031 Label Capacity 150kg With extend platform For AMWP8 1 100 9424023 Label Capacity 150kg Standard platform 9424029 Label Capacity 125kg With extend platform For AMWP9 5 1100 9424027 Label Capacity 125kg S
4. 103 YOLVOIGNI QVOTH3AO VV V V V VN V V V V V V V V V VY VV 96 Yo Y8 27 2 Y2 01201 98 I X 26 ds 6 Vp 00 qr 52 99 9 d do JI al ee aul l i Qc ina E gt Org Ogo OF S og D gt P gt gt 28229 8899 S28 o 8 2 5 8 9988 2 5 i 8 2 d lt lt lt SZZ cS gt E gt ZC lt S 2 91 1 8Z 5 lt lt HOLO3NNOO NOILISOd9 gt 17 gt 82253 9 lt Sein lt g 2 m 52686 m JMA 1331 3 Qs _ ane ee Em ax e cM ES E 072 HOLO3NNOO 0 91 gt gt q 7935 292525 oa o 2 2 SU mo 2 91 LWN 24 2 gt a SF vy T 5T AAWA LHS 18 UY 4 LAA AAWA dn rant 00L2 S8 6HMINV 0012 06 2 i t 001 L S 624MIAV 001 L 8dMIAV Ug 3AT1VA 1411 peijddy si Buimesq 9u deco 1 S DUIMEJ 9JON os le 0 0c gas RE TT a 4 WH 91 Z AN9 gt 80 4322719 2 0 ig 5 91 M8 gt gt 25 ASIMYSHLO 960 NaOH gt G3LON SSIINN Uuug 0 LH HOSN3S HO 9MV8I SAMIM TIV 310N 3216 91 GU ND 1 06 51 4 91 LAWN 2 90 5 5 HOLIMS LOALOYd 310H1Od LHOlH YOS
5. Result No functions should operate 7 Pull out the red Emergency Stop button to the on position Test Up Down Functions A buzzer with different sound frequency is controlled in central system The descent alarm sounds at 60 beeps per minute The alarm that goes off when the machine is not level sounds at 150 beeps per minute An optional automotive style horn is also available 8 Turn the key switch to off or platform position 9 Move up and hold the platform up down switch Result No function should operate 10 Turn the key switch to ground control position 11 Move up and hold the platform up down switch Result The platform should raise 12 Move down and hold the platform up down switch Result The platform should lower Test the Emergency Lowering 13 Activate the up function and raise the platform approximately 60 cm 14 Pull the emergency lowering knob Result The platform should lower The descent alarm will not sound 15 Turn the key switch to platform control At the Platform Controls Test Emergency Stop 16 Push in the platform red Emergency Stop button to the off position Result No functions should operate 17 Pull the red Emergency Stop button out to the on position 2 Result The LED indicator light should come on Test the Horn 18 Push the horn button Result The horn should sound Test Function Enable and Up Down Functions 19 Do
6. g or soft surfaces including trucks trailers railway cars floating vessels scaffolds or samiliar areas 5 Do not move machine near drop offs holes or other hazards 8 Make sure operating will support the machine 7 Make sure ali tires are in good condition Death or serious injury could occur from a tip over 4 9324011 Su Dingi Chassis 9424129 Self Propelled 45 9514201 3 9311015 Vertical Lits DANGER 5 SGSC Tip over Hazard Q H sounds unit is on a severe Work Pressure to level surface lope Death or Manual Force 44 93 1 1 03 1 serious njury the 2 Move the machine Max Wheel Load 450 kg Dwerat Dumansson ower 9514301 9311017 Crushing hazard 1 Keep hands and limbs out of mas EMERGENCY LOWER 2 Make sure tha Chock in Pull knob to lower platform place during maintenance 3311017 4233013 47 9421019 16 AMWP8 1100 Height working maximum Height platform maximum Height stowed maximum Height guard rails Width Length platform retracted Platform dimensions Platform length x width Maximum load capacity Maximum wind speed Wheelbase Turning radius outside Turning radius inside Ground clearance Weight Machine weights vary with option configurations Power source Controls AC outlet in platform Maximum hydraulic pressure functions System voltage OPERATOR S MAN
7. 9 5 1100 Platform 2 9414111 CAUTION ERG ONES Thin machina ix intended ina 7 9424123 1 9424127 Costin Haza Id Max Manual Force USE INDOORS ONLY and miast mot ba ubod outdoors clear al abatructinna J Keap all body parts iade plationn during egeration Failure jo follow instructions Gould result in death or serious injury wend forces may make unsitatle Falling H Hazard WAZ allowed wind 0 mia i Keep bath feat platform fiac Don jim ait ar on pln atio nmm giard raila naurg mntra aram is properly cle fh oF dla ibama im te a praparhy i du Falling from platfarm could cause deaih or serious 24241317 Electrocution Hazard This machina not inmauladasd Keup a away if machine is neni al jites OF equapment 5 9314011 becomes Shaheed Tip over Hazard 9424111 in nar excaed pinrtform eapnciy or raped number Gig Veils haad i pig platform winds or horizoniad forces h achims mi on Firm amd aurada before a S S tevaning plalform 0514201 Jo na uneven Mapang or 5 ing nal plainer an ur 9514301 inchodin radars raiteay can Moanin vessels scafint simmar mani Da nat mie
8. 91 xia M KEN on aun 11 INA cao 99 1531 Electrical Schematic 63 OPERATOR S MANUAL with Maintenance Information Inspection and Repair Log Inspection and Repair Log
9. Checklist C Procedures C 1 Test the Platform Overload System if equipped DINGLI requires that this procedure be performed every 500 hours or six months whichever comes first or when the machine fails to lift the maximum rated load Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over this procedure with the machine on a firm level surface 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Determine the maximum platform capacity 3 Using a suitable lifting device place appropriate test weight equal to the maximum platform capacity in the center of the platform floor 2 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 4 Addan additional weight to the platform not to exceed 1096 of the maximum rated load 2 Result The overload alarm at the platform controls sound indicating a normal condition Result The overload alarm at the platform controls does not sound Calibrate the pla
10. INSTANT NORGE AS AERE A Dingi Machinery 120380802 008 PDE USER MANUAL OPERATOR S SAFETY AND MAINTENANCE AERIAL WORK PLATFORM 1 100 AMWP9 5 1 100 AMWP9 5 2100 AMWP 11 2100 A Cl WARNING B 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 OPERATOR S MANUAL with Maintenance Information Version of the Record Version of the Record 5 0509111 _Rev1 0 2009 05 Jinchu Lu 5 0509111 2 0 2011 06 Jinchu Lu Important Read understand and obey these safety rules OPERATOR S MANUAL with Maintenance Information and operating instructions before operating this machine Only trained and authorized personnel shall be permitted to operate this machine This manual should be considered a permanent part of your machine and should remain with the machine at all times If you have any questions please call DINGLI Machinery Contents Page Safety Rules 1 Legend 7 Decals 9 Specifications 17 Control panel 21 Pre Operating Instructions 24 Workplace Inspection 26 Function Tests 27 Operating Instructions 31 Transport and Lifting Instructions 39 Maintenance 40 schematic 61 Inspection and Repair Log 64 Owners Users an
11. 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Inspect the workplace 4 Always perform function tests prior to use Know and understand the function tests before going on to the next section 5 Only use the machine as it was intended 2 Function Tests 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 qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection and function tests again before putting the machine into service OPERATOR S MANUAL with Maintenance Information Function Tests 1 Select a test area that is firm level and free of obstruction 2 sure the battery pack is connected At the Ground Controls 3 Pull out the platform and ground red Emergency Stop buttons to the on position 4 Turn the key switch to ground control 5 Observe the diagnostic LED readout on the ECU window CO Result The LED should look like the picture at right Test Emergency Stop 6 Push in the ground red Emergency Stop button to the off position
12. Maximum capacity Model load occupants AMWP8 1100 150kg 1 AMWP9 5 1100 125kg 1 AMWP9 5 2100 200kg 1 AMWP 11 2100 150kg 1 Work Area Safety Do not raise the platform unless the machine is on a firm level surface Do not drive over 1 1km h with the platform raised Do not depend on the tilt alarm as a level indicator The tilt alarm sounds on the chassis and in the platform when the machine is on a slope OPERATOR S MANUAL with Maintenance Information If the tilt alarm sounds Lower the platform Move the machine to a firm level surface If the tilt alarm sounds when the platform is raised use extreme caution to lower the platform Do not use the platform 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 the platform using the ground controls Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain debris unstable or slippery surfaces and near holes and drop offs Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the platform raised Do not push off or pull toward any object outside of the platform Maximum allowable manual force 200N Do not use the machine as a crane Do not place or attach fixed or overhanging loads to any part of this machine Do n
13. Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection e Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours e A Inspection E Quarterly or 250 hours A B Inspection E semi annually or 500 A B C hours Inspection E Annually or 1000 hours A B C D Inspection Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an 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 43 Checklist A A 1 Inspect the manuals and decals A 2 Pre operation inspection A 3 Function tests Perform after 40 hours A 4 30 day service Perform every 100 hours A 5 Grease steer yokes Checklist B B 1 Batteries B 2 Electrical wiring B 3 Tires and wheels B 4 Emergency stop B 5 Lifting Chains B 6 Clean and Lubricate the Columns B 7 Test the up limit switches B 8 Key switch B 9 Horn if equipped B 10 Drive brakes B 11 Drive speed stowed B 12 Drive speed raised B 13 Hydraulic oil analysis B 14 Tank venting system Checklist C
14. Move the switch down and the platform will lower 2 Hour meter 6 Key switch for platform off ground control selection 3 Red Emergency Stop button 7 Turn the key switch to the platform position Push in the red Emergency Stop button to and the platform controls will operate Turn the off position to stop all functions Pull out the key switch to the off position and the the red Emergency Stop button to the on machine will be off Turn the key switch to position to operate the machine the base position and the ground controls will operate 4 7 amp breaker for electric circuits 7 Brake release switch 21 OPERATOR S MANUAL with Maintenance Information Control Panel Platform Control Panel 1 Thumb rocker switch for steer functions 2 Drive function select button 3 Drive speed button 4 Emergency Stop button 5 LED 22 Horn button Lift function select button Proportional control handle Function enable switch for lift and drive functions OPERATOR S MANUAL with Maintenance Information Platform Control Panel 1 Thumb rocker switch for steer functions Press the thumb rocker switch in either direction to activate steer function Drive function select button Press this button to activate the drive function Drive speed button Press this button to activate the slow or fast drive function Red Emergency Stop button Push in the red Emergency Stop button to the off position to sto
15. lithium based or equivalent OPERATOR S MANUAL with Maintenance Information Checklist B Procedures B 1 Inspect the Batteries DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first 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 A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry A WARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Besure that the battery retainers and cable connections are tight 4 Fully charge 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 Maintenance 5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 6 Check the am
16. Turn the key switch to ground control 2 Pull out both ground and platform red Emergency Stop buttons to the on position 3 sure the battery pack is connected before operating the machine To Position Platform 1 Move the up down switch according to the markings on the control panel Drive and steer functions are not available from the ground controls Operation from Platform 1 Turn the key switch to platform control 2 Pull out the ground and platform red Emergency Stop buttons to the on position 3 sure the battery pack is connected before operating the machine To Position Platform 1 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 Press the drive function select button 2 Press and hold the function enable switch on the control handle 3 Increase speed Slowly move the control handle off center Decrease speed Slowly move the control handle toward center Stop Return the control handle to center or release the function enable switch Use the color coded direction arrows on the platform controls and on the platform to identify the
17. are designed to discover any malfunctions 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 OPERATOR S MANUAL with Maintenance Information Maintenance A 4 Perform 30 Day Service The 30 day maintenance procedure is time procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures B 3 Inspect the Tires Wheels and Castle Nut Torque 46 A 5 Grease 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 multipurpose grease into the steer yoke until the steer yoke is full and grease is being forced past the bearings 4 Install the cover 5 Repeat this step for the other steer yoke Grease Specification Chevron Ultra duty grease EP NLGI 1
18. be no lower 2 the middle link of the mast than specification 3 the transmission chain Result The machine should be lower than specification 4 adjusting bolt The following sketch shows the connection of o adjusting lock nut the masts and the transmission chain 6 chainwheel 7 chainwheel shaft 8 the last link of the mast 3 When regulating the length of the chain please select the mast that needs increasing its height As shown in the sketch regulating the nut 5 tightly makes the last link of the mast 8 move upwards The dual nuts 5 should be connected with each other tightly after regulating the length of the chain 51 OPERATOR S MANUAL with Maintenance Information Maintenance 4 The same link of the mast is pulled by two chains and endures the raised weight loads at the same time If one of the chains loses efficacy the other will play an important safety role therefore try to make both chains as loose or tight as consistent each other when regulating the length of the chain The methods of judge at site are as follows Press the two chains by hands to compare their tautness under lifting status AWARNING Make sure the chock is in place during maintenance A WARNING When the work platform of a GTWY needs to be raised for routine servicing purposes a captive chock shall be used to enable the extending structure to be held in the required position to prevent work platform B 6 Clea
19. ground 12 2 m apart 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Press lift function select button lt gt OA affa 00 pg lift function select button b drive function select button 56 Press and hold the function enable switch on the joystick Raise the platform approximately 1 2 from the ground Press the drive function select button Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full soeed and note the time when your reference point on the machine passes over the finish line Refer to specifications OPERATOR S MANUAL with Maintenance Information B 13 Perform Hydraulic Oil Analysis DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oi
20. measure the distance from the bottom of the piece of wood to the ground Divide the tape measure distance rise by the length of the piece of wood run and multiply by 100 Example Run 3 6 m Rise 0 3 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 33 OPERATOR S MANUAL with Maintenance Information Operating Instructions Error indicator readout If the LED diagnostic readout displays an error code such as LL push in and pull out the red Emergency Stop button to reset the system List of Fault Codes Display Description Lift Reaction 01 System initialization Fault May display 10 on PCU Disables All Motion 02 System communication Fault May display 20 on PCU Disables All Motion 03 Invalid option setting Fault Disables All Motion 10 As seen on PCU System initialization Fault Disables All Motion 12 Chassis Up Down Switch ON at Power up Disable Chassis Control 18 Pothole Guard Fault Disable Lifting and Driving 20 As seen on PCU System communication Fault Disables All Motion 31 Pressure Sensor Fault Disables All Motion 32 Angle Sensor Fault Disables All Motion Disables Drive Fast and 36 Battery Low Fault Lifting functions 42 Platform Left Turn Switch ON at power up Message Diagnostic Message Only 43 Platform Right Turn Switch ON at power up Message Diagnostic Message Only 46 Platfo
21. nut torque DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion 1 Check the tire surface and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks 50 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 the ground controls will override the platform controls except the platform red Emergency Stop button 1 the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Push the red Emergency Stop button at the ground controls to the off position Result No machine functions should operate 3 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and p
