DINGLI BA14J-AWD Operation And Maintenance Manual
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DINGLI BA14J-AWD Operation And Maintenance Manual

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Operation & Maintenance Manual
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Summary of Contents for DINGLI BA14J-AWD

  • Page 1 Operation & Maintenance Manual Table of Contents Series 1 Dingli Machinery...

  • Page 2: Table Of Contents

    2 Specifications Machine Specifications Performance Specifications Hydraulic Specifications Kubota 2403-M Engine Specifications Perkins 404D-22 Engine Specifications Bolt Torque Specifications Section User responsibility, Machine Preparation, and Inspection Personal Training Operator Training Training Supervision Operator Responsibility Preparation, Inspection, and Maintenance Dingli Machinery...
  • Page 3 4-14 Placards and Decals 4-15 Section 5 Operation Instruction Description Operating Characteristics and Limitations Capacities Stability Engine Operation Staring Procedure Shutdown Procedure Traveling(Driving) Operation Driving Forward and Reverse Steering Operation Platform Operation Platform Level Adjustment Operation Platform Rotation Dingli Machinery...
  • Page 4 Power/Emergency Stop Switches Ground Control Station Auxiliary Power Emergency Operation Use of Ground Controls Operator Unable to Control Machine Platform or Boom Caught Overhead Post Incident Inspection and Repair Incident Notification Section 7 General Maintenance General Lubrication Specification Dingli Machinery...
  • Page 5 7.4.6 Replace the Engine Fuel Filter 7.4.7 Replace the Water Separator 7.4.8 Tires & Wheels Maintenance Tire Damage Tire Replacement Wheel Replacement Wheel Installation 7.4.9 Battery Maintenance 7-10 Section 8 Troubleshooting and Schematics General Introduction Hydraulic System Schedule Drawing Electric Circuit Principle Drawing Dingli Machinery...

  • Page 6: Foreword

    If a tool, procedure, work method or operating technique that is not specifically recommended by Dingli is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedure that you choose.

  • Page 7: Safety Alert Symbols And Safety Signal Word

    If there is a question on application and/or operation, Dingli Machinery Co，Ltd, should be consulted. Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions.

  • Page 8: Operator Training And Knowledge

     All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual.  Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to operation of the machine. Dingli Machinery...

  • Page 9: Workplace Inspection

     Be sure that the ground conditions are able to support the maximum load shown on the decals located on the machine.  This machine can be operated in temperatures of -20℃ to 40℃. Consult Dingli for operation outside this range.

  • Page 10: Trip And Fall Hazard

    Attach only one (1) lanyard per lanyard anchorage point.  Before operating the machine, make sure all gates are closed and fastened in their proper position. Dingli Machinery...

  • Page 11: Electrocution Hazards

    Face the machine, maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand during entry and exit. Electrocution Hazards  This machine is not insulated and does not provide protection from contact or proximity to electrical current. Dingli Machinery...

  • Page 12: Tipping Hazards

     The user should be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving.  Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface. Dingli Machinery...
  • Page 13  Do not push or pull any object with the boom.  Never attempt to use the machine as a crane.  Do not tie off machine to any adjacent structure.  Do not operate the machine when wind conditions exceed 28 mph (12.5 m/s). Dingli Machinery...

  • Page 14: Crushing And Collision Hazards

     Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping.  Travel grades in low speed only.  Do not use high speed drive in restricted or close quarters or when driving in reverse. Dingli Machinery...

  • Page 15: Towing, Lifting, And Hauling

     When lifting machine, lift only at designated areas of the machine. Lift the unit with equipment of adequate capacity.  Refer to the Machine Operation section of this manual for lifting information. 1.6 ADDITIONAL HAZARDS / SAFETY Dingli Machinery...
  • Page 16  Do not refuel the machine with the engine running.  Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times.  Charge batteries only in a well ventilated area. Dingli Machinery 1-10...

  • Page 17: Specifications

    Maximum Up and Over Height 7.67m Maximum Horizontal Reach 7.47 Main Boom Up Angle Main Boom Down Angle Maximum Turntable Tailswing Wheelbase 2.2m Minimum Turning Circle Inside 2.22m Maximum Turning Circle Outside 5.10m Turntable Rotation 357 non-continuous Platform Rotation Tire and Wheels Dingli Machinery...

