DINGLI BT22ERT Operation & Maintenance Manual
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DINGLI BT22ERT Operation & Maintenance Manual

Self-propelled telescopic boom lifts
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Part Number:
SM0320117
Rev1.0, First Edition, March 2021 Printing

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Summary of Contents for DINGLI BT22ERT

  • Page 1 Part Number: SM0320117 Rev1.0, First Edition, March 2021 Printing...

  • Page 3: Table Of Contents

    This Manual is an integral part of Legend............11 the machine and must always be kept safe in Specification...........12 the machine. In case of doubt, contact DINGLI at the address shown below. Controls............17 Placards and Decals........25 Pre-operative Inspections......29 Identification of the Manual Workplace Inspection........

  • Page 5: Marking

    Marking Marking The identification tag bearing the manufacturing number and CE marking shown here is affixed on the RH side of the chassis and shows the machine data.

  • Page 6: Introduction

    Maintenance of the safety stickers Thanks for having chosen a DINGLI machine. The main priority of DINGLI is the user's safety; Replace all missing or damaged safety a joint effort is however required to achieve stickers. Always bear the safety of operators in this.
  • Page 7 Introduction DANGER √ Read, understand and observe the national regulatory standard in force. Failure to observe the instructions and safety standards contained in √ The machine must be used only by this Manual can cause severe injuries qualified personnel, familiar with the necessary safety standards.

  • Page 8: Personnel Safety

    Personnel safety Protection of personnel from falls Personal protective equipment (PPE) for protection from falling from heights must be used with this machine. The workers in the platform must wear a safety belt or harness in compliance with the national regulations in force.

  • Page 9: Electrocution Hazards

    Model platform number of capacity occupants standards in force concerning the BT22ERT 454kg distance required If accessories are used, read, understand and from electricity follow the indications on the stickers, lines. At least the instructions and Manuals supplied with the safety distance accessories.
  • Page 10 Work Area Safety and the side-shift function in one or both directions is not operative. Stabilise the Use utmost caution and low speed when the position of the boom with respect to the slope machine is moved with the platform retracted as shown below.
  • Page 11 Work Area Safety structures. Do not position or fix Do not position loads outside the platform weights or loads perimeter. projecting from any Do not pull or push on part of the machine. any object which is outside the platform. Do not position Maximum permitted ladders or scaffolding...

  • Page 12: Danger Of Falling

    Work Area Safety Danger due to movement on slopes Do not climb down from the platform if it Do not move the machine on a slope that is raised. exceeds the maximum limits established for ascent, descent and lateral movement of the machine.
  • Page 13 Make sure the maintenance checks have been carried out as specified in this Manual and in Danger of personal injuries the DINGLI Maintenance Manual concerned. Always use the machine in a well-ventilated Make sure all the stickers are present and area to prevent the risk of poisoning by carbon legible.

  • Page 14: Danger Of Burns

    Work Area Safety Do not use the machine in the presence of an explosive atmosphere. Do not use the machine if the environmental lighting does not ensure sufficient visibility in carrying out the jobs or movements in safety conditions. Do not use the machine if someone is present in the range of actions of the machine and in the immediate vicinity.

  • Page 15: Legend

    Legend Legend LH view 上视图 1 - Aerial platform 6 - Control panel on the ground 2 - Fly boom 7 - Control panel on platform 3 - Primary telescopic boom 8 - Pedal-operated enable switch 4 - Rear wheels axle 9 - Battery compartment 5 - Front wheels axle 10 - Tanks compartment...

  • Page 16: Specification

    Specification Machine Specification Stowed Dimension Overall Length 10.16m Overall Width 2.5m Width (transport position) 2.28m Overall Height 2.65m Height (transport position) 2.46m Rated Load Rated Load (unstrict/strict) 454kg Max. occupants Platform Size Platform Length 2.44m Platform Width 0.9m Operation Dimension Maximum Platform Height 20.51m Maximum Working Height...