22. on a firm level surface that is free of obstructions 1 Create start and finish lines by marking two lines on the ground 12 2 m apart 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to stowed position 4 Press the 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 start and finish lines 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to specifications OPERATOR S MANUAL with Maintenance Information Maintenance B 12 Test the Drive Speed Raised Position DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation 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 finish lines by marking two lines on the
23. the coil itself to see if it is open or shorted Left Turn Coil Fault Check the connections to the Coil s terminals and make sure they are tight If so check the coil itself to see if it is open or shorted General Brake Coil Fault Check the connections to the Coil s terminals and make sure they are tight If so check the coil itself to see if it is open or shorted Motor Controller Current Sensor Fault Drive or Lift Motor may be overheating Let the lift cool down If that does not help cycle power to reset the Motor controller If the problem persists check the wiring and if OK try replacing the Motor Controller Motor Controller Hardware Failsafe Fault Cycle power If that does not resolve the issue check for noise sources If still needed try replacing the Motor Controller Motor Controller SRO Fault Look at motor enable delay with the Dingli Programmer it may be too short Make sure other Motor Controller parameters are properly selected Steering or Speed Input Voltages out of Acquired range The steering voltages may need to be re Acquired or the entire ZAPI parameter set re loaded or firmware defaults re written 36 Display 68 69 70 71 73 74 75 76 77 78 80 81 82 83 90 99 OL LL OPERATOR S MANUAL with Maintenance Information Operating Instructions Description Unsafe Power Conditions or Interruptions Check battery voltage and charge batteries if necessar
24. the machine weight See the serial plate for the machine weight 39 Brake Release Operation 1 Chock the wheels to prevent the machine from rolling Pull out the red Emergency Stop button on both the ground and platform controls to the on position Press the brake release switch to on position Press and hold lift switch to down position in ground control meanwhile turn on the key switch to the Ground position The brake will be released after Alarm alerts If you want to close the brake release just turn off the key switch in ground position Push the red Emergency stop button on both the ground and platform controls to the off position If the machine must be towed do not exceed Akm h OPERATOR S MANUAL with Maintenance Information Transport and Lifting Instructions 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 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 40 Lifting the Machine with a Forklift Be sure the extension deck controls and component trays are secure Remove all loose items on the machine Fully lower the pl
25. 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 been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements OPERATOR S MANUAL with Maintenance Information Maintenance Pre delivery Preparation Report Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently
26. wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in this manual 42 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 each part is completed Follow the instructions in the operator s manual If any inspection receives remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Pre Delivery Preparation Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company OPERATOR S MANUAL with Maintenance Information Maintenance Maintenance Inspection Report
27. Beyond Safe Limits Fault If the machine is tilted find a way to make it level If the machine is level check the wiring to the tilt sensor and then the sensor itself For more information please consult the appropriate Dingli Service Dept 3 OPERATOR S MANUAL with Maintenance Information Operating Instructions Battery and Charger Instructions Observe and Obey Do not use an external charger or booster battery Charge the battery in a well ventilated area Use proper AC input voltage for charging as indicated on the charger Use only a Dingli authorized battery and charger To Charge Battery 1 gt sure the battery is connected before charging Maintenance free battery 2 Connect the battery charger to a grounded AC circuit 3 charger will indicate when the battery is fully charged Standard Battery 4 Remove the battery vent caps and check the battery acid level If necessary add only enough distilled water to cover the plates Do not overfill prior to the charge cycle o Replace the battery vent caps 6 Connect the battery charger to a grounded AC circuit 7 he charger will indicate when the battery is fully charged 8 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 the battery vent caps and permanently remove the
28. C 1 Platform overload C 2 Breather cap models with optional oil Checklist D D 1 Hydraulic oil OPERATOR S MANUAL with Maintenance Information Maintenance Checklist A Procedures A 1 Inspect the Manuals and Decals Maintaining the operator s manual in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator manual is present and complete in the storage container on the platform Examine the pages of manual to be sure that they are legible and in good condition 2 Result The operator 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 illegible Remove the machine from service until th
29. UAL with Maintenance Information 8 0m 6 0m 1 99m 1 1m 0 76m 1 41m 0 78x0 70m 150kg m s 1 07m 1 55m 0 1010kg 2x12V 120AH Proportional Standard 180bar 24V Specifications Driving wheels 305x100mm Airborne noise emissions lt 0dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s Maximum slope rating Stowed position 25 Maximum side slope rating 10 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope X 1 5 Y 3 Drive speeds otowed maximum 4 0km h Platform raised maximum 1 1km h Floor loading information Tire load maximum 350 kg Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation OPERATOR S MANUAL with Maintenance Information Specifications AMWP9 5 1100 Height working maximum Height platform maximum Height stowed maximum Height guard rails Width Length platform retracted Platform dimensions Platform length x width Maximum load capacity Maximum wind speed Wheelbase Turning radius outside Turning radius inside Ground clearance Weight Machine weights vary with option configurat
30. UAL with Maintenance Information Safety Rules Avoid electrical shock from contact with battery terminals Remove all rings watches and other jewelry Tip over Hazard Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh 28 kg 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 the off position and remove the key to secure from unauthorized use 4 Chock the wheels 5 Charge the batteries Legend 8 1100 9 5 1100 1 Platform entry mid rail 2 Platform controls 3 Platform 4 Front Wheel 5 Chassis 6 Pothole device 7 Rear Wheel OPERATOR S MANUAL with Maintenance Information M PN _ ut 10 11 12 Legend Motor Pump Reservoir Unit Clocated under the cover and not displayed Ground Control Cover Masts Assembly Platform guard rails OPERATOR S MANUAL with Maintenance Information Legend 9 5 2100 AMWP11 2100
31. X Z lt 91 Lng 1 901 HOLIMS LOALOYNd AIOHLOd 1451 OS gt m m am m I D 9 Qo b 91 1 811 8 Bn zd n S HOLIMS LINIT dA LANT E 2 M JI ZR Q oo e N X 91 n8 N9 1 22 HOLIMS LINITNMOG 141 ZOS 36 36 38 e ue 9 A C 25200 YOLVOIGNI HOLVOIQONI YOLVOIGNI Q3ads A M NOOV38 SMO anya ONIHSV14 A gt at 91 au na i CS Dv E 4 91 LINO 4 1 9 4 YOSNAS m94 quina z oLo NOd U oe 91 1 010 xog A HOLIMS A3M 2 JOHINOO 2 71 aH 00 Q INHOZILIV 1d 91 00 24 91 1 00 71 9 au na amp 00 gt Q e E HOLIMS gt ras Puls 2 UJ 88842 2 5 ao Sue 00 5 2 269 Zz k el Ob ol LE Irk R HOLIMS 3 vose y PE gt v 100 v 1 100 3 00 lt gt ISN vn MOLOVINOO ES 91 5 600 lt lt 9 00 12 e kd A m 4 2 2 NN Ri n YOLOW 1431 YO LOW ANSLIVS AY3LLYg T 91
32. aca during maintenance 433055 EB OPERATOR S MANUAL with Maintenance Information Decals AMWP11 2100 1 9424127 Crushing Hazard 1 Always look in the direction of movement 2 Koop clear of obstructions 2 Keep all body parts intide plarf rm during operation Failure to follow instructions could result in death of senous injury Falling Hazard Platform 2 9414111 A CAUTION Max Manual Force 7 9424131 Tip over Hazard This machine is intended for USE INDOORS ONLY and must not be used outdoors as wind forces may make it unstabie allowed wind speed 0 mis 2412 1 Keep both feet on platform 2 Do not climb ait or stand on platform guard rails 3 Ensure entrance area is property closed 4 Do not use planks ladders or similar items in platform 10 gut added reach 5 All quard rails must be properly imatalled during operation Falling from platform could cause death or serious injury 2424127 Electrocution Hazard This machine ts not insulated Keep away machine is near electrical lines oc equipment Death or sarious injury will from contact with machene if it becomes electrically charged Tip over Hazard 4741 Do not exceed ptatform rated capacity or rated mumber of people Evenly distribute load 2 Do not expose platform 10 winds or honzontal forces Machine mus be on firm and tevel surface before elevating platform Do not raise platform when on uneven