  • Page 18: Performance Specifications

    24-28 sec Main Lift Down 20-24 sec Swing Right & Left 80-90 sec Telescope Extent Out 15-20 sec Telescope Retract In 9-15 sec Platform Rotate R & L 25-32 sec Jib Up 20-31 sec Jib Down 19-25 sec Dingli Machinery...
  • Page 19 4. The platform speed knob control must be at full speed (turned clockwise completely). 5. Function speeds may vary due to cold, thick hydraulic oil. Test should be run with the oil temperature above 100° F (38° C). Dingli Machinery...
  • Page 20 Main Boom Telescopic Extent and Retract Pressure 180 bar Setting Jib Up and Down Pressure Setting 124 bar Platform Rotate R&L Pressure Setting Platform Level Up Pressure Setting 190 bar Platform Level Down Pressure Setting 124 bar Steering Pressure Setting 124 bar Dingli Machinery...

  • Page 21: Kubota 2403-M Engine Specifications

    Better than API CD class.10W-30 Use Oil Meeting API Classification SF(labeled SF/CC or SF/CD) for Improved Wear protection. Starter Motor 12V-2.0kW Battery Type 12V92AH equivalent Quality Fuel Pump Mechanical Engine Coolant LLC50%:50% Capacity 3.7L Alternator Output 12V-40A Fan belt Deflection Dingli Machinery...

  • Page 22: Perkins 404D-22 Engine Specifications

    Please refer to the engine Operator’s Manual on your machine for Detail information. Engine Coolant Capacity About 10 Liters Alternator Output 65A@13,8VDC Fan belt Diflection 9-12mm 2.6 Bolt Torque Specifications Thread Class 8.8 Metric Class 10.9 Metric Class 12.9 Metric Dingli Machinery...
  • Page 23 Bolts and Nuts Bolts and Nuts (Nm) (Nm) (Nm) M8×1 M10×1 M12×1.25 M12×1.5 M14×1.5 M16×1.5 M18×1.5 M20×1.5 1050 M22×1.5 1150 1350 M24×2 1050 1220 1650 1950 M27×2 1150 1100 1550 1800 2350 2750 M30×2 1650 2100 2450 1450 Dingli Machinery...

  • Page 24: Section 3 User Responsibility, Machine Preparation

    It is important that the information contained in this section be read and understood before any attempt is made to operate the machine. Ensure that all the Dingli Machinery...

  • Page 25: Preparation For Use

    These procedures will aid in obtaining maximum service life and safe operation. The following table covers the periodic machine inspections and maintenance recommended by Dingli Machinery Co, Ltd. Consult local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

  • Page 26: Delivery And Frequent Inspection

    2) Check swing bearing for damage, wear, lubrication and loose or missing bearing bolts. 3) Check solenoid valves and hydraulic lines for damage, leakage, security and electrical Dingli Machinery...
  • Page 27 10) Check fuel tank for damage, leakage and filler cap for security. 11) Check hydraulic reservoir and hydraulic lines for damage, leakage and security. NOTE: Dingli Co.,Ltd. recommends replacing the hydraulic filter element after the first 50 hours of operation and then every 300 hours thereafter, unless system indicator require earlier replacement.

  • Page 28: Daily Walk-Around Inspection

    Check all standing surfaces for oil, fuel and hydraulic oil spillage and foreign objects. Ensure overall cleanliness. 2) Placards. Keep all information and operating placards clean and unobstructed. Cover when spray painting or shot blasting to protect legibility. 3) Operation and Safety Manual. Dingli Machinery...
  • Page 29 NOTE: On new machines, those recently overhauled, or after changing hydraulic oil, operate all systems a minimum of two complete cycles and recheck oil level in reservoir. 8) Assure that all items requiring lubrication are serviced. Refer to Figure 3-1., Lubrication Diagram for specific requirements. Dingli Machinery...
  • Page 30 Section3-User Responsibility, Machine Operation & Maintenance Manual Preparation, and Inspection Dingli Machinery...
  • Page 31 Oil Supply - Full mark on dipstick; filler cap secure. Muffler and Exhaust System - Properly secured no evidence of leakage. The coolant level. 22) Hood, Right Side - Properly secured; no loose or missing parts. 23) Turntable Bearing - No loose or missing hardware; no visible; evidence of proper Dingli Machinery...