  • Page 17: Performance Specification

    Specification Gross Machine Weight 13200kg Ground Clearance 0.28m Battery Type lithium battery Capacity 420Ah Nominal Voltage Tire and Wheels Type Foam Filled Tire And Wheel Model 315/55D-20 Outer Diameter 848mm Width 319mm Performance Specification Driving Speed (Boom Stowed, high range) (km/h) Driving Speed (Boom Raised or Extended) (km/h) Boom Lift Up (s) 60～75...
  • Page 18 Specification mode. Start approximately 8 m from starting point so that the unit is at maximum speed when starting the test. Results should be recorded for a 60 m course. Drive Forward, record time. Drive Reverses, Record Time. Drive (Above Horizontal): Test should be done on a smooth level surface. Drive Select Switch should be set to low speed mode.
  • Page 19 Specification Hydraulic System Specification Function Pump Type Variable displacement piston pump Rated Working Pressure 265bar Displacement per revolution 28cc Function Main Relief Pressure 300bar Main Boom Telescopic Extent Pressure Setting 160bar Main Boom Telescopic Retract Pressure Setting 200bar Lift Up Pressure Setting 240bar Lift Down Pressure Setting 135bar...
  • Page 20 Specification Work Scope -3 -2 -1 11 12 13 14 15 16 17 18 19 20 21 22 22.51 m 20.51 m -3 -2 -1 11 12 13 14 15 16 17 18 19 20 21 22 17.28 m...

  • Page 21: Controls

    Controls stop button. To activate the machine, pull Control panel on the ground the red emergency stop button to the ON position by turning it clockwise. The control panel on the ground must be usually used to operate the platform for Auxiliary power supply button storage and for operating tests.
  • Page 22 Controls movement speed selection indicator depressing setting button and hold on for  light: slow/fast; one second. The optional function can be turned on or off without password, after controls position indicator light;  entering setting interface. The procedures ground/basket. are as follows: The central band shows: the motor rev counter to the LH,...
  • Page 23 Controls When the battery power is less than Not used. 20%, the system will display low Acoustic warning button battery alarm and limit the high speed. To activate the acoustic signal press the when ”F606 low battery normal yellow button. working”...
  • Page 24 Controls signals highlighted on the diagnostics panel. 13 Secondary telescopic boom lift selector Not used. 14 Second telescopic boom extension selector Not used. 15 Jib levelling selector To level up jib, turn the selector up, otherwise, turn it down. 16 Platform rotation selector To rotate the platform counter clockwise, turn the selector to the LH.
  • Page 25 Controls Control panel on platform To impart the platform commands, Extended use will affect the battery press the movement enable pedal charge: only use in case of present on the platform. emergency. Levelling the jib Engine start up When the secondary boom exceeds the Spare horizontal levelling limit in positive or Indicator lights panel...
  • Page 26 Controls Rear axle wheels alignment The green indicator light indicates the alignment of the front axle wheels with the truck axis. Turret/telescopic boom alignment The green indicator light indicates the Load indicator on platform alignment of the turret/telescopic The yellow indicator lights up to boom with the truck axis.
  • Page 27 Controls The green light indicates selection of Note: The four wheels should be at original steering mode with the axles parallel position before changing the steering for lateral movements. mode. Differential block 11 Primary telescopic boom The yellow light indicates activation of Not used the differential block 12 Lateral movements of the truck...
  • Page 28 Controls and the machine has to be moved or loaded, the switch can be used to do, while the persons in the platform and around the machine are safe. Arbitrary usage of the switch will result in damage and serious injury. 17 Turret rotation /secondary boom lifting Move the joystick in both horizontal directions to rotate the turret.

  • Page 29: Placards And Decals

    Placards and Decals Placards and Decals Read and understand all placards and decals. Do not operate any machine on which DANGER, WARNING, CAUTION OR INSTRUCTION PLACARDS OR DECALS ARE MISSING OR ILLEGIBLE. Replace placards and decals if damaged, missing or illegible.
  • Page 30 Placards and Decals...
  • Page 31 Placards and Decals Parts No. Description Qty. Remark 09630049 Decal, Label-BT22ERT 09320014 Decal, Instructions-Lift point 09310366 Decal, Instructions-Tie down point 09410117 Decal, Symbols-Crushing hazard 09310300 Decal, Instructions-Grease filling port 09310251 Decal, Instructions-Black arrow forward Decal, Instructions-Maximum wheel load 09310213 6650kg...
  • Page 32 Placards and Decals Parts No. Description Qty. Remark 09440187 Decal, Label-Capacity 454kg 09310006 Decal, Notice-Main power switch operation 09310250 Decal, Instructions-White arrow reverse 09410032 Decal, Warning-Explosion/fire hazard...