33. aintenance Information Workplace Inspection Do Not Operate Unless Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations workplace 2 Always perform a pre operation It is the operator s responsibility to read and inspection remember the workplace hazards then watch 3 Inspect the workplace for and avoid them while moving setting up and operating the machine Know and understand the workplace inspection before going on to the next 90 Workplace Inspection 4 Always perform function tests prior to use Be aware of and avoid the following hazardous situations 5 Only use the machine as it was Drop offs or holes Bumps floor obstructions or debris Sloped surfaces Unstable or slippery surfaces Overhead obstructions and high voltage conductors Hazardous locations Inadequate surface support to withstand all load forces imposed by the machine The presence of unauthorized personnel Other possible unsafe conditions 26 OPERATOR S MANUAL with Maintenance Information Do Not Operate Unless You learn and practice the principles safe machine operation contained in this operator s manual
34. atform 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 Raise the machine 6 in 15 cm and then tilt the forks back slightly to keep the machine secure Be sure the machine is level when lowering the forks NOTICE Lifting the machine from the side can result in component damage OPERATOR S MANUAL with Maintenance Information Observe and Obey Only routine maintenance items specified in this manual shall be performed by the operator Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in this manual Maintenance Symbols Legend NOTICE The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform this procedure 41 Maintenance Pre delivery Preparation Report The pre delivery preparation report contains checklists for each
35. bient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 5 5 C above 26 77 Subtract 0 004 from the reading of each cell for every 5 5 C below 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 10 Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 7 7 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hours 8 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 9 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 5 5 C above 26 7 C e Subtract 0 004 from the reading of each cell for every 5 5 below 26 77 2 Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 10 OPERATOR S MANUAL with Maintenance Information Maintenance Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery 10 Check the battery acid level If needed replenish with distilled water to 3 mm below th
36. d in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the pre operation inspection before going on to the next section 3 Inspect the workplace 4 Always perform function tests prior to use 5 Only use the machine as it was intended 24 Fundamentals It is the responsibility of the operator to perform a pre operation inspection and routine maintenance The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to 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 from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer
37. d operators Dingli appreciates your choice of our machine for your application User s safety is our priority SO we hope you can 1 Comply with employer job site and governmental rules Read understand and follow the instructions in this and other manuals supplied with this machine Use good safe work practices in a commonsense way Only have trained certified operators directed by informed and knowledgeable supervision running the machine If there is anything in this manual that is not clear or which you believe should be added please contact us Contact us Manufacturer s address ZheJiang Dingli Machinery Co Ltd 1255 Baiyun South Road Leidian Town Deaing Zhejiang China Importer INSTANT NORGE AS Enebakkveien 441 B 1290 OSLO Norway Tel 23 19 11 00 Fax 23 19 11 01 E mail post instant no Web www instant no www dingli eu OPERATOR S MANUAL with Maintenance Information Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Know and understand the safety rules before going on to the next section 2 Always perform pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was
38. direction the machine will travel Machine travel speed is restricted when the platform is raised Battery condition will affect machine performance Machine drive speed and function speed will drop when the battery level indicator is flashing To reduce drive speed The drive controls can operate in two different drive speed modes When the drive speed button light is on slow drive speed mode is active When the button light is off fast drive speed mode is active Press the drive speed button to select the desired drive speed OPERATOR S MANUAL with Maintenance Information Operating Instructions A Driving on a slope See Transport and Lifting section Determine the slope and side slope ratings for the machine and determine the slope grade AMWP8 1100 AMWP9 5 1100 9 5 2100 AMWP11 2100 Maximum slope rating stowed position 25 Maximum side slope rating stowed position 10 Note Slope rating is subject to ground conditions and adequate traction Press the drive speed button 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 1m 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 While holding the piece of wood level
39. e manual is replaced Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage 44 2 Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manual to the storage container after use Note Contact your authorized DINGLI distributor or DINGLI Industries if replacement manuals or decals are needed OPERATOR S MANUAL with Maintenance Information A 2 Perform Pre operation Inspection Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to 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 Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine 45 Maintenance A 3 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests
40. e bottom of the battery fill tube Do not overfill 11 Install the vent caps and neutralize any electrolyte that may have spilled All models 12 Check each battery pack and verify that the batteries are wired correctly 13 Inspect the battery charger plug and pigtail for damage or excessive insulation wear Replace as required 14 Connect the battery charger to a properly grounded 110 230V 50 60 Hz single phase AC power supply 2 Result The charger should operate and begin charging the batteries Result If simultaneously the charger alarm sounds and the LEDs blink correct the charger connections at the fuse and battery The charger will then operate correctly and begin charging the batteries Note For best results use an extension of adequate size with a length no longer than 15m Note If you have any further questions regarding the battery charger operation please contact the DINGLI Service Department 48 OPERATOR S MANUAL with Maintenance Information B 2 Inspect the Electrical Wiring DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage A WARNING Electrocution burn hazard Con
41. e steer wheels should turn in the direction that the white right arrow points on the control panel Test Drive and Braking 30 Press and hold the function enable switch on the control handle 31 Slowly move the control handle in the direction indicated by the blue up arrow on 29 Function Tests the control panel until the machine begins to move then return the handle to the center position 2 Result The machine should move in the direction that the blue up arrow points on the control panel then come to an abrupt stop 32 Press and hold the function enable switch on the control handle 33 Slowly move the control handle in the direction indicated by the yellow down arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the yellow down arrow points on the control panel then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Test Limited Drive Speed 34 Press the lift function enable switch Raise the platform approximately 2m from the ground 35 Press and hold the function enable switch on the control handle 36 Slowly move the control handle to the full drive position Result The maximum achievable drive speed with the platform raised should not exceed 20 cm s Result If the drive speed with the platform raised exceeds 20 cm s im