  • Page 32: Daily Function Check

    Raise and lower Boom. Check for smooth operation. Check Boom Upright tilting for proper synchronization. If the upright is tilted or the boom will not fully lower, refer to the Boom Synchronizing Procedure in Section 5.8. NOTE: Perform checks from ground controls first, then from platform controls. Dingli Machinery...
  • Page 33 Place Ground/Platform Select switch to Ground. Start engine. Platform controls should not operate. 3.3 Oscillating Axle Lockout Test (If Equipped) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. Dingli Machinery 3-10...
  • Page 34 Drive to release cylinders. 13) If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation. Dingli Machinery 3-11...

  • Page 35: Section 4 Machine Controls And Indicators

    Telescope, Swing, Tower Lift, Main Lift, Jib Lift, Platform Level Override, and Platform Rotate functions. DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY. PERFORM AS MANY PRE-OPERATIONAL CHECK AND INSPECTIONS FROM GROUND CONTROLS AS POSSIBLE. Dingli Machinery...
  • Page 36 Operation & Maintenance Manual Section4-Machine Controls and Indicators Dingli Machinery...
  • Page 37 OFF.  NOTE: With PLATFORM/GROUND SELECT switch in the center position, power is shut off to controls at both operating Console. Engine Starting Switch A three position Toggle Switch, it is used to start the Dingli Machinery...
  • Page 38 Boom Up to the Up limited position. And Push the toggle lever to the opposite direction, the Lower and Mid Boom would be got Down until the Boom to the Lowest Position. Once the toggle lever is released, it would return to the Original position automatically. Dingli Machinery...
  • Page 39 Main Boom Three Position Toggle Switch, Provides for Raiding and Lowering of the Jib Boom The Jib Boom Up & Down Controller The Platform Rotate A three position Toggle Switch allows the operator to Controller rotate the Platform Dingli Machinery...

  • Page 40: Platform Control Station

    ONLY PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. 4.2.2 Platform Control Station Dingli Machinery...
  • Page 41 Operation & Maintenance Manual Section4-Machine Controls and Indicators Figure 4-2 Platform Console Panel Dingli Machinery...
  • Page 42 When pushed in (OFF), power is shut off to the Platform Select switch. The Control EUM Unit and Refer to Display Panel for detail information Panel The Horn Button If pressed, this switch supplies power to the horn. Dingli Machinery...
  • Page 43  Move right to swing the turntable to right; move left to swing the turntable to left. NOTE: Main lift and swing functions may be selected at the same time. Maximum speed is reduced when both functions are selected. Dingli Machinery...
  • Page 44 Control Switch rotate the Platform The Driving Controller Drive/Steer The DRIVE joystick provides for driving either forward or backward. The controller is ‘ramped’ to allow variable drive speed. Steering is controlled by a thumb operated switch on top Dingli Machinery 4-10...

  • Page 45: The Multi-Function Gauge

    Operation & Maintenance Manual Section4-Machine Controls and Indicators of the joystick. 4.2.3 The Multi-Function Gauge Item Name & Figure Description Hydraulic Filter Warning indicator. It would be displayed once the filter is clogged. Change the filter element immediately. Dingli Machinery 4-11...

  • Page 46: The Control Unit Display Panel

    System Error Warning indicator. Low Charge Pressure Warning Indicator.(Option) 4.2.4 The Control Unit Display Panel Function Key Indicator Lights Graphic Display S TO P A C T Index Enter Function Key Description: Item Name & Figure Description Dingli Machinery 4-12...
  • Page 47 3 degree. Indicate that the engine is in High speed working status. Indicate that the emergency button is depressed down. Indicate that the engine coolant temperature is more105 degree. Stop the engine immaterially and make a troubleshooting. Dingli Machinery 4-13...

  • Page 48: Tilt Alarm Warning

    NOTE: For engine starting, the footswitch must be in the released (up) position. Dingli Machinery 4-14...

  • Page 49: Placards And Decals

    Simply peel off the back, and press new decal onto surface. NOTE: Placards and Decals can be ordered by using part numbers located by each placard or decal. (See Figure4-5 Danger and Warning Decal Location.) Dingli Machinery 4-15...
  • Page 50 Operation & Maintenance Manual Section4-Machine Controls and Indicators Figure 4-5 Danger and Warning Decal Position Dingli Machinery 4-16...
  • Page 51 Operation & Maintenance Manual Section4-Machine Controls and Indicators Dingli Machinery 4-17...
  • Page 52 Operation & Maintenance Manual Section4-Machine Controls and Indicators Dingli Machinery 4-18...
  • Page 53 Operation & Maintenance Manual Section4-Machine Controls and Indicators Dingli Machinery 4-19...