  • Page 33: Pre-Operative Inspections

    Pre-operative Inspections Do Not Operate Unless: Fundamental elements of pre-operative inspection √ Before using the machine, it is necessary to understand and apply the fundamental The operator is responsible for carrying out the principles regarding the working of the pre-operative inspection and routine machine in the safety conditions contained maintenance.
  • Page 34 Pre-operative Inspections Pre-operative inspections Check the entire machine if necessary for the  Make sure the Operator Manual, Manuals presence of: on safety and responsibilities are intact, legible and placed safe inside the  Cracks in the welds or in the container concerned on the platform.

  • Page 35: Workplace Inspection

    Workplace Inspection Inspection of the workplace √ Before using the machine, it is necessary to understand and apply the fundamental Identify and avoid the following hazard principles regarding the working of the situations: machine in the safety conditions contained cliffs or ditches ...

  • Page 36: Functional Tests

    Functional Tests Fundamental elements of √ Before using the machine, it is necessary to functional test understand and apply the fundamental principles regarding the working of the Functional test makes it possible for the machine in the safety conditions contained operator to make sure the machine is in safety in this Operator's Manual.
  • Page 37 Functional Tests Controls on the ground Testing the warning sound Press the yellow button of the warning  Select a stable, level work area free of  sound and check its working. obstacles. Checking the errors Position the key-operated switch of the ...
  • Page 38 Functional Tests Press the movement enable pedal and act but also electronically by means of software  on the joysticks: the functions must be installed on the truck: as soon as the primary operative. telescopic boom moves from the completely lowered, retracted position, the electronic Auxiliary pump test control automatically activates low speed to...
  • Page 39 Functional Tests truck then stop suddenly. Slowly move the movement control knob  in the direction indicated by the white arrow on the control panel until the machine starts moving, then restore the knob to the central position. Result: the machine must move in the ...

  • Page 40: Operating Instructions

    Operating Instructions Fundamental elements of √ Before using the machine, it is necessary to understand and apply the fundamental operating instructions operating principles of the machine in the The machine described in this Manual is safety conditions contained in this Operator designed to lift persons, tools and equipment Manual.
  • Page 41 Note ： The charging pile must be bought There are two power sockets on the end of Li from DingLi when the rapid charge mode is battery tank, near the front axle. No 1 for rapid chosen. Otherwise, there will be some charge, and No 2 for trickle charge.
  • Page 42 Operating Instructions Emergency Stowing Just when there is some failure warning except deadly security alarm and the platform has to be lowered or loaded, push Bypass Switch up and hold on, and then activate the footswitch and corresponding switch to complete it. The fault is divided into three classes: class A/B/C.
  • Page 43 Operating Instructions Class B Item Fault Restriction logic restrict moving, showing code 46 moving joystick initialization fault after restarting moving joystick fault up system, restrict moving and show code 36 restrict main boom telescopic operation, showing corresponding faulty code. main boom telescopic joystick telescopic joystick initialization fault after fault restarting up system, restrict telescopic and...

  • Page 44: Instructions For Transport

    DingLi provides the following information regarding the handling and transport of the Use all four fixing devices provided on the machine only as recommendation.

  • Page 45: Towing The Vehicle

    Instructions for Transport Towing the vehicle Towing the vehicle using an incorrect procedure can cause serious accidents. Before disengaging the negative brake manually, block the machine to prevent its movement. Follow the instructions given below to tow the machine correctly. Go under the vehicle near the front axle.
  • Page 46 Adjust the lifting devices in such a way as to keep the machine level and without causing damage to it. Centre of gravity Model X（mm） Y（mm） BT22ERT 1135 Note: The centre of gravity of every machine is not accurate but recommendation.

  • Page 47: Observe And Obey

    Manual of this machine. condition. √ Dispose of the materials in compliance with If they are damaged or illegible, ask your the national regulatory standards in force. dealer for a replacement copy. √ Only use spare parts authorised by DingLi.
  • Page 48 Maintenance MAINTENANCE SCHEDULE D-2 Turret rotation slewing ring gear - check tightening of bolts Read and understand all the warnings and E Every 1000 hours of operation or instructions before starting any maintenance every year operation. E-1 Differentials oil - change Before carrying out any maintenance operation, make sure all the scheduled actions E-2 Wheel reduction gears oil - change...