42. en removing the rail pins Do not allow the platform guard rails to fall OPERATOR S MANUAL with Maintenance Information Safety Rules A Operation on Slopes Hazard Do not drive the machine on a slope that exceeds the slope and side slope rating of the machine Slope rating applies to machines in the stowed position Maximum Maximum side Model slope rating X slope rating stowed stowed position position AMWP8 1100 25 10 9 5 1100 25 10 9 5 2100 25 10 9 5 2100 25 10 Note Slope rating is subject to ground conditions and adequate traction A Fall Hazard The guard rail iA yee provides fall protection During operation occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point Attach only one 1 lanyard per lanyard anchorage point Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times Do not climb down from the platform when raised Keep the platform floor clear of debris Close the entry gate before operating Do not operate the machine the entry gate is secured for operation A Collision Hazard Be aware of limited sight distance and blind spots when driving or operating Operators must comply with employer job site and governmental rules regarding use of personal protective equipment Check the work area for overhead obs
43. ensing Angle Sensor Fault Check the wiring to the sensor and then the sensor itself Also check to make sure that the correct option is properly selected or not for load sensing Check voltage on the batteries and for loose connections in the power supply cabling Platform Left Turn Switch ON at power up Message Ensure that nothing is holding the Joystick Toggle Switches down If OK consider replacing the Joystick or PCU Platform Right Turn Switch ON at power up Message Ensure that nothing is holding the Joystick Toggle Switches down If OK consider replacing the Joystick or PCU 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 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 Dingli Programmer If its OK consider replacing the Joystick or the PCU Lift Up Coil Fault Check the connections to the Coil s terminals and make sure they tight If so check the coil itself to see if it is open or shorted Lift Down Coil Fault Check the connections to the Coil s terminals and make sure they are tight If so check the coil itself to see if it is open or shorted Right Turn Coil Fault Check the connections to the Coil s terminals and make sure they are tight If so check
44. er Pump Motor Fault Check connections to the Pump Motor Cycle power to the lift and if that does not resolve the issue replace the Motor Controller Motor Controller Left Drive Motor Fault Check connections to the motors Cycle power to the lift and if that does not resolve the issue replace the Motor Controller Motor Controller Right Drive Motor Fault Check connections to the motors Cycle power to the lift and if that does not resolve the issue replace the Motor Controller Pump Motor Short Fault Check connections to the pump motor Cycle power to the lift and if that does not resolve the issue replace the Motor Controller Over 80 Load Warning Platform is getting close to its limit of weight Consider not adding more load Right Drive Motor Short Fault Check the Motor connections and make sure they are tight Check the Motor for a short Right Brake Coil Fault Check the connections to the Coil s terminals and make sure they are tight If so check the coil itself to see if it is open or shorted Left Brake Coil Fault Check the connections to the Coil s terminals and make sure they are tight If so check the coil itself to see if it is open or shorted Over 90 Load Warning Platform is getting close to its limit of weight Consider not adding more load Over 99 Load Warning Platform has reached its limit of weight Do not add more load Overloaded Platform Fault Remove the excess load immediately Machine Tilted
45. gory 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 31 Operating Instructions The Operating Instructions section provides instructions for each aspect of machine operation It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a workplace inspection before using the machine OPERATOR S MANUAL with Maintenance Information Operating Instructions Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all machine functions Repair any function that operates when either red Emergency Stop button is pushed in Emergency Lowering 1 Pull the emergency lowering knob Operation from Ground 1
46. intended You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals You read understand and obey employer s safety rules and worksite regulations You read understand and obey all applicable governmental regulations You are properly trained to safely operate the machine Safety Rules Decal Legend DINGLI product decals use symbols color coding and signal words to identify the following AN oafety 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 DANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury LOE Blue without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage OPERATOR S MANUAL with Maintenance Information Safety Rules Intended Use This machine is intended to be used only to lift personnel along wi
47. ions Power source Controls AC outlet in platform Maximum hydraulic pressure functions System voltage 9 5m 7 5m 1 99m 1 1m 0 76m 1 41m 0 78x0 70m 125kg m s 1 07 1 55 0 ocm 1070kg 2x12V 120AH Proportional Standard 180bar 24V Driving wheels 305x100mm Airborne noise emissions TOdB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s Maximum slope rating Stowed position 25 Maximum side slope rating 10 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope X 1 5 Y 3 Drive speeds Stowed maximum 4 0km h Platform raised maximum 1 1km h Floor loading information Tire load maximum 350kg Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation AMWP9 5 2100 Height working maximum Height platform maximum Height stowed maximum Height guard rails Width Length platform retracted Platform dimensions Platform length x width Maximum load capacity Maximum wind speed Wheelbase Turning radius outside Turning radius inside Ground clearance Weight Machine weights vary with option configurations Powe
48. l changes to be performed more often 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 D 1 Test or Replace the Hydraulic Oil Maintenance B 14 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 machine to perform poorly Extremely dirty conditions may require that the cap be inspected more often 1 Open the cover 2 Remove the breather cap from the hydraulic tank 3 Check for proper venting 2 Result Air passes through the breather cap Result If air does not pass through the cap clean or replace the cap Proceed to step 4 Note When checking for positive tank cap venting air should pass freely through the cap 4 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat step 3 o Install the breather cap onto the hydraulic tank 6 Install the cover OPERATOR S MANUAL with Maintenance Information Maintenance
49. l decals are in place and legible Be sure the manuals are complete legible and in the storage container located in the platform Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak 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 Safety Rules A Battery Safety A Burn Hazard w gt Batteries contain acid Always wear protective clothing and eye wear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water A Explosion Hazard Keep sparks flames and lighted tobacco away from batteries Batteries emit explosive gas The battery tray should remain open during the entire charging cycle Do not contact the battery terminals or the cable clamps with tools that may cause sparks A Component Damage Hazard Do not use any battery charger greater than 24V to charge the batteries Electrocution Burn Hazard Connect the battery charger to a grounded AC 3 wire electrical outlet only Inspect daily for damaged cords cables and wires Replace damaged items before operating OPERATOR S MAN
50. latform controls 4 Push down the red Emergency Stop button at the platform controls to the off position 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 OPERATOR S MANUAL with Maintenance Information Maintenance B 5 Lubricate the Lifting Chains Lubricated chains are essential to good machine performance and safe operation pum Extremely dirty conditions may require that the ZA chains be cleaned and lubricated more often The direct result of wearing the transmission d Bl chain is to stretch the total length of the chain 1 Measure the stretching rate of the used 8 transmission chain by eye every three months 4 N M n The mast connected to the elongated chain would be lower in position so that the top of _ NIN each mast is obviously uneven in stored position It may lead to damage on guide roller BN 9 if the problem is serious NOTICE Every link of the transmission d chain is associated with three links of the masts mE 1 Lower the platform to the stowed position 2 Measure the maximum height of the machine 1 next link of the mast Result The machine should