  • Page 54: Section 5 Operation Instruction

    The machine is hydraulically powered using hydraulic motors and cylinders for various machine motions. The hydraulic components are controlled by electrically activated hydraulic valves using switches and control levers. The speeds of functions controlled by control levers Dingli Machinery...

  • Page 55: Operating Characteristics And Limitations

    2) Load is within manufacturer’s rated capacity. 3) All machine systems are functioning properly. 4) Proper tire pressure( for pneumatic tire). 5) Machine is as originally equipped from Dingli. Stability Machine stability is based on two (2) conditions which are called FORWARD and BACKWARD stability.
  • Page 56 Operation & Maintenance Manual Section5-Operation Instruction Dingli Machinery...
  • Page 57 MACHINE WILL TIP OVER IN THIS DIRECTION IF OPERATED ON AN OUT OF LEVER SURFACE MAIN BOOM FULLY RAISED AND THE PLYBOOM FULLY RETRACTED MID BOOM FULLY RAISED LOWER BOOM FULLY RAISED Figure 5-2 Position of Least Backward Stability Dingli Machinery...

  • Page 58: Engine Operation

    1) Remove all loads and allow engine to operate at low speed for 3-5 minutes; this allows further reduction of internal engine temperature. 2) Push POWER/EMERGENCY STOP switch in. 3) Turn MASTER switch to Off. Refer to Engine Manufacturer’s manual for detailed information. Dingli Machinery...

  • Page 59: Traveling(Driving) Operation

    LEVEL DO NOT DRIVE THE MACHINE ON GRADES AND SIDESLOPES EXCEEDING THOSE SPEICIFIED ON THE TECHNICAL SPECIFICATION Traveling Forward and Reverse 1) With the engine running, activate footswitch. 2) Position Drive controller to FORWARD or REVERSE as desired. Dingli Machinery...

  • Page 60: Steering Operation

    CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN RELEASED. IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR Dingli Machinery...

  • Page 61: Boom Operation

    5) Pull and hold out the red re-level knob on the synchronizing valve located beside the main control valve. 6) From the ground controls, activate the lift control switch, and raise the lower boom approximately 6 feet (2 m). Dingli Machinery...

  • Page 62: Raising And Lowering The Main(Upper) Boom

    3) Depress and hold footswitch. 4) Operate appropriate control switch or lever for desired function and hold. 5) Position Auxiliary Power switch to the ON position and hold. 6) Release Auxiliary Power switch, selected control switch or lever, and footswitch. Dingli Machinery...

  • Page 63: Lifting And Tie Down

    When transporting machine, boom must be in the stowed mode and machine securely tied down to truck or trailer deck. Four tie down eyes are provided in the frame slab, one at each corner of the machine. (See Figure 5-3. and Figure 5-4.) Dingli Machinery 5-10...
  • Page 64 Operation & Maintenance Manual Section5-Operation Instruction 1. Place the boom in the stowed position. 2. Remove all loose items from the machine. 3. Secure the chassis and the platform using straps or chains of adequate strength. Dingli Machinery 5-11...
  • Page 65 Operation & Maintenance Manual Section5-Operation Instruction Dingli Machinery 5-12...
  • Page 66 Operation & Maintenance Manual Section5-Operation Instruction Dingli Machinery 5-13...

  • Page 67: Towing Operation

    1. Retract, lower and position boom over rear drive wheels in line with direction of travel. 2. Disconnect drive hubs by inverting disconnect cap. (See Figure 5-5.) After towing the machine, complete the following: 3. Reconnect drive hubs by inverting disconnect cap. (See Figure 5-5.) Figure 5-5 Disengage the Drive Hub Dingli Machinery 5-14...

  • Page 68: Section 6 Emergency Procedures

    3) Connect suitable equipment, remove chocks, and move machine. After moving machine, complete the following procedures: 1) Position machine on a firm and level surface. 2) Chock wheels securely. 3) Engage drive hubs by reversing disconnect caps on hubs. Dingli Machinery...

  • Page 69: Emergency Controls And Their Locations

    6) Release AUXILIARY POWER switch, selected control switch, lever or controller, and footswitch. 7) Position POWER/EMERGENCY STOP switch to OFF. To activate auxiliary power from the ground control station: 1) Position PLATFORM/GROUND SELECT KEY SWITCH to GROUND. 2) Position POWER/EMERGENCY STOP switch to ON. Dingli Machinery...