  • Page 49: Visual Inspection

    Maintenance A-1 Visual inspection A-2 Telescopic boom sliding blocks - check To ensure the maximum useful operating life of the vehicle, proceed with a thorough visual Extend the telescopic boom completely. inspection before every starting up. Check to make sure the boom movement Look around and under the vehicle, is smooth.
  • Page 50 Bolt -checking Check if there is some bolts is slacken or missing and the sensor undamaged. If there is abnormal condition, ask for help from DingLi or your agency. Overload Sensor - checking It is critically important for safety of life and property of operators to make sure the sensor works well.
  • Page 51 Maintenance B-1 Transmission shaft - lubrication of universal joints Cage load parameter shows the current load in the platform. Cage load parameter will show 0kg when Set the vehicle in the parking position. Make the load in the platform is removed sure no one approaches the work area.

  • Page 52: Hydraulic Oil Level-Check

    Maintenance B-2 Axles-lubrication of B-3 Hydraulic oil level-check oscillation bushes For correct working of the machine, check to make sure the level of oil in the hydraulic system is sufficient. Incorrect level of oil in the hydraulic system can damage the components. Daily inspections will make it possible to detect changes in the oil level which could indicate the presence of faults in the hydraulic system...
  • Page 53 MULTIS EP2 5. Remove excess grease to prevent dirt PLUS build-up and refit the dust guard gaskets. LAGERMEIST CEPLATTYN FUCHS ER EP2 KG 10 HMF If the machine is used in the severe environment, refer to DingLi for the grease.
  • Page 54 Maintenance B-6 Wheels - check tightening of B-7 Steering elements - nuts Lubrication It is extremely important to apply and maintain proper mounting torque. Tighten the lug nuts to the proper torque to prevent coming loose. Wheel nuts should be torque after first 50 hours of operation and after each wheel removal.
  • Page 55 Maintenance C-1 Axle box lubricate oil - C-2 Wheel reduction gears oil - Check Check Set the vehicle in the parking position. Turn the reduction gear cap in the horizontal position 2. Remove the cap. The oil level is correct when the oil flows out through the filler hole.
  • Page 56 Maintenance C-3 Turret rotation slewing ring C-4 Dropbox oil - Check gear - check reduction gear oil level Set the vehicle in the parking position. Retract and lift the telescopic boom Make sure no one approaches the work completely. Rotate the turret for better area.
  • Page 57 Maintenance D-1 Hydraulic oil filter - Wire mesh filter replacement ATTENTION The machines use four filters for hydraulic fluid: one filter placed on the inside of the hydraulic tank has the combined function for oil at the suction as well as return, and the second one is wire mesh filter.
  • Page 58 Maintenance D-2 Turret rotation slewing ring PLFA filter（Inlet of upper control gear - check tightening of bolts valve） Check the turret fixing nuts on the slewing ring gear. Check for rusted, slackened or missing Clean the area around the oil filter, and nuts.
  • Page 59 Maintenance E-1 Lubricate oil in the axle box- E-2 Wheel reduction gears oil - Change Change Place a suitable sized container under the reduction gear. Turn the reduction gear cap in position 1. Remove the cap and wait for the oil to drain out completely.
  • Page 60 Maintenance E-3 Telescopic boom sliding stage. If the space between the sliding surface of the block 3 and the sliding blocks - Adjusting the play surface of the first boom exceeds 0.5mm, Park the vehicle in a suitable sized area. some pads 2 need to be added.
  • Page 61 Maintenance E-4 Turret rotation slewing ring Start the machine from the ground controls and fully elevate, but do not gear - change reduction gear oil extend, the primary boom and jib. The - check play riser should remain in its stowed position. Place a dial indicator with accuracy of Changing the rotation reduction gear oil 0.01, between the drive chassis and the...
  • Page 62 Maintenance E-5 Overload Sensor - E-6 Differentials oil - Change calibration How much the load weighted by the overload sensor is in the platform will be indicated on the panel on the ground control console. If the load in the platform does not exceed rated load, the vehicle is safe during work.

  • Page 63: Hydraulic Fluid - Change

    Maintenance G-1 Hydraulic fluid - change Go under the vehicle to access the tanks drainage caps. Place a suitable sized container under the drainage cap. Unscrew the cap and drain out the oil. To speed up the operation, also unscrew the filler cap. Install the plug on the drain port.

  • Page 64: Schematic

    Schematic Hydraulic Schematic...
  • Page 65 Schematic Electrical Schematic...
  • Page 66 Schematic...
  • Page 67 Schematic CBS1 CBS2...

  • Page 68: Inspection Register

    Inspection Register The maintenance checks carried out on the machine must be recorded in a document called the Inspection Register. Replacements of the components of the hydraulic system, electrical system, mechanisms or structural elements, safety devices as well as faults of a certain entity and relative repairs must also be recorded in the Inspection Register.

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