51. latform from the ground controls push in the roller of the up limit switch to activate the limit switch 2 Result The platform stops raising The machine is functioning properly Result The platform continues to raise Adjust or replace the up limit switch Maintenance B 8 Test the Key Switch DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation Perform this procedure from the ground using the platform controls Do not stand in the platform 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform 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 gt Result No function should operate OPERATOR S MANUAL with Maintenance Information Maintenance B 9 Test the Automotive sty
52. le Horn if equipped DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Push down the horn button at the platform controls Result The horn should sound 54 10 Test the Drive Brakes DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe 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 not fully operational Perform this procedure with the machine on a firm level surface that is free of obstructions with the platform extension deck fully retracted and the platform in the stowed position 1 Mark a test line on the ground for reference 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Press the drive functi
53. mach aar drop holes or B sure operating surface will support he machin Make gure adi tires aro in good condition Death or serious injury could occur Tram tip ower Self Propelled Tip ovar Vertical Lifts Hazard Modi IT hil toundu uni n LE Death su ricum injury z125kg 25kg 100kg xus 4 12 OPERATOR S MANUAL with Maintenance Information Decals 9 5 2100 AMWP11 2100 No Part No Description Qty Remark seen foon 0 sono ener e e _ 1 e suos faapa coner ft _ ft 0 0 o 2 _ peer meoere ft _ _ snos rerio 8 Demos faameo _ 2 ES NN ER RN ft De son 0 2 _ e soror emeret 1 _ Um sos tt _ OPERATOR S MANUAL with Maintenance Information Decals 9 5 2100 AMWP11 2100
54. mediately 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 OPERATOR S MANUAL with Maintenance Information Function Tests 37 Fully lower the platform under a pothole guard Raise the platform 38 Place a 2x10cm for AMWP8 1100 2 Result Before the platform is raised 2 m AMWP9 5 1100 4x10cm for from the ground an alarm should sound AMWP9 5 2100 AMWP 11 2100 or similar and the drive function should not Work piece of wood under both wheels on one 46 Lower the platform and remove the 5x10 side and drive the machine up onto them wood block 39 Raise the platform at least 2 m Result The platform should stop and the tilt alarm will sound at 150 beeps per minute 40 Move the drive control handle in the direction indicated by the blue up arrow then move the drive control handle in the direction indicated by the white down arrow Result The drive function should not work in either direction 41 Lower the platform and drive the machine off the block Test the Pothole Guards Note The pothole guards should automatically deploy when the platform is raised The pothole guards activate another limit switch which allows the machine to continue to function If the pothole guards do not deploy an alarm sounds and the machine will not drive 42 Raise the platform Result When the platfo
55. n and Lubricate the Columns Clean and properly lubricated columns are essential to good machine performance and safe operation Extremely dirty conditions may require that the columns be cleaned and lubricated more often 1 Raise the platform to the maximum height 2 Visually inspect the inner and outer channels of the columns for debris or foreign material If necessary use a mild cleaning solvent to clean the columns 3 bearing between chain wheel with the shaft is lubricated with the calcium base grease in raising 4 Lubricate the place between chain wheel with chain used grease gun 5 Lubricate the lead rail with the calcium base grease in raising A WARNING This procedure will require the use of additional access equipment Do not place ladders or scaffold on or against any part of the machine Performing this procedure without the proper skills and tools may result in death or serious injury Dealer service is strongly recommended OPERATOR S MANUAL with Maintenance Information B 7 Test the Up Limit Switch 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 1 Turn the key switch to ground control 2 While raising the p
56. not hold the function enable switch on the control handle 20 Slowly move the control handle in the direction indicated by the blue arrow then in the direction indicated by the yellow arrow Result No functions should operate 21 Press the lift function select button OPERATOR S MANUAL with Maintenance Information 22 Press and hold the function enable switch on the control handle 23 Slowly move the control handle in the direction indicated by the blue arrow Result The platform should raise 24 Release the control handle 2 Result The platform should stop raising 25 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 tests stand in the platform facing the steer end of the machine 26 Press the drive function select switch Press and hold the function enable switch on the control handle 2 28 Depress the thumb rocker switch on top of the control handle in the direction identified by the blue left arrow on the control panel Result The steer wheels should turn in the direction that the blue left arrow points on the control panel 29 Depress the thumb rocker switch in the direction identified by the white right arrow on the control panel Result Th
57. o or rabed number poopie Evendy diskibuls haad 2 Do nat expe tiorm r winds ar h rizontal farce 3 Machine mi iui bio Y lanes surtaca bof rg elavating platform 4 D nat races plata mm unayan aba ng or irfaces ineladin radars raiteay can Moanin nr simmar mani 5 Do mot mova machina poar drap alfs milies or abnar ur operating surface will support this michina H iram aro in good Death or serious injury could occur Tram tig ower Tip ovar Hazard toand unit i De ath ngur 15069 1 xus 4 94 2403 Aga OPERATOR S MANUAL with Maintenance Information Platform 2 9414111 A CAUTION Max Manual Force 5 9314011 Decals 7 9424123 Tip over Hazard This machina ix intended USE INDOORS ONLY and mast mot ba wind wend forces may make wins 0 miu Electrocution Hazard This machina ig nod md Keep Aw ny achina is nen at jites ps equapmnnit Daal or saricus injury will occu Iram Genet with machina i becemms charge Chassis 5 9514201 i6 9514301 Self Propelled Vertical Lifts 9421019 amp DANGER 9311011 11 OPERATOR S MANUAL with Maintenance Information Decals
58. od Death of serious injury could occur from a lip over Chassis 3 9311015 45 9514201 Wheel Load 450 kg 0311043 EMERGENCY LOWER Pull knob bo lower platform 10 9424129 OPERATOR S MANUAL with Maintenance Information Decals Platform 2 9414111 A CAUTION Manual Force Tip over Hazard IF 11 EC FI urn bi savons sippe Death sodes injury Loewner Tha 15 0 Tip over Hazard machinis vended far USE INDOORS ONLY and musi be used euldaors wind forces mmy maka il unatabia allowed wind speed mls Electrocution Hazard This mot ingulmmed If machina naar nas oF Baath serious injury will occur fram coniact wih machine Wil boimas electrically charged Salf Propallad Vertical Lifts Serial Wiorkeng Height Wind Speed Mas Force 2 Move ihe machine Work Praasune bevel COrearall Dimangiar Gross Weight LP Date MFG Made in China A Zhegang Cingi Mactenary Go Lid 1225 Baipun Seth Heg is 1M Crushing hazard 1 hands and limbs oul of ral 2 Make sura the chock is in pl
59. on select button 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 OPERATOR S MANUAL with Maintenance Information 6 Bring the machine to top drive speed before reaching the test line Release the function enable switch or the joystick when your reference point on the machine crosses the test line 7 Measure the distance between the test line and your machine reference point 2 Result The machine stops within the specified braking distance No action required Result The machine does not stop within the specified braking distance Note The brakes must be able to hold the machine on any slope it is able to climb 8 Replace the brakes and repeat this procedure beginning with step 1 Braking distance maximum High range on paved surface 61cm 30cm 55 Maintenance B 11 Test the Drive Speed Stowed Position DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Perform this procedure with the machine
60. orm the tray 5 Loose and remove the bolts and separate the tank from the pump body 6 all of the oil into a suitable container A WARNING 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 7 Clean up any oil that may have spilled Properly discard the used oil 8 Clean the inside of the hydraulic tank using a mild solvent Allow the tank to dry completely 9 Install the hydraulic tank and install and tighten the hydraulic tank retaining fasteners Torque to specification Torque specifications Hydraulic tank retaining fasteners dry 4 Nm Hydraulic tank retaining fasteners lubricated 2 9Nm 10 Install the hydraulic power pack into the tray Install the fitting and hydraulic hoses onto the hydraulic power pack and torque 11 Fill the tank with hydraulic oil until the fluid is full in the hydraulic tank Do not overfill 12 Activate the pump to fill the hydraulic system with oil and bleed the system of air A WARNING 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 Do not allow the pump to cavitate 60 OPERATOR S MANUAL with Maintenance Information Schematic Hydraulic Schematic AMWP8 1100 9 5 1100
61. ot push the machine or other objects with the platform Do not contact adjacent structures with the platform Do not alter or disable the limit switches Do not tie the platform to adjacent structures Safety Rules Do not place loads outside the platform perimeter Do not place ladders or scaffolds in 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 Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine Stability with items of different weight or specification Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh 28 kg Do not modify or alter an aerial work platform without prior written permission from the manufacturer Mounting attachments for holding tools or other materials onto the platform toe boards or guard rail system can increase the weight in the platform and the surface area of the platform or the load Crushing Hazard Keep hands and limbs out of scissors Maintain a firm grasp on the platform rail wh
62. p all functions Pull out the red Emergency Stop button to the on position to operate the machine LED Diagnostic read out and battery charge indicator Horn Button Push the horn button and the horn will sound Release the horn button and the horn will stop Control Panel Lift function select button Press this button to activate the lift function Proportional control handle function enable switch for lift and drive functions 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 while the platform is lowering Drive function Press and hold the function enable switch to enable the drive function 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 Move the control handle in the direction indicated by the yellow arrow on the control panel and the machine will move in the direction that the yellow arrow points OPERATOR S MANUAL with Maintenance Information Pre operation Inspection Do Not Operate Unless You learn and practice the principles of safe machine operation containe
63. plastic seal from the battery vent openings 2 Fil each cell with battery acid electrolyte until the level is sufficient to cover the plates Do not fill to the maximum level until the battery charge cycle is complete Overfilling can cause the battery acid to overflow during charging Neutralize battery acid spills with baking soda and water 3 Install the battery vent caps 4 Charge 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 OPERATOR S MANUAL with Maintenance Information Transport and Lifting Instructions Observe and Obey Common sense planning must be applied to control the movement of the machine when lifting it with a crane or forklift Only qualified aerial lift operators should move the machine on or off the truck The transport vehicle must be parked level surface The transport vehicle must be secured to prevent rolling while the machine is being loaded Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight See the serial label for the machine weight The machine must be on a level surface or secured before releasing the brakes Only qualified forklift operators should lift the machine with a forklift Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand
64. r source Controls AC outlet in platform Maximum hydraulic pressure functions System voltage OPERATOR S MANUAL with Maintenance Information 9 5m 7 5 2 1 1m 1 01m 1 55m 1 00 0 70 200kg Om s 1 23 1 9m 0 8cm 1270kg 2x12V 120AH Proportional Standard 180bar 24V Specifications Driving wheels 305x100mm Airborne noise emissions lt 0dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s Maximum slope rating Stowed position 25 Maximum side slope rating 10 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope X 2 Y 3 Drive speeds otowed maximum 4 0km h Platform raised maximum 1 1km h Floor loading information Tire load maximum 450 kg Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation OPERATOR S MANUAL with Maintenance Information Specifications AMWP11 2100 Height working maximum Height platform maximum Height stowed maximum Height guard rails Width Length platform retracted Platform dimensions Platform length x width Maximum load capacity Maximum wind speed Wheelbase Turning
65. radius outside Turning radius inside Ground clearance Weight Machine weights vary with option configurations Power source Controls AC outlet in platform Maximum hydraulic pressure functions System voltage 11m 9m 2m 1 1m 1 01m 1 55m 1 00 0 70 150kg Om s 1 23 1 9m 0 8cm 1345kg 2x12V 120AH Proportional Standard 180bar 24V Driving wheels 305x100mm Airborne noise emissions TOdB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s Maximum slope rating Stowed position 25 Maximum side slope rating 10 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope X 2 Y 3 Drive speeds Stowed maximum 4 0km h Platform raised maximum 1 1km h Floor loading information Tire load maximum 450kg Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation OPERATOR S MANUAL with Maintenance Information Control Panel Ground Control Panel HC JR METER 1 000040 1 1 LED 5 Platform up down switch Diagnostic read out and battery charge Move the switch up and the platform will indicator raise
66. re often 1 Open the cover 2 Remove and discard the hydraulic tank breather cap 3 Install new cap onto the tank 4 Install the cover 59 OPERATOR S MANUAL with Maintenance Information Maintenance Checklist D Procedure D 1 Test or Replace the Hydraulic Oil DINGLI requires that this procedure be performed every 1000 hours or every one year whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often 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 Note Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Open the cover 3 Tag and disconnect the hydraulic pump outlet line and remove the line from the pump Cap the fitting on the pump 4 Loose the bolt and remove the hydraulic power pack f
67. rm Joystick Enable Switch ON at power up Fault Disable Platform Control 47 Platform Joystick not in neutral at power up Message Diagnostic Message Only 54 Lift Up Coil Fault Disable Lifting and Driving 55 Lift Down Coil Fault Disable Lifting and Driving 56 Right Turn Coil Fault Disable Lifting and Driving 57 Left Turn Coil Fault Disable Lifting and Driving 58 General Brake Coil Fault Disable Lifting and Driving 61 Motor Controller Current Sensor Fault Controller Dependent 62 Motor Controller Hardware or Software Fault Controller Dependent C2 OPERATOR S MANUAL with Maintenance Information Operating Instructions Display Description Lift Reaction 64 Motor Controller SRO Fault Controller Dependent ZAPI Steering or Speed Input Voltages out of Acquired range 67 Controller Dependent 68 Unsafe Power Conditions or Interruptions Disable All Motion 69 High Neutral Current Fault Disable All Motion 70 Steering Input out of Range Disable All Motion 71 Motor Controller Main Contactor or Pump Motor Short Disable Lifting and Driving 73 Motor Controller Thermal Cutback Fault Controller Dependent 14 Motor Controller Motor Fault Controller Dependent 75 Motor Controller Pump Motor Open Fault Controller Dependent 76 Motor Controller Left Drive Motor Open Fault Controller Dependent 77 Motor Controller Right Drive Motor Open Fault Controller Dependent 78 Pump Motor Short Fault or Wrong Pump Speed Input Disable Lifting and Driving 19 Left Dri
68. rm is raised 2m from the ground the pothole guards should deploy 43 Press on the pothole guards on one side and then the other 2 Result The pothole guards should not move 44 Lower the platform 2 Result The pothole guards should return to the stowed position 45 Place a 5x10 or similar piece of wood 30 OPERATOR S MANUAL with Maintenance Information Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Inspect the workplace 4 Always perform function tests prior to use 5 Only use the machine as it was intended Fundamentals This machine is a self propelled hydraulic lift equipped with a work platform on the Vertical mechanism Vibrations emitted by these machines are not hazardous to an operator in the work platform The machine can be used to position personnel with their tools and supplies at position above ground level and can be used to reach work areas located above and over machinery or equipment A full and detailed implementation of EN ISO 13849 1 2 is correctly applied on our MEWP design SISTEMA a software tool for PL Calculation Tool is also 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 Cate