  • Page 70: Emergency Operation

    3) Cranes, forklift trucks or other equipment which may be available are to be used to remove platform occupants and stabilize motion of the machine in case machine controls are inadequate or malfunction when used. Platform or Boom Caught Overhead Dingli Machinery...

  • Page 71: Post Incident Inspection And Repair

    It should be noted that failure to notify the manufacturer of an incident involving a Dingli product within 48 hours of such an occurrence may void any warranty consideration on that particular machine.

  • Page 72: General

    Refer to the configure for normally lubrication point and Item LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY. Dingli Machinery...
  • Page 73 Operation & Maintenance Manual Section7-General Maintenance Dingli Machinery...

  • Page 74: Operator Maintenance

    5) Located the grease fitting on the inside of the bearing in the middle of the turntable. 6) Pump grease into the turntable rotation bearing. Rotate the turntable in increments of 4 to 5 inch(10-13cm) at a time and repeat this step until the entire bearing has been greased. OVERGREASE BEARINGS. OVERGREASING Dingli Machinery...

  • Page 75: Test And Replace The Hydraulic Oil

    2) Completely drain the tank into a suitable container. See capacity specifications listed below. 3) Rinse out the inside of the tank with a mild solvent. 4) Change the Suction port filter net(refer Replace the Suction Filter) 5) Change the Return filter element(refer to Replace the Return filter element) Dingli Machinery...

  • Page 76: Replace The Hydraulic Filters

    2) pull out the filter element from the filter assembly chamber, 3) Install the new filter element to the filter assembly chamber. 4) Install the filter assembly cover and tighten it. Clean up any oil that may have spilled Dingli Machinery...

  • Page 77: Replace The Return Filter Procedure

    Section7-General Maintenance during the replacement procedure 5) The charge filter assembly Dingli Part Number is PLF60*10, and the charge filter element Dingli Part Number is LH0060D10BN3HC. 6) Interval—Change after first 50 hrs, and every 6 months or 300 hrs. thereafter or as...

  • Page 78: Replace The Suction Filter Procedure

    6) Repeat step 1) to step 5 with another circuit suction port II the new filter element to the filter assembly chamber. 7) The suction filter element Dingli Part Number is WU-63*80-J 8) Interval—Every 2years or 1200 hours of operation. Remove and clean at time of hydraulic oil change.

  • Page 79: Replace The Water Separator

    A Water Separator is installed between the Fuel tank and the Fuel filter to separate the water from the fuel. It is useful to prevent the water enter the fuel system causing the component damaged. Reference the Replace the Engine Filter 1 Engine Oil Filter 2 Water Separator 3 Fuel Filter Dingli Machinery...

  • Page 80: Tires & Wheels Maintenance

    Tire Replacement Dingli recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the Parts Manual for the part number of the approved tires for a particular machine model.

  • Page 81: Battery Maintenance

    TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVICING. ALWAYS WEAR EYE PROTECTION WHEN SERVICING BATTERIES. The battery is maintenance free except for occasional battery terminal cleaning, as Dingli Machinery 7-10...
  • Page 82 Follow manufacturer’s directions for Jump start of engines with aid of extra battery. Operator must be at a control station when jump starting engine so that machine will be under control when engine starts. Jump starting is a two-person operation. Dingli Machinery 7-11...
  • Page 83 The best place to begin the problem analysis is at the power source (pump). Once it is determined that the pump is serviceable, then a systematic check of the circuit components, beginning with the control, would follow. For aid in troubleshooting, refer to the followed hydraulic schematics and Electric schematics. Dingli Machinery...
  • Page 84 Operation & Maintenance Manual Section8-Schematics Dingli Machinery...
  • Page 85 Operation & Maintenance Manual Section8-Schematics Dingli Machinery...
  • Page 86 Operation & Maintenance Manual Section8-Schematics Dingli Machinery...
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  • Page 92 Operation & Maintenance Manual Section8-Schematics Dingli Machinery 8-10...
  • Page 93 Operation & Maintenance Manual Section8-Schematics Dingli Machinery 8-11...
  • Page 94 Operation & Maintenance Manual Section8-Schematics Dingli Machinery 8-12...
  • Page 95 Operation & Maintenance Manual Section8-Schematics Dingli Machinery 8-13...
  • Page 96 Operation & Maintenance Manual Section8-Schematics Dingli Machinery 8-14...
  • Page 97 Operation & Maintenance Manual Section8-Schematics Dingli Machinery 8-15...

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