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DINGLI S03-E Operation, Service & Parts Manual

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S03-E
ELECTRIC SCISSOR LIFTS
Operation Service & Parts Manual
Zhejiang Dingli machinery Co., Ltd.
2010-10

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Summary of Contents for DINGLI S03-E

  • Page 1 S03-E ELECTRIC SCISSOR LIFTS Operation Service & Parts Manual Zhejiang Dingli machinery Co., Ltd. 2010-10...
  • Page 2 Comply with employer, job site and at all times. If you have any questions, please governmental rules. call DINGLI Machinery. Read, understand and follow the instructions in this and other manuals supplied with this machine.
  • Page 3 OPERATOR’S MANUAL with Maintenance Information Safety Rules Decal Legend Danger DINGLI product decals use symbols, color Failure to obey the instructions and coding and signal words to identify the following: safety rules in this manual will result in death or serious injury.
  • Page 4 This machine is not electrically insulated and Occupants, equipment and materials must not will not provide protection from contact with or exceed the maximum platform capacity. proximity to electrical current. Maximum capacity – S03-E Maximum occupants Platform retracted 240 kg Platform retracted wind rating 12.5m/s...
  • Page 5 OPERATOR’S MANUAL with Maintenance Information Safety Rules terrain, unstable surfaces or other hazardous conditions with the platform raised. Do not replace items critical to machine stability with items of different weight or specification. Do not use the machine on a moving or mobile surface or vehicle.
  • Page 6 OPERATOR’S MANUAL with Maintenance Information Safety Rules Fall Hazards Collision Hazards The guard rail system provides fall protection. If occupant(s) of the platform are required to wear personal fall protection equipment (PFPE) due to job site or employer rules, PFPE equipment and its use shall be in accordance with the Be aware of limited sight distance and blind PFPE manufacturer’s instructions and...
  • Page 7 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 and the appropriate DINGLI service manual.
  • Page 8 OPERATOR’S MANUAL with Maintenance Information Safety Rules Battery Safety Burn Hazards 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. Explosion Hazard Keep sparks, flames and lighted tobacco away from batteries.
  • Page 9 OPERATOR’S MANUAL with Maintenance Information Safety Rules Legend 1 Platform controller 9 Ground Control Panel 2 Platform guard rails 10 Batteries charger 3 Platform 11 Steer Wheel 4 Scissor 12 Step 5 Hydraulic cylinder 13 Batteries (in the Drawer) 6 Drive wheels 14 Hydraulic power pack (in the Drawer) 7 Pump &...
  • Page 10 OPERATOR’S MANUAL with Maintenance Information Control Panel Ground Control Panel 5 Key switch for platform / off / ground control 1 Break release button selection 2 Platform up button Turn the key switch to the platform position and the platform controls will operate. Turn the key Press the button and the platform will raise.
  • Page 11 OPERATOR’S MANUAL with Maintenance Information Control Panel Platform Control Drive Function (Enable) Battery Charge/Fault Code ( LEDs ) Platform Function (Enable) Max. Drive Speed Setting ( LEDs ) Joystick with Enable Button Decrease Max. Drive Speed Red Emergency Stop button Increase Max.
  • Page 12 OPERATOR’S MANUAL with Maintenance Information Control Panel Drive Function (Enable) Platform Control Panel Press the button to enable the Battery Charge/Fault Code (LEDs) drive function. Platform Function (Enable) Press the button to enable the On normal power-up and operation this Left function.
  • Page 13 OPERATOR’S MANUAL with Maintenance Information Pre-operation Inspection Fundamentals Do Not Operate Unless: It is the responsibility of the operator to perform √ You learn and practice the principles of a pre-operation inspection and routine safe machine operation contained in this maintenance.
  • Page 14 OPERATOR’S MANUAL with Maintenance Information Pre-operation Inspection Pre-operation Inspection Check entire machine for: □ Be sure that the operator’s, safety and responsibilities manuals are complete, legible □ Cracks in welds or structural components and in the storage container located in the □...
  • Page 15 OPERATOR’S MANUAL with Maintenance Information Maintenance Observe and Obey: Check the Batteries □ Only routine maintenance items specified in this manual shall be performed by the operator. Proper battery condition is essential to good □ Scheduled maintenance inspections shall be engine performance and operational safety.
  • Page 16 OPERATOR’S MANUAL with Maintenance Information Maintenance Check the Hydraulic Oil Level Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Maintaining the hydraulic oil at the proper level this machine according to the procedures found is essential to machine operation.
  • Page 17 OPERATOR’S MANUAL with Maintenance Information Function Tests Fundamentals The function tests are designed to discover any Do Not Operate Unless: malfunctions before the machine is put into √ You learn and practice the principles of safe service. machine operation contained in this operator's The operator must follow the step-by-step manual.
  • Page 18 OPERATOR’S MANUAL with Maintenance Information Function Tests Select a test area that is firm, level and free At the Platform Controls of obstruction. Test Emergency Stop Be sure the battery pack is connected. 13 Push in the platform red Emergency Stop At the Ground Controls button to the off position.
  • Page 19 OPERATOR’S MANUAL with Maintenance Information Function Tests Test the Steering Test Limited Drive Speed Note: When performing the steer and drive 26 Press and release the Platform Function function tests, stand in the platform facing the Button to active lift function. Press and hold steer end of the machine.
  • Page 20 OPERATOR’S MANUAL with Maintenance Information Function Tests either direction. 36 Press and release the Platform Function Button to active the lift function. 37 Lower the platform and drive the machine off the block. Test the Up Limit 38 Press and release the Platform Function Button to active the lift function.
  • Page 21 OPERATOR’S MANUAL with Maintenance Information Workplace Inspection Fundamentals Do Not Operate Unless: The workplace inspection helps the operator √ You learn and practice the principles of safe determine if the workplace is suitable for safe machine operation contained in this operator's machine operation.
  • Page 22 OPERATOR’S MANUAL with Maintenance Information Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations: - 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...
  • Page 23 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. Do Not Operate Unless: It is the operator's responsibility to follow all the √ You learn and practice the principles of safety rules and instructions in the operator's, safe machine operation contained in this safety and responsibilities manuals.
  • Page 24 OPERATOR’S MANUAL with Maintenance Information Operating Instructions To Steer Emergency Stop Press and release the Platform Function Push in the red Emergency Stop button to the Button to active drive function. off position at the ground controls or the platform controls to stop all machine functions . Press and hold the function enable switch, Move the control handle left to turn the Repair any function that operates when either...
  • Page 25 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Fall Protection Personal fall protection equipment (PFPE) is not required when operating this machine. If PFPE is required by job site or employer rules, the following shall apply: All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the manufacturer’s instructions.
  • Page 26 OPERATOR’S MANUAL with Maintenance Information Operating Instructions...
  • Page 27 Remove the battery vent caps and check the battery acid level. If necessary, add as indicated on the machine. only enough distilled water to cover the √ Use only a Dingli authorized battery and plates. Do not overfill prior to the charge charger. cycle.
  • Page 28 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Brake Release Operation Observe and Obey: Chock the wheels to prevent the machine from rolling. √ Common sense and planning must be applied to control the movement of the machine Be sure the winch line is properly secured when lifting it with a crane or forklift.
  • Page 29 OPERATOR’S MANUAL with Maintenance Information Transport and Lifting Instructions Be sure the machine is level when lowering the Securing to Truck or Trailer for forks. Transit Lifting the machine from the Always chock the machine wheels in side can result in component preparation for transport.
  • Page 30 OPERATOR’S MANUAL with Maintenance Information Decals S03-E Green - used to indicate operation or maintenance information.
  • Page 31 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. Part No. Description Qty. Logo 9413013 Warning-Crushing Hazard/Fall Hazard 9413011 Warning-Tip-over Hazard...
  • Page 32 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.
  • Page 33 OPERATOR’S MANUAL with Maintenance Information Schematic Hydraulic Schematic CYLINDER SOLENOID 　 RETURN 　 FLOW 　 VALVE REGULATOR FILTER NON 　 RETURN 　 VALVE RELIEF 　 EMERGENCY VALVE RELEASE VALVE MOTOR PUMP FILTER RESERVOIR...
  • Page 34 OPERATOR’S MANUAL with Maintenance Information Schematic Electrical Schematic L ift D riv e M o to r B ra k e R E D C h a rg e r E m e rg e n c y S to p B L A C K Y E L L O W P la tfo rm C o n tro l...
  • Page 35 OPERATOR’S MANUAL with Maintenance Information Schematic J o y s tic k H a n d le O p e ra tio n P u m p M o to r C h a rg e r C o n tro l T im e d e la y L o w e r lim ite d S w itc h H o rn...
  • Page 36 OPERATOR’S MANUAL with Maintenance Information Schematic Q’ty. Symbol Description Battery Fuse Lower Limited Switch Horn Buzzer Alarm Beacon Down Valve Time delay Lift Drive Motor Right Drive Motor Pump Motor...
  • Page 37 OPERATOR’S MANUAL with Maintenance Information Maintenance and Repair Record Maintenance Date Scheduled maintenance undertaken Repairs Date Repairs undertaken Examinations / tests Date Examinations / tests undertaken Please photocopy this page for your own use, as required...
  • Page 38 OPERATOR’S MANUAL with Maintenance Information Part Manual Chassis...
  • Page 39 OPERATOR’S MANUAL with Maintenance Information Part Manual Parts NO. Description Qty. Remark JCPT5007MQ-113004 Cover plate2 JCPT5007MQ-113003 Cover plate JCPT5007MQ-113002 Plate JCPT5007MQ-113100 Chassis JCPT5007MQ-113001 Pedal plate GB/T 819.2-1997 Screw M8×30 6’’ swivel wheel GB/T 93-1987 Washer 10 GB/T 97.1-2002 Washer 10 GB/T 5782-2000 Bolt M10×45...
  • Page 40 OPERATOR’S MANUAL with Maintenance Information Part Manual Parts NO. Description Qty. Remark GB/T 818-2000 Screw M4×20-H JCPT0630-12012 Lock Charger 25’Bi=57N.1PZ Towline 19 step Battery 95AH JCPT5007MQ-113005 Plate Driving wheel D230x80 GB/T 70.1-2000 Screw M10×65 Shield sleeve 12 JCPT3707M-00018 Shield sleeve 6 Alarm beacon JCPT5007MQ-113200 Battery box weld...
  • Page 41 OPERATOR’S MANUAL with Maintenance Information Part Manual PUMP Assembly...
  • Page 42 OPERATOR’S MANUAL with Maintenance Information Part Manual Ground Station...
  • Page 43 OPERATOR’S MANUAL with Maintenance Information Part Manual Drive Motor Assembly...
  • Page 44 OPERATOR’S MANUAL with Maintenance Information Part Manual Scissors Arms Assembly...
  • Page 45 OPERATOR’S MANUAL with Maintenance Information Part Manual Parts NO. Description Qty. Remark JCPT5007MQ-131100 Inner 1 arm JCPT5007MQ-131200 Out 1 arm JCPT5007MQ-131009 Axis JCPT5007MQ-131010 Axis Flange GB894.2-1986 Bead flange D20 JCPT5007MQ-131006 Safety arm JCPT5007MQ-131007 Safety holder GB/T 97.1-2002 Washer 6 GB/T 5783-2000 Bolt M6×20 GB/T 889.1-2000 Nut M6...
  • Page 46 OPERATOR’S MANUAL with Maintenance Information Part Manual Platform with one extension deck...
  • Page 47 OPERATOR’S MANUAL with Maintenance Information Part Manual Parts No. Description Qty. Remark JCPT5007MQ-43410B Rail,Side Extension（Left) JCPT5007MQ-43420B Rail,Side Extension（Right) GB/T 5782-2000 Bolt M6×50 GB/T 848-1985 Washer 6 TYHY6957-8020 Hinge 31 JCPT5007MQ-44430B Door JCPT3707M-43301 Doorknob GB/T 93-1987 Washer 6 GB/T 6182-2000 Nut M6 JCPT5007MQ-145200 Deck,Extension 76-30...
  • Page 48 OPERATOR’S MANUAL with Maintenance Information Part Manual Up Controller...
  • Page 49 OPERATOR’S MANUAL with Maintenance Information Part Manual Inspection and Repair Log Date Comments...