69. s specifications and the requirements listed in this manual OPERATOR S MANUAL with Maintenance Information Pre operation Inspection Pre operation Inspection Be sure that the operator s manual are Check entire machine for complete legible and in the storage container located in the platform Cracks in welds or structural components Be sure that all decals are legible and in Dents or damage to machine place See Decals section Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Battery pack and connections Drive motors Wear pads Wheels Lifting chains and idler wheels Mast and mast braces Limit switches alarms and horn Nuts bolts and other fasteners Platform entry gate and guard rail Alarms and beacons if equipped Platform extension if equipped Platform Control Panel 0 0 Pothole guard 25 OPERATOR S MANUAL with M
70. tact 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 Mast cable e Platform controls Power to platform wiring Ground control panel e Hydraulic power unit module tray 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Raise the platform approximately 2 m from the ground 5 Place a lifting strap from an overhead crane under the platform Support the platform Do not apply any lifting pressure 49 Maintenance A WARNING Component damage hazard The platform railings can be damaged if they are used to lift the platform Do not attach the lifting strap to the platform railings 6 Inspect for a liberal coating of dielectric grease in the following locations Between the ECU and platform controls All wire harness connectors Level sensor 7 Open the cover 8 Inspect the battery tray for burnt chafed and pinched cables 9 Close the battery tray cover 10 11 Remove the strap from the platform Lower the platform to the stowed position and turn the machine off OPERATOR S MANUAL with Maintenance Information Maintenance B 3 Inspect the Tires and Wheels Including castle
71. tandard platform 12 9222011 Decal Machine Plate 3 9311015 Instructions Tie Down Point 14 cO 321051 Wheel Load 350kg cO 15 514201 SGS CE 16 cO 514301 Cosmetic IPAF N 9421019 Danger Do not stand Co 9311011 Instructions Forklift Pockets 9 9311017 Instructions Emergency down 20 9121019 Label Ground Console Panel OPERATOR S MANUAL with Maintenance Information Decals For AMWP8 1100 AMWP9 5 1100 10 AMWP8 1100 1 9424127 Hazard lpok m ite dqenacbonmof mien jafructinna all body parts inside platlerm during epaeratien Failure follow instructions could result death or serious inju ury Falling Hazard 1 h feoton platform fioc 2 Do nel climb ait ar and on ds n 3 Ensure entrance ansa properly elo 4 uad n re oF vilas iba aides A Guard be properly dunng operab n Falling from platfarm could cause deaih or serious Hania Hazard mar rasg
72. tform overload system 5 Test all machine functions from the platform controls Result All platform control functions should not operate 6 Turn the key switch to ground control Test all machine functions from the ground controls gt Result All ground control functions should not operate 8 Lift the test weight off the platform floor using a Suitable lifting device 2 Result The overload alarm at the platform controls should not sound indicating a normal condition 22 Result The overload alarm at the platform controls sounds Calibrate the platform overload system 9 Test all machine functions from the ground controls gt Result All ground control functions should operate 10 Turn the key switch to platform control 11 Test all machine functions from the platform controls Result All platform control functions should operate OPERATOR S MANUAL with Maintenance Information Maintenance C 2 Replace the Hydraulic 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 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 mo
73. th their tools and materials to an aerial work site machine is intended for use INDOORS ONLY and must not be used outdoors as wind forces may make it unstable Safety Sign Maintenance Replace any missing or damaged safety signs Keep operator safety in mind at all times Use mild soap and water to clean safety signs Do not use solvent based cleaners because they may damage the safety sign material A Electrocution Hazard This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Minimum Safe Approach Distance Meters Voltage Phase to Phase to 300V Avoid Contact 300V to 50KV 3 05 50KV to 200KV 4 60 200 to 350KV 6 10 350KV to 500KV 7 62 500KV to 750KV 10 67 750KV to 1000KV 13 72 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 use the machine as a ground for welding A Tip over Hazard Occupants equipment and materials must not exceed the maximum platform capacity or the maximum capacity of the platform extension This machine is intended for use INDOORS ONLY and must not be used outdoors as wind forces may make it unstable
74. tructions or other possible hazards Be aware of crushing hazards when grasping the platform guard rail 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 have been taken to prevent any potential collision No stunt driving or horseplay while operating a machine Do not lower the platform unless the area below is clear of personnel and obstructions Limit travel speed according to the condition of the ground surface congestion slope location of personnel and any other factors which may cause oollision OPERATOR S MANUAL with Maintenance Information Component Damage Hazard Do not use any battery or charger greater than 24V Do not use the machine as a ground for welding Explosion and Fire Hazard Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Damaged Machine Hazard Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection of the machine and test all functions before each work shift Immediately tag and remove from service a damaged or malfunctioning machine Be sure all maintenance has been performed as specified in this manual Be sure al
75. ve 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 Right Brake Coil Fault Disable Lifting and Driving 83 Left Brake Coil Open or Short Fault Disable Lifting and Driving 90 Over 90 Load Warning Warning Only 99 Over 99 Load Warning Warning Only OL Overloaded Platform Fault Disable All Motion LL Machine Tilted Beyond Safe Limits Fault Disable Lifting and Driving 5 MANUAL with Maintenance Information Operating Instructions Troubleshooting Guide Display 01 02 03 12 18 31 32 36 42 43 46 47 54 55 56 57 58 61 62 64 67 Description System Initialization Fault ECU may be malfunctioning replace it System Communication Fault Check communications cable connections and other wiring If that does not resolve the problem try replacing the PCU or ECU Invalid Option setting Fault Set appropriate option for this lift Chassis Toggle Switch ON at power up Fault Check the wires to the Toggle Switch or look for a stuck Toggle Switch Pothole Guard Fault Check that the pothole guards are extended check the pothole limit switches Check wires to the switches check the down limit switch and connections Pressure Sensor Fault Check the wiring to the sensor and then the sensor itself Also check to make sure that the correct option is properly selected or not for load s
76. y Check the battery and power switch connections and tighten or clean Check the voltage to the ECU and PCU This fault can also be generated when the power switch or relays experience a sudden jolt 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 Steering Input Out of Range There is an inappropriate voltage at the steering input of the ZAPI motor controller The ZAPI may need to be trained for the three steering voltages on Differential Steered machines Or the steering voltage from the ECU was at some point outside of the range that was recorded during the training session Retrain the ZAPI and or check for fluctuating voltages due to lose wires etc Motor Controller Main Contactor Fault Check the connections to the main contactor Replace the contactor if necessary Replace the Motor Controller if necessary Motor Controller Thermal Cutback Fault Drive or Lift Motor may be overheating Let the lift cool down If that does not help cycle power to reset the Motor controller If that doesn t resolve the issue replace the Motor Controller Motor Controller Motor Fault Check connections to the motors Cycle power to the lift and if that does not resolve the issue replace the Motor Controller Motor Controll